Bobcat Manual de Servicio S185 6987049

Service Manual
S185 Skid-Steer Loader

S/N A3L911001 & Above
S/N A3LH11001 & Above
S/N AEYU11001 & Above
Dealer Copy -- Not for Resale
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6987049enUS (01-15) (T) Printed in U.S.A. © Bobcat Company 2015
iT4
1 of 994
2 of 994
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15535 B-15524
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-15734 B-15732 B-15525
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15733 B-15523 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW07-0409
3 of 994 1-1 S185 Service Manual


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


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

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

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

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


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

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

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

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

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

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

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

the work lights.
FW SSL-1008 SM

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

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

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

FW SSL-1008 SM

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

operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.
This notice identifies procedures which must be • The Service Manual and Parts Manual are available
followed to avoid damage to the machine. from your dealer for use by mechanics to do shop-
I-2019-0284 type service and repair work.
• The Skid-Steer Loader Operator Training Course is

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

WARNING your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-0913 SM

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

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

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

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-0913 SM

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

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

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

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
Check all electrical wiring and connections for damage. system, but the muffler and the exhaust gases are still
Keep the battery terminals clean and tight. Repair or hot.
replace any damaged part or wires that are loose or
frayed. Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
Battery gas can explode and cause serious injury. Use procedure in the Operation & Maintenance Manual for
the procedure in the Operation & Maintenance Manual cleaning the spark arrester muffler (if equipped).
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-0913 SM

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

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

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

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-0913 SM

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-76882
The engine serial number is located on the side of the

engine (Item 1) [Figure 2] above the alternator.

P-31843B
The loader serial number plate is located on the outside

of the loader frame [Figure 1].
Explanation of loader Serial Number:

XXXX XXXXX
Module 2. - Production
Sequence (Series)
Module 1. - Model / Engine

Combination
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 3
B-16315
The Delivery Report [Figure 3] must be completed by

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

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
GRAB OPERATOR’S
HANDLES HANDBOOK
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
†BUCKET

STEP
BUCKET
STEPS
● OPERATOR CAB
LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
REAR SUPPORT DEVICE
GRILLE
BACK-UP
LIFT ARM
ALARM
REAR
LIGHT
REAR
TAIL LIGHT *TIRES B-16604B
DOOR B-16605C
* TIRES - The Bobcat loader is factory equipped with standard tires

† BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I. Level II
is available.

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

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

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

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

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

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
REMOTE START TOOL KIT-1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Tool - 1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2
Service Tool Harness Communicator - 1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

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

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

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

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3

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

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders) . . 10-120-3
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders) . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-8

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

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

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

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

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

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

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

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
N-18877
Put the floor jack under the front of the loader [Figure 10-
B-7023A 10-2].
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-2].
WARNING

NOTE: Make sure the jackstands do not touch the
tires. Make sure tires clear floor or any
obstacles.
Instructions are necessary before operating or
Figure 10-10-3
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Always park the loader on a level surface.
WARNING P-31849
Put jackstands under the front axles and rear corners

Put the floor jack under the rear of the loader [Figure 10-
of the frame before running the engine for service.
10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Lift the rear of the loader and install jackstands [Figure
W-2017-0286
10-10-3].
23 of 994 10-10-1 S185 Service Manual


LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing 1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts P-43747 P-31266

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death. Put jackstands under the rear corners of the loader frame
W-2572-0407 (Inset) [Figure 10-20-1]
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from storage position.

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

Installation on Page 50-40-1.) OR (See Removal And
Installation on Page 50-41-1.)
P-31857
Have a second person install the lift arm support device

over the rod of one of the lift cylinders [Figure 10-20-2].
The lift arm support device must be tight against the

cylinder rod.

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

device.
Lower the lift arms all the way and stop the engine.
P-10136
Return the lift arm support device to storage position and
secure with clamping knobs.
Remove the jackstands.
P-31856B
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure

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

OPERATOR CAB Figure 10-30-1
Description
The Bobcat loader has an operator cab (ROPS and

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

Never modify the cab. Replace the cab and hardware if
damaged.
ROPS - Roll-Over Protective Structure per ISO 3471 and P-43747
FOPS - Falling-Object Protective Structure per ISO 3449,

Level I. Level II is available.
Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Level I
Figure 10-30-2
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
forestry.
WARNING
P-31288 P-31289
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to Remove the nuts and plates [Figure 10-30-2] (both
the cab can cause loss of operator protection from sides) at the front corners of the cab.
rollover and falling objects, and result in injury or
death.
W-2069-0200
Raising WARNING
Always stop the engine before raising or lowering the UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
cab. MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
Stop the loader on a level surface. Lower the lift arms. If INJURY OR DEATH
the lift arms must be up while raising the operator cab, • STOP ENGINE before raising or lowering cab.
install the lift arm support device. (See LIFT ARM W-2758-0908
SUPPORT DEVICE on Page 10-20-1.)
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.

OPERATOR CAB (CONT’D)
Raising (Cont’d)
WARNING
Figure 10-30-3
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
P-31858A
Support the cab and release the latching mechanism
(Inset) [Figure 10-30-4]. Remove your hand from the
Lift on the grab handles and bottom of the operator cab latch mechanism when the cab is past the latch stop. Use
[Figure 10-30-3] slowly until the cab is all the way up and both hands to lower the cab all the way down.
the latching mechanism engages.

Lowering
WARNING
Always stop the engine before raising or lowering the
cab.
PINCH POINT CAN CAUSE INJURY
NOTE: Always use the grab handles to lower the cab. Remove your hand from the latching mechanism
when the cab is past the latch stop.
Figure 10-30-4 W-2469-0803
Figure 10-30-5
N-20120 P-31859A
P-31288 P-31289
Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Install the plates and nuts (both sides) [Figure 10-30-5].
NOTE: The weight of the cab increases when
equipped with options and accessories such Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
as cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised
slightly from the latch to be able to release the
latch.

OPERATOR CAB (CONT’D) Figure 10-30-8
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
P-76461Q
The LIFT & TILT VALVE light (Item 1) [Figure 10-30-7]

will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
1 the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.
[DOOR] will appear in the data display [Figure 10-30-8].

P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
P-76459B
The LIFT & TILT VALVE light (Item 1) [Figure 10-30-7]

will be OFF when the door is closed, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.

OPERATOR CAB (CONT’D) Special Applications Kit Inspection And Maintenance
Special Applications Kit • Inspect for cracks or damage. Replace if required.

• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
Some attachment applications can cause flying • Do not clean with metal blades or scrapers.
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-9

B-25286A
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.5 in) thick
polycarbonate front door, top and rear windows [Figure
10-30-9].

TRANSPORTING LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-31228 P-73276
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Capacities on Page SPEC-10-4.)
Figure 10-40-1

Alternate Front Tie Down
P-31829
1 P-24480
P-31912
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
• Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader • Stop the engine.
to prevent the front end of the trailer from raising up.
• Engage the parking brake.
• Install chains at the front and rear loader tie down

positions [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.


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

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

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires / tracks will not turn.) There might be slight
wear to the tires / tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times

the weight of the loader (See (S185) LOADER
SPECIFICATIONS on Page SPEC-10-1.)


REMOTE START TOOL KIT-1563 Figure 10-60-2
Remote Start Tool - 1563
Tools that will be needed to complete the following steps

are:
2
1563 - Remote Start Tool Kit 3
1566 - Service Tool Harness Communicator (Computer 1
Interface)
Figure 10-60-1
1
P16117
The traction lock switch (Item 1) [Figure 10-60-2] is used

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

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

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

REMOTE START TOOL KIT-1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - 1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
P16116
Remove the service tool harness (Item 1) from the cover
(Item 2) [Figure 10-60-5].
Figure 10-60-4
Figure 10-60-6

1
P16120
N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-

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

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

REMOTE START TOOL KIT-1563 (CONT'D) Service Tool Harness Communicator - 1566
Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8
Figure 10-60-7 2
2
1
1
P16119
N-19631
The service tool harness communicator (Item 1) [Figure
10-60-8] is required to connect remote start tool to the
Loaders equipped with an attachment harness (Item 1) Service PC (Item 2) [Figure 10-60-8].
[Figure 10-60-7] must disconnect the attachment

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

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

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

REMOTE START TOOL KIT-1563 (CONT’D) Figure 10-60-10
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
1563: Remote Start Tool Kit
Figure 10-60-9 1
N-19151
Figure 10-60-11

P16115
1
The remote start tool (Item 1) [Figure 10-60-9] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.) N-19150
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See LIFT Remove the plug (Item 1) [Figure 10-60-10] or
ARM SUPPORT DEVICE on Page 10-20-1.) disconnect the attachment control harness (Item 1)
[Figure 10-60-11] if connected.
Raise the operator cab (if required by the procedure).
(See Raising on Page 10-30-1.)
Open the rear door of the loader.

REMOTE START TOOL KIT-1563 (CONT’D) Figure 10-60-13
Remote Start Procedure (Cont’d)
Figure 10-60-12
P16116
The remote start tool (Item 1) [Figure 10-60-13] has

P13861 three rocker switches.
Connect the remote start tool to the engine harness

connector [Figure 10-60-12].

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
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area.
W-2457-1110

REMOTE START TOOL KIT-1563 (CONT’D)
Remote Start Procedure (Cont’d)

WARNING
Figure 10-60-14
• Use traction lock override switch for service work
with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
2 • Traction lock is disengaged when light is ON.
3 1
• See Service Manual for more instruction.
W-2785-0209

engine to stop in three seconds. To relieve the
P16118
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
The traction lock switch (Item 1) [Figure 10-60-14] is
used to turn traction lock on or off. Push the switch to the Figure 10-60-15

override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow / variable flow switch (Item 2) [Figure

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

14] is used to release hydraulic pressure to the front and P-34661
/ or rear auxiliary couplers. To release pressure; push
and hold the switch for three seconds.
Push the couplers on the front auxiliary block toward the
block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

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

replacement tool for MEL1563 Remote Start Tool and
MEL1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,

can be used to service older loaders with the BOSS®
system using the supplied BOSS® Service Tool Harness
P/N 6689745.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,

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

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

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

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

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

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

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

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

7003031 (CONT'D)
Loader Service Tool Harness - 6689747 2
Figure 10-61-3
P-76452
2
Loaders with an attachment control harness (7 pin or 14

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

3] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].
Figure 10-61-4
P-76451
Loaders without an attachment control harness, remove

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7003031 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
3 2
1 P-76450
P-76453 The computer service tool harness (Item 1) [Figure 10-

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

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

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

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The right instrument panel (Deluxe

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

REMOTE START TOOL (SERVICE TOOL) KIT - Raise the lift arms (if required by the procedure) and
7003031 (CONT'D) install an approved lift arm support device.
Remote Start Procedure Raise the operator cab (if required by the procedure).
WARNING Figure 10-61-9
UNAUTHORIZED AND UNEXPECTED ENGINE

START-UP CAN CAUSE SERIOUS INJURY OR DEATH
1
With the 7-pin connector plugged into the machine
and Remote Start Tool RUN button not illuminated,
the engine can be started from the operator panel
inside the cab.
• Press the RUN button of the Remote Start Tool to
disconnect the operator panel from the start
circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area. P-76451
W-2661-1110

Loaders without an attachment control harness, remove
the loader harness cap (Item 1) [Figure 10-61-9] and
procedure:
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
7003031: Remote Start Tool (Service Tool) Kit
Figure 10-61-10
Figure 10-61-8
P-76452
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure Loaders with an attachment control harness (7 pin or 14
10-61-8] is required when the operator cab is in the pin), the attachment harness (Item 1) must be
raised position for service and the service technician disconnected from the loader harness (Item 2) [Figure
needs to turn on the loader or start the engine. Example: 10-61-10].
adjusting the steering linkage.
When the remote start procedure is completed, replace
Lift and block the loader. the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
harness [Figure 10-61-10].

7003031 (CONT'D)
2
Remote Start Procedure (Cont'd)
Figure 10-61-11
5 3
2
6 4
1
P-76439
3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-12] has five buttons.
P-76453
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.

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

7003031 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-61-13
1 2
P-34661
Push the couplers on the front auxiliary block toward the

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

10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

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

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


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

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

dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS™) bar raised. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏
MAINTENANCE in this manual.)
Spark Arrester Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed.
conditioning, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS™)
Engine Oil and Filter Replace oil and filter. ▲ ✶
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed or as
scheduled.
✶ Change oil and filter every 100 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.


AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-3
Figure 10-80-1
2 2
1
3
P-76460G
P-76883
Figure 10-80-2
Open the latches (Item 1) and remove the dust cover
(Item 2) [Figure 10-80-3].
Figure 10-80-4

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

necessary. The Service indicator (Item 1) will FLASH and
P-76884
service code [M0117] (Air Filter Plugged) will show in the
Data Display (Item 2) when the Information button (Item
3) [Figure 10-80-1] is held for two seconds. Pull the outer filter element (Item 1) [Figure 10-80-4] out
and discard.
The Air Cleaner icon on the Deluxe Instrumentation
Panel, if equipped, will be ON (Item 1) [Figure 10-80-2]. NOTE: Make sure all sealing surfaces are free of dirt
and debris. Do not use compressed air.
Replace the inner filter every third time the outer filter is
replaced or as indicated. Install new filter element. Push all the way in until it
contacts the base of the housing.
Install the dust cover and secure the latches [Figure 10-
80-3]

AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Elements (Cont’d)
Inner Filter
2
Only replace the inner filter element under the following
conditions:
1
• Replace the inner filter element every third time the
outer filter is replaced.
• After the outer element has been replaced, start the

engine and run at full rpm. If the HOURMETER /
CODE DISPLAY shows [M0117] (Air Filter
Plugged), replace the inner filter element. P-76883
Figure 10-80-5
Install the dust cover (Item 2) and secure the latches
(Item 1) [Figure 10-80-6].

1
P-76885
Remove the inner filter element (Item 1) [Figure 10-80-

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

and debris.
Install new filter element. Push all the way in until it

contacts the base of the housing.
Install the outer element [Figure 10-80-4].

ENGINE COOLING SYSTEM Figure 10-90-2
Cleaning
Check the cooling system every day to prevent over- 1

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

Remove the rear grille. (See REAR GRILLE on Page 50- low air pressure or water pressure to clean the top of the
60-1.) oil cooler (Item 2) [Figure 10-90-2].
Figure 10-90-1 Figure 10-90-3
P-76181 P-76190
NOTE: Be careful when raising and lowering the oil

Use low air pressure or water pressure to clean the top of cooler so that the oil cooler does not fall on
the air conditioning condenser (Item 1) [Figure 10-90-1], the radiator and damage the fins.
if equipped.
Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)
[Figure 10-90-3].
Lower the oil cooler.
Lower the air conditioning condenser, if equipped.
Check the cooling system for leaks.
Install the rear grille and close the rear door.

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-4
Checking Level
Open the rear door and raise the rear grille.
Check coolant level using the level markers (Item 3) 1

[Figure 10-90-5] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
hot.
Close the rear door before operating the loader.
IMPORTANT P-76780
AVOID ENGINE DAMAGE NOTE: All access covers (Item 1) [Figure 10-90-4]
Always use the correct ratio of water to antifreeze. (both sides) must be in place to ensure
correct air flow through the oil cooler which
Too much antifreeze reduces cooling system will ensure cooling for engine and hydraulic
efficiency and may cause serious premature engine system.
damage.

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

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

ENGINE COOLING SYSTEM (CONT’D) Install the rear grille and close the rear door.
Removing And Replacing Coolant
Open the rear door and remove the rear grille.
Figure 10-90-5
P-76892 P-76972
Remove the coolant fill cap (Item 1) [Figure 10-90-5].

Remove the plug (Item 2) [Figure 10-90-5]. Open the
drain valve and drain the coolant into a container. Close
the drain valve.
After all the coolant is removed, close the drain valve and
remove the hose. Recycle or dispose of coolant in an
environmentally safe manner.
Mix new coolant in a separate container. (See (S185)

LOADER SPECIFICATIONS on Page SPEC-10-1.)
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the coolant tank until the coolant level reaches
the lower marker on the tank [Figure 10-90-5].
The correct mixture of coolant to provide a -37°C (-34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S gal propylene glycol mixed with 3.5 qt
of water.
Fill the tank until it is at the lower marker on the tank and
replace the coolant fill cap.
NOTE: When installing the coolant fill cap, the cap

must be tightened until it clicks.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Use a
refractometer to check the condition of propylene glycol
in your cooling system. Add coolant as needed.


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

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

mg/kg (15 ppm) sulfur maximum.
Apply the following guidelines if biodiesel blend fuel is
• Biodiesel Blend Fuel - Must contain no more than five
used:
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
• Ensure the fuel tank is as full as possible at all times
marketed as B5 blended diesel fuel. B5 blended
to prevent moisture from collecting in the fuel tank.
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,

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

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

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

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

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

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1 B-15650
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
1 SMOKING! [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1].
WARNING
P-76886
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter. (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water WARNING

Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
2
Figure 10-100-4

P-76887
1
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the
filter.
Replacing Element
2
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on P-76888
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Remove the air from the fuel system. (See Removing Air housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
WARNING Close the vent (Item 1) [Figure 10-100-4].
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil ENGINE OIL

RECOMMENDED SAE VISCOSITY NUMBER
Check the engine oil level every day before starting the (LUBRICATION OILS FOR DIESEL ENGINE
engine for the work shift. CRANKCASE)
Figure 10-110-2
Figure 10-110-1
3
2
4
P-76971

Park the machine on level ground. Open the rear door TEMPERATURE RANGE ANTICIPATED BEFORE
and remove the dipstick (Item1) [Figure 10-110-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick. Do [1]Synthetic Oil - Use recommendation from Synthetic Oil
not overfill. Manufacturer.
Use good quality engine oil that meets API Service

Classification of CI-4 or better. [Figure 10-110-2].

ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter WARNING

For the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Run the engine until it is at operating temperature. Stop sparks or lighted tobacco away from fuel and oil.
the engine. Failure to use care around combustibles can cause
explosion or fire.
Open the rear door and remove the drain hose from the W-2103-0508
storage position (Item 4) [Figure 10-110-1].
Figure 10-110-3

P-76891
Remove the oil drain cap (Item 1) [Figure 10-110-3] and

drain the oil into a container. Recycle or dispose of used
oil in an environmentally safe manner.
Install the oil drain cap.
Remove the oil filter (Item 2) [Figure 10-110-1] and clean

the filter housing surface.
Use genuine Bobcat filter only. Put oil on the new filter
gasket, install the filter and hand tighten.
Remove the fill cap (Item 3) [Figure 10-110-1]. Put oil in

the engine. For the correct quantity (See (S185)
LOADER SPECIFICATIONS on Page SPEC-10-1.) Do
not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-1] and

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

dipstick. Install the dipstick and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3
Check the hydraulic / hydrostatic fluid level everyday HYDRAULIC / HYDROSTATIC FLUID
before starting the work shift. RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms and
tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic

Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
P-31283A prevent oxidation and thermal breakdown at operating
temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure
Use only recommended fluid in the hydraulic system
10-120-1].
[Figure 10-120-3]. (See Hydraulic System on Page
SPEC-10-3.)
Figure 10-120-2
P-76899
Open the rear door and remove the rear grille. Remove
the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level to the center of the

sight gauge. Install the fill cap (Item 1) [Figure 10-120-2].
Install the rear grille and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Replace the fill cap, install the rear grille and close the
rear door.
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic
(See SERVICE SCHEDULE on Page 10-70-1.), for the Filter
service interval.
Replace the fluid if it becomes contaminated or after (See SERVICE SCHEDULE on Page 10-70-1.) for the
major repair. correct service intervals.
Always replace the hydraulic / hydrostatic filter, the case Open the rear door.
drain filters and the hydraulic charge filter whenever the
hydraulic fluid is replaced. (See Removing And Replacing Figure 10-120-5
Hydraulic / Hydrostatic Filter on Page 10-120-2.)
Open the rear door and raise the rear grille. Remove the
fill cap
Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 10-120-4

1
P-76900
Remove the filter (Item 1) [Figure 10-120-5].
Clean the surface of the filter housing where the filter seal
contacts the housing. Put clean oil on the seal of the new
P-24751
filter element. Install and hand tighten the filter element.
Remove the plug from the top of the reservoir (Item 1)
[Figure 10-120-4]. Pump the fluid out of the reservoir
and into a container.
Recycle or dispose of the used fluid in an
WARNING
WARNING sparks or lighted tobacco away from fuel and oil.
explosion or fire.
AVOID INJURY OR DEATH W-2103-0508
sparks or lighted tobacco away from fuel and oil. Close the rear door before operating the loader.
explosion or fire. Start the engine and operate the loader hydraulic
W-2103-0508
controls.
Install the plug (Item 1) [Figure 10-120-4] and lower the Stop the engine and check for leaks at the filter.
operator cab. (See Lowering on Page 10-30-2.)
Check the fluid level in the reservoir and add as needed.
Add the correct fluid to the reservoir until the fluid level is (See Checking And Adding Fluid on Page 10-120-1.)
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Case Drain

Filters (Single Speed Loaders) WARNING
For the correct service interval (See SERVICE
SCHEDULE on Page 10-70-1.).
Figure 10-120-6
Left Side Shown explosion or fire.
W-2103-0508
1
Recycle or dispose of used fluid in an environmentally

safe manner.
Start the engine and operate the loader hydraulic

controls.
WARNING
P-45492

Remove both hydrostatic motor covers (Item 1) [Figure
10-120-6].
Figure 10-120-7
1 W-2072-0807
Stop the engine and check for leaks at the filter

assemblies.

(See Checking And Adding Fluid on Page 10-120-1.)
P-45499 P-45493
Remove the case drain filter assemblies (Item 1) [Figure

10-120-7] near the hydrostatic motors. Install the fittings
from the old filter assembly onto the new filter assembly.
Install new filter assemblies. Install motor covers.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-9

Filters (Two-Speed Loaders)
Raise the lift arms and install the lift arm support device.
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.) 1
DANGER
P-76168
Remove the case drain filter assembly (Item 1) [Figure

10-120-9]. Install the fittings from the old filter assembly
P-90328
onto the new filter assembly.
AVOID DEATH Install new case drain filter assembly and replace the
• Disconnecting or loosening any hydraulic side access cover.

can cause lift arms to drop. Recycle or dispose of used fluid in an environmentally
• Keep out of this area when lift arms are raised safe manner.
support. Replace if damaged. SJC equipped machines skip ahead to [Figure 10-120-
D-1009-0409 11].
Raise the operator cab. (See Raising on Page 10-30-1.) Figure 10-120-10
Figure 10-120-8
1 2 2
1
1
P-76174
P-76171
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 10-120-10] which are connected to the
Remove the left side access cover (Item 1) [Figure 10- steering shaft on the control panel.
120-8] near the rear tire.
Remove the four steering linkage mounting bolts (Item 2)
[Figure 10-120-10].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Start the engine and operate the loader hydraulic
controls.
Filters (Two-Speed Loaders) (Cont’d)
Figure 10-120-11 WARNING

1 penetrate skin or eyes, causing serious injury or
W-2072-0807
Stop the engine and check for leaks at the filter

assemblies.
P-76160
Remove the case drain filter assembly (Item 1) [Figure

10-120-11]. Install the fittings from the old filter assembly
onto the new filter assembly.
Install new case drain filter assembly.
WARNING
explosion or fire.
W-2103-0508
Standard Controls and ACS only: Align the marks on the

steering linkage bars. Install the steering linkage
mounting bolts (Item 2) [Figure 10-120-10] in the proper
orientation (two bolts facing up and two bolts facing
down). Tighten the steering linkage mounting bolts to
47,5 - 54,2 N•m (35 - 40 ft-lb).
Recycle or dispose of the used fluid in an

Lower the operator cab. (See Lowering on Page 10-30-

2.)
Remove the lift arm support device and lower the lift
arms. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Later Models
Removing And Replacing Hydraulic Charge Filter Figure 10-120-13

SCHEDULE on Page 10-70-1.)
Earlier Models 1
Figure 10-120-12
P-76676A
1
Place a suitable container below the filter housing and
remove the filter housing (Item 1) [Figure 10-120-13].
Recycle or dispose of used fluid in an environmentally

safe manner.

P-64239 Figure 10-120-14
Clean the surface of the filter housing where the filter seal
contacts the housing.
Put clean oil on the seal of the new filter. Install and hand 1
tighten the new filter.
P-76553A
Remove and discard the filter element (Item 1) [Figure

10-120-14].
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.
Put clean oil on the seal of the new filter element. Install
the element on the filter base. Install and hand tighten the
filter housing to 65 - 70 N•m (48 - 52 ft-lb) torque.

Removing And Replacing Hydraulic Charge Filter

(Cont’d)
All Models
WARNING
explosion or fire.
W-2103-0508

2.)
Start the engine and operate the loader hydraulic

controls.

WARNING
W-2072-0807
Stop the engine and check for leaks at the filter.


Breather Cap

Figure 10-120-15

P-76881
Remove the breather cap (Item 1) [Figure 10-120-15]

and discard.
Install new breather cap.

2.)

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

chains. Use the same type of oil as the hydraulic /
hydrostatic system. (See (S185) LOADER
SPECIFICATIONS on Page SPEC-10-1.).
1
Park the loader on a level surface and stop the engine.
Figure 10-130-1
1
P-76684
Remove the check plug (Item 1) [Figure 10-130-2] from

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

P-31287
Remove the drain plug (Item 1) [Figure 10-130-1] from

the front of the chaincase housing.
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
oil flows from the hole.
P-31287A
Install and tighten the plug.
Remove the oil from the chaincase [Figure 10-130-3].
Recycle or dispose of the used oil in an environmentally

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


BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Inspection And Maintenance 140-2].
Figure 10-140-1 If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
P-31693
Move the Bob-Tach levers down to engage the wedges

[Figure 10-140-1].

The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-140-2
1 B-17460
Inspect the mounting frame on the attachment and the

2 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Wedge must contact Look for cracked welds.

lower edge of hole in the
attachment. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.), and (See Lubrication Locations on Page
10-150-1.).
P-31233 B-15177
The wedges (Item 1) [Figure 10-140-2] must extend

through the holes in the attachment mounting frame.


BOB-TACH (POWER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
This machine may be equipped with a Power Bob-Tach. 141-2].
Inspection And Maintenance If the wedges do not contact the lower edge of the holes
[Figure 10-141-2], the attachment will be loose and can
Figure 10-141-1 come off the Bob-Tach.
Figure 10-141-3
1
.B-15993Q
Push and hold the BOB-TACH “WEDGES UP” switch

(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down.
The levers and wedges must move freely.

WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-141-2
2 B-17460
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
Wedge must contact damage [Figure 10-141-3]. Replace any parts that are
lower edge of hole in the damaged, bent or missing. Keep all fasteners tight.
attachment.
Look for cracked welds.
P-31233 B-15177
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.), (See Lubrication Locations on Page 10-
The wedges (Item 1) [Figure 10-141-2] must extend 150-1.).
through the holes in the attachment mounting frame.


LUBRICATING THE LOADER Figure 10-150-3
Lubrication Locations
Lubricate the loader as specified in the for the best

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
Record the operating hours each time you lubricate the 5

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

grease when you lubricate the loader. Apply lubricant
until extra grease shows.
Lubricate the following: N-18510
Figure 10-150-1
5. Tilt Cylinder Base End (Both Sides) [Figure 10-150-
3].
Figure 10-150-4

6
N-18505 7
1. Stabilizer Rod - Front (Both Sides) [Figure 10-150-1]

Figure 10-150-2
N-18509
3
6. Tilt Cylinder Rod End (Both Sides). [Figure 10-150-
4].
2
4 7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-4].
N-18506
Access
Hole
P-31841B
2. Stabilizer Rod - Rear (Both Sides) [Figure 10-150-2].

3. Lift Cylinder Rod End (Both Sides) [Figure 10-150-2].
4. Lift Cylinder Base End (Both Sides) [Figure 10-150-
2].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-7
Lubrication Locations (Cont’d)
Figure 10-150-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-150-
9 7].
P-16045 Figure 10-150-8
8. Bob-Tach Wedge (Both Sides) [Figure 10-150-5].

9. Power Bob-Tach Cylinder (Both Sides) [Figure 10-
150-5].
Figure 10-150-6
12
10
P-24703
NOTE: SJC equipped machines do not have a

steering lever shaft.
12. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-

8].
N-18508
10. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-6].

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

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

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

P-54291
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
(See SERVICE SCHEDULE on Page 10-70-1.) for the
service interval to check the wheel nuts [Figure 10-160- Avoid excessive pressure which can rupture the tire and

1]. cause serious injury or death.
When installing wheel nuts, tighten to 217 N•m (160 ft-lb) During inflation of the tire, check the tire pressure
torque. frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench
to 190 N•m (140 ft-lb) to prevent over-tightening.
Rotating
WARNING
Check the tires regularly for wear, damage and pressure. AVOID INJURY OR DEATH
Do not inflate tires above specified pressure. Failure
Figure 10-160-2 to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].


SPARK ARRESTER MUFFLER Remove the plug (Item 1) [Figure 10-170-1] from the
bottom of the muffler.
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrester muffler. (See SERVICE WARNING
Do not operate the loader with a defective exhaust When the engine is running during service, the
system. driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
cause injury or death.
W-2006-1209
IMPORTANT Start the engine and run for about 10 seconds while a
second person, wearing safety glasses, holds a piece of
This machine is factory equipped with a U.S.D.A. wood over the outlet of the muffler.
Forestry Service approved spark arrester exhaust
system. This will force contaminants out through the clean out
hole.
The spark arrester muffler, if equipped, must be
cleaned to keep it in working condition. The spark Stop the engine.
arrester muffler must be serviced by dumping the Install and tighten the plug.
spark chamber every 100 hours of operation.
Close the rear door.

On some models, the turbocharger functions as the
spark arrester and must operate correctly for proper
spark arrester function.
WARNING
If this machine is operated on flammable forest,
brush, or grass covered land, it must be equipped AVOID INJURY OR DEATH
with a spark arrester attached to the exhaust system When an engine is running in an enclosed area, fresh
and maintained in working order. Failure to do so will air must be added to avoid concentration of exhaust
be in violation of California State Law, Section 4442. fumes. If the engine is stationary, vent the exhaust
PRC. Refer to local laws and regulations for spark outside. Exhaust fumes contain odorless, invisible
arrester requirements. gases which can kill without warning.
I-2284-0111 W-2050-0807
Stop the engine. Open the rear door.

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
1
WARNING
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
P-76902 flammable material. Failure to obey warnings can
W-2068-1285


PIVOT PINS
Inspection And Maintenance
Figure 10-180-1
P-31309
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure

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

- 40 ft-lb) torque.


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

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

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

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

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

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

condition.


STOPPING THE ENGINE AND LEAVING THE LOADER NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Procedure Deluxe Instrumentation Panel allows
operation of the loader without using a
Stop the loader on level ground. password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Fully lower the lift arms and put the attachment flat on the Feature on Page 60-191-1.)
ground.
Figure 10-200-3
Figure 10-200-1
P-66659 P-66660

P-31864
Pull the engine speed control fully backward [Figure 10- Exit the loader using grab handles, safety tread and steps
200-1] to decrease the engine speed. (maintaining a 3-point contact) [Figure 10-200-3].
Engage the parking brake.

1 2
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
2 • Engage the parking brake.
P-76603 P-90809A B-15553L • Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
Turn the key switch to the STOP position (Item 1) or
drive functions are deactivated.
press the STOP button (Item 2) [Figure 10-200-2].
NOTE: If the loader lights are ON, they will remain ON The seat bar system must deactivate these functions
for approximately 90 seconds after turning when the seat bar is up. See your Bobcat dealer for
the loader OFF. service if controls do not deactivate.
W-2463-1110
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to

prevent operation of the loader by unauthorized
personnel.


EMERGENCY EXIT Front Door
The front opening on the operator cab and rear window This machine may be equipped with a front door.
provide exits.
NOTE: When an Operator Cab Enclosure Kit is
Rear Window installed, the window of the front door can be
used as an emergency exit. [Figure 10-210-3]
Figure 10-210-1
NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
NOT an emergency exit.
Figure 10-210-3
P-64994

Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-210-1].
P-85439
Push the rear window out of the rear of the operator cab.
Figure 10-210-2 Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-210-3].
Figure 10-210-4
X X
P-31269A
X X
Exit through the rear of the operator cab [Figure 10-210-
S0363
2].
Push the window out with your foot at any corner of the
window [Figure 10-210-4].
Exit through the front door.


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

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

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

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

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

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

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

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

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have deteriorated.


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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Rod End Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . 20-21-4
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

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

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-9
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-40-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-12
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Auxiliary Solenoid Removal And Installation
(S/N A3L934999 & Below And A3LH34999 & Below) . . . . . . . . . . . . . . . . . . . . . . 20-40-30

(S/N A3L935001 & Above And A3LH35001 & Above) . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-35
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-35
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-36

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-11
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-12
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
(S/N A3L934999 & Below And A3LH34999 & Below) . . . . . . . . . . . . . . . . . . . . . . 20-41-26

Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
HYDRAULIC PUMP (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8

HYDRAULIC PUMP (SJC) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-10
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Charge Filter Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-3
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
High Flow Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3


HYDRAULIC/HYDROSTATIC SCHEMATIC
S185 (S/N A3L911001 AND ABOVE)
(S/N A3LH11001 AND ABOVE)
(S/N AEYU11001 AND ABOVE)
(PRINTED JANUARY 2009)
V-1130legend Printable Version Click Here
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
2 SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 45 RESTRICTION - 0.089 inch (2,26 mm)
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - BICS CONTROL 32 FILTER - CASE DRAIN (SINTERED
36-44 PSI (2,5-3,0 Bar) BRONZE) 46 RESTRICTION - 0.025 inch (0,6 mm)
17 PILOTED ACTIVATED DIRECTIONAL
Normally Closed
CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
4 DRIVE MOTOR SHUTTLE VALVE (SCREEN)
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
34 CHECK VALVE - BUCKET POSITION
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED VALVE
49 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT
6 RELIEF VALVE - CHARGE INLET: 35 RESTRICTION CONTROL VALVE (TWO COIL)
ARM BY-PASS
360 PSI (24,8 Bar) 50 FIXED CAPACITY DISPLACEMENT
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
36 VARIABLE CAPACITY DISPLACEMENT HYDRAULIC MOTOR
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - UNLOADING
BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 51 ANTICAVITATION VALVE
7 FRONT AUXILIARY MANUAL PRESSURE 37 SHUTTLE RELIEF VALVE
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL (Not Adjustable - Factory Set) 52 PROPORTIONAL RELIEF VALVE –
SPOOL 65 PSI (4,5 Bar) (Fan Speed Regulator):
8 HYDRAULIC PUMP . . . . . . . Gear Type 1566 - 1784 PSI (108 - 123 bar)
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT
53 FILTER - BOB-TACH VALVE
BIDIRECTIONAL HYDROSTATIC
9 RELIEF VALVE - MAIN: MOTOR 54
23 SOLENOID ACTIVATED DIRECTIONAL RESTRICTION - 0.343 inch (8,73 mm)
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
at Front Quick Couplers 55 SENSOR – CHARGE PRESSURE – Fan
24 SOLENOID ACTIVATED DIRECTIONAL Filter
10 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
PORT 3500 PSI (241,3 Bar) 56 SENSOR – HYD. TEMP. – Hyd. Filter
CONTROL VALVE - BUCKET POSITION
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF)
26 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE

CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
42 CHARGE PUMP -
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL 12.8 GPM (48,5 L/min) at High Engine Idle
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY
28 43 CHECK VALVE - With 300 PSI (20,7 Bar)
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE Spring And With 0.016 inch (0,40 mm) Orifice
29 RESTRICTOR - 0.031 inch (0,8 mm) NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1130legend (1-13-09)

99 of 994
(REAR QUICK
FEMALE COUPLERS) MALE
BASE ROD REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK
(PRINTED JANUARY 2009) COUPLER BLOCK
V-1130 Printable Version Click Here 23 24
25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
32 BUCKET POSITION VALVE (OPTIONAL)
38
D
HYDRAULIC FILTER 34
31
56 OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
13
20
AUXILIARY
CHARGE
54
INLET Dealer Copy -- Not for Resale
12
SPOOL
12
13 B
B A
55
3 14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
LIFT ARM BY PASS VALVE
32
19
Printed in U.S.A. V-1130 (1-13-09)
100 of 994
WITH 2 SPEED OPTION
(PRINTED JANUARY 2009) Printable Version Click Here
V-1131legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 47 RELIEF VALVE - 2000 PSI (137 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - BICS CONTROL BRONZE) CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 Bar) 33 FILTER - BICS CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
Normally Closed (SCREEN) HYDRAULIC MOTOR
CONTROL VALVE - TILT CONTROL
4 DRIVE MOTOR SHUTTLE VALVE 34 CHECK VALVE - BUCKET POSITION
18 PILOTED ACTIVATED DIRECTIONAL 51 ANTICAVITATION VALVE
CONTROL VALVE - LIFT CONTROL VALVE
5 RELIEF/REPLENISHING VALVE - HIGH 35 RESTRICTION 52 PROPORTIONAL RELIEF VALVE –
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED (Fan Speed Regulator):
DIRECTIONAL CONTROL VALVE - LIFT 36 VARIABLE CAPACITY DISPLACEMENT 1566 - 1784 PSI (108 - 123 bar)
6 RELIEF VALVE - CHARGE INLET: ARM BY-PASS BIDIRECTIONAL HYDROSTATIC PUMP
360 PSI (24,8 Bar) 53 FILTER - BOB-TACH VALVE
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL Dealer Copy --37NotCHECK
for Resale
VALVE - With 5 PSI (0,34 Bar) Spring
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - UNLOADING 54 RESTRICTION - 0.343 inch (8,73 mm)
SPOOL 38 BIDIRECTIONAL HYDROSTATIC
MOTOR – 2 SPEED 55 SENSOR – CHARGE PRESSURE – Fan
7 FRONT AUXILIARY MANUAL PRESSURE 21 PILOTED ACTIVATED DIRECTIONAL
Filter
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL
SPOOL 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 56 SENSOR – HYD. TEMP. – Hyd. Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 57 HIGH PRESSURE SHUTTLE
CONTROL VALVE - BUCKET POSITION
9 RELIEF VALVE - MAIN: 23 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 58 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE CONTROL VALVE – WARM UP
at Front Quick Couplers 41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL 59 SOLENOID ACTIVATED DIRECTIONAL
10 RELIEF/ANTICAVITATION VALVE - 42 CHARGE PUMP -
CONTROL VALVE - ROD CONTROL VALVE – 2 SPEED
PORT 3500 PSI (241,3 Bar) 12.8 GPM (48,5 L/min) at High Engine Idle
60 PILOT ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE – HIGH / LO SPEED
43 CHECK VALVE - With 300 PSI (20,7 Bar)
Spring And With 0.016 inch (0,40 mm) Orifice 61 CHECK VALVE – With 125 PSI (8,6 bar) Spring
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY
45 RESTRICTION - 0.089 inch (2,26 mm)
28 RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE
pressure value.

101 of 994
(REAR QUICK
WITH 2 SPEED OPTION
INTEGRATED QUICK
(PRINTED JANUARY 2009) COUPLER BLOCK
Printable Version Click Here 23 24
V-1131 25 MALE
26
DRIVE MOTOR MALE
38 7 LEFT SIDE LIFT ARM)
(2 SPEED)
29
61 4 1 30
FEMALE
27
57
P-OUT P-IN T

60
D
HYDRAULIC FILTER 34
31
56 OIL
2 22
COOLER
5 36
5
A
6 3 40 C
21
13
20
AUXILIARY
CHARGE
12
SPOOL
12
13 B
B A
54
3
31 14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
55
2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
52 (OPTIONAL) 11
HYDRAULIC
51 POWERED 14
DRIVE MOTOR BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
(2 SPEED)
38 18
39
60 DR B A
37 13 LIFT
58
CYLINDER
43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
57 PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
59
4 32
19
61
Printed in U.S.A. V-1132 (1-13-09)
102 of 994
WITH HIGH FLOW OPTION
V-1132legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 45 RESTRICTION - 0.089 inch (2,26 mm)
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - BICS CONTROL 32 FILTER - CASE DRAIN (SINTERED
36-44 PSI (2,5-3,0 Bar) BRONZE) 46 RESTRICTION - 0.025 inch (0,6 mm)
Normally Closed
CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
4 DRIVE MOTOR SHUTTLE VALVE (SCREEN)
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
34 CHECK VALVE - BUCKET POSITION
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED VALVE
DIRECTIONAL CONTROL VALVE - LIFT
6 RELIEF VALVE - CHARGE INLET: 35 RESTRICTION CONTROL VALVE (TWO COIL)
ARM BY-PASS
360 PSI (24,8 Bar) 50 RELIEF VALVE - 3300 PSI (228 Bar)
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
36 VARIABLE CAPACITY DISPLACEMENT
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - UNLOADING 51 DUMP VALVE - (ON/OFF)
BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 37 SHUTTLE RELIEF VALVE 52 CHECK VALVE
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL (Not Adjustable - Factory Set)
65 PSI (4,5 Bar) 53 FILTER - BOB-TACH VALVE
SPOOL
8 HYDRAULIC PUMP . . . . . . . Gear Type
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT 54 AUXILIARY HYDRAULIC PUMP -
BIDIRECTIONAL HYDROSTATIC 9.5 GPM (36 L/min) at High Engine Idle
9 RELIEF VALVE - MAIN: MOTOR
23 SOLENOID ACTIVATED DIRECTIONAL 55 FIXED CAPACITY DISPLACEMENT
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
at Front Quick Couplers HYDRAULIC MOTOR
24 SOLENOID ACTIVATED DIRECTIONAL 56 ANTICAVITATION VALVE
10 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
PORT 3500 PSI (241,3 Bar)
CONTROL VALVE - BUCKET POSITION 57 PROPORTIONAL RELIEF VALVE –
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF) (Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
26 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 58 RESTRICTION - 0.343 inch (8,73 mm)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
42 CHARGE PUMP -
13 27 PILOT ACTIVATED DIRECTIONAL 12.8 GPM (48,5 L/min) at High Engine Idle 59 SENSOR – CHARGE PRESSURE – Fan
RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - REAR AUXILIARY Filter
PORT (OPTIONAL) 3500 PSI (241,3 Bar)
28 43 CHECK VALVE - With 300 PSI (20,7 Bar) 60 SENSOR – HYD. TEMP. – Hyd. Filter
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE Spring And With 0.016 inch (0,40 mm) Orifice
pressure value.

103 of 994
(REAR QUICK
WITH HIGH FLOW OPTION
(PRINTED JANUARY 2009) INTEGRATED QUICK
23 24 COUPLER BLOCK
V-1132
Printable Version Click Here 25 MALE
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
60 2 22
COOLER
5 36
5
A
6 3 40 C
21
13
20
AUXILIARY
CHARGE
58
12
SPOOL
12
13 B
B A
3
14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
59 2
51
8
50
52
55 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
54 (OPTIONAL) 11
HYDRAULIC
57 56 POWERED 14
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
32
19
Printed in U.S.A. V-1132 (1-13-09)
104 of 994
WITH HIGH FLOW & 2 SPEED OPTION
V-1133legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 50 RELIEF VALVE - 3300 PSI (228 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
51 DUMP VALVE - (ON/OFF)
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 Bar) (SCREEN)
CONTROL VALVE - TILT CONTROL 52 CHECK VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 34 CHECK VALVE - BUCKET POSITION
18 PILOTED ACTIVATED DIRECTIONAL 53 FILTER - BOB-TACH VALVE
36-44 PSI (2,5-3,0 Bar) CONTROL VALVE - LIFT CONTROL VALVE
Normally Closed 35 RESTRICTION 54
19 PULL BUTTON ACTIVATED AUXILIARY HYDRAULIC PUMP -
4 DRIVE MOTOR SHUTTLE VALVE DIRECTIONAL CONTROL VALVE - LIFT 9.5 GPM (36 L/min) at High Engine Idle
36 VARIABLE CAPACITY DISPLACEMENT
ARM BY-PASS BIDIRECTIONAL HYDROSTATIC PUMP
5 RELIEF/REPLENISHING VALVE - HIGH 55 FIXED CAPACITY DISPLACEMENT
PRESSURE: 5000 PSI (345 Bar) 20 PILOTED ACTIVATED DIRECTIONAL 37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring HYDRAULIC MOTOR
CONTROL VALVE - UNLOADING 56
6 RELIEF VALVE - CHARGE INLET: ANTICAVITATION VALVE
SPOOL 38 BIDIRECTIONAL HYDROSTATIC
360 PSI (24,8 Bar)
21 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not MOTOR – 2 SPEED
for Resale 57 PROPORTIONAL RELIEF VALVE –
at High Engine Idle
CONTROL VALVE - FLOW CONTROL 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring (Fan Speed Regulator):
With 140 degrees F. (60 degrees C.) Fluid
SPOOL 1566 - 1784 PSI (108 - 123 bar)
7 FRONT AUXILIARY MANUAL PRESSURE 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 58 RESTRICTION - 0.343 inch (8,73 mm)
BLEED-OFF VALVE CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF) 59 SENSOR – CHARGE PRESSURE – Fan
8 HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL
Filter
16.9 GPM (64 L/min.) at High Engine Idle CONTROL VALVE - BASE 41 CHECK VALVE - BICS CONTROL VALVE
60 SENSOR – HYD. TEMP. – Hyd. Filter
9 RELIEF VALVE - MAIN: 42 CHARGE PUMP -
CONTROL VALVE - ROD
3250-3350 PSI (224-231 Bar) 12.8 GPM (48,5 L/min) at High Engine Idle 61 HIGH PRESSURE SHUTTLE
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 43 CHECK VALVE - With 300 PSI (20,7 Bar) 62 SOLENOID ACTIVATED DIRECTIONAL
10 RELIEF/ANTICAVITATION VALVE - Spring And With 0.016 inch (0,40 mm) Orifice CONTROL VALVE – WARM UP
PORT 3500 PSI (241,3 Bar) 26 SOLENOID ACTIVATED DIRECTIONAL
44 PILOT ACTIVATED DIRECTIONAL 63 SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
CONTROL VALVE - HYDRAULIC CONTROL VALVE – 2 SPEED
27 PILOT ACTIVATED DIRECTIONAL POWERED BOB-TACH
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 64 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 45 RESTRICTION - 0.089 inch (2,26 mm) CONTROL VALVE – HIGH / LO SPEED
13 RELIEF/ANTICAVITATION VALVE - 65 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
PORT (OPTIONAL) 3500 PSI (241,3 Bar) 29 RESTRICTOR - 0.031 inch (0,8 mm)
14 LOAD CHECK VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
30 RELIEF VALVE: 3300 PSI (228 Bar)
15 LIFT CYLINDER SPOOL - MADE TO 48 RELIEF VALVE - 1200 PSI (83 Bar) NOTE: Unless otherwise specified
RESTRICT FLOW DURING BOOM 31 FILTER - HYDRAULIC (CANISTER) springs have NO significant
DOWN BUT NOT DURING BOOM UP CONTROL VALVE (TWO COIL) pressure value.

105 of 994
(REAR QUICK
WITH HIGH FLOW & 2 SPEED OPTION
(S/N A3LH11001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

V-1133 INTEGRATED QUICK
23 24 COUPLER BLOCK
Printable Version Click Here MALE
25
26
DRIVE MOTOR (2 SPEED) MALE
29
65 4 1 30
FEMALE
27
61
P-OUT P-IN T

64
D
HYDRAULIC FILTER 34
31
OIL
60 2 22
COOLER
5 36
5
A
6 3 40 C
21
13
20
AUXILIARY
CHARGE
12
SPOOL
12
13 B
B A
58
3
14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
59 2
51
8
50
52
55 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
54 (OPTIONAL) 11
57
HYDRAULIC
56 POWERED 14
DRIVE MOTOR (2 SPEED) (OPTIONAL) 10
38 18
39
64 DR B A
13 LIFT
62 37
CYLINDER
43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
PILOT CIRCUITS
61
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
63 LIFT ARM BY PASS VALVE
32
4 19
65
Printed in U.S.A. V-1133 (1-13-09)
106 of 994
WITH SJC OPTION
V-1134legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
19 PULL BUTTON ACTIVATED HYDRAULIC MOTOR
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 PROPORTIONAL RELIEF VALVE –
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL (Fan Speed Regulator):
BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 1566 - 1784 PSI (108 - 123 bar)
6 RELIEF VALVE - CHARGE INLET: SPOOL 37 SHUTTLE RELIEF VALVE
360 PSI (24,8 bar) (Not Adjustable - Factory Set) 53 CHARGE PUMP -
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL 65 PSI (4,5 bar) 12.8 GPM (48,5 L/min) at High Engine Idle
CONTROL VALVE - FLOW CONTROL
SPOOL 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL with 0.016 inch (0,40 mm) orifice
22 FLOW DIVIDER ADJUSTMENT VALVE BI-DIRECTIONAL HYDROSTATIC
PRESSURE BLEED-OFF VALVE MOTOR 55 SOLENOID ACTIVATED CONTROL
8 VALVE - FORWARD/REVERSE
HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 56 SERVO PISTON -Swash Plate
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE
40 SOLENOID ACTIVATED DIRECTIONAL 57 POSITION SENSOR -Swash Plate
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar) 58 CHARGE PRESSURE SENSOR
VALVE (ON/OFF)
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE
10 PORT RELIEF/ANTICAVITATION VALVE 59 SENSOR – CHARGE PRESSURE – Fan
3500 PSI (241,3 bar) 26 Filter
SOLENOID ACTIVATED DIRECTIONAL
42 RESTRICTION - 0.343 inch (8,7 mm) 60 SENSOR – HYD. TEMP. – Hyd. Filter
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 FILTER - Bob-Tach Valve
CONTROL VALVE - AUXILIARY
13 PORT RELIEF/ANTICAVITATION VALVE: 44 PILOT ACTIVATED DIRECTIONAL
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
3500 PSI (241,3 bar) POWERED BOB-TACH
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-1134legend (1-13-09)
Printed in U.S.A.
107 of 994
(REAR QUICK
WITH SJC OPTION

(PRINTED JANUARY 2009) INTEGRATED QUICK
(V-1134) 23 24 COUPLER BLOCK
Printable Version Click Here MALE
25
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
38 HYDRAULIC FILTER 34
31
B HYDROSTATIC PUMPS A OIL

60 22
2 COOLER
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
59 57 14
36
10 TILT CYLINDERS
31 BICS CONTROL VALVE
5 56 5
55
3 2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
50 LIFT CYLINDERS
52 51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P2 LIFT ARM BY PASS VALVE
P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-1134 (1-13-09)
108 of 994
WITH SJC & 2 SPEED OPTION
V-1135legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 51 ANTICAVITATION VALVE
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
52 PROPORTIONAL RELIEF VALVE –
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE (Fan Speed Regulator):
VALVE: 45-55 PSI (3,1-3,8 bar) 17 PILOTED ACTIVATED DIRECTIONAL (SCREEN)
CONTROL VALVE - TILT CONTROL 1566 - 1784 PSI (108 - 123 bar)
3 DIFFERENTIAL PRESSURE SWITCH: 34 CHECK VALVE - BUCKET POSITION
18 PILOTED ACTIVATED DIRECTIONAL 53 CHARGE PUMP -
36-44 PSI (2,5-3,0 bar) VALVE
Normally Closed CONTROL VALVE - LIFT CONTROL 12.8 GPM (48,5 L/min) at High Engine Idle
35 RESTRICTION
4 19 PULL BUTTON ACTIVATED 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - 36 VARIABLE CAPACITY DISPLACEMENT with 0.016 inch (0,40 mm) orifice
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS BI-DIRECTIONAL HYDROSTATIC PUMP 55 SOLENOID ACTIVATED CONTROL
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL VALVE - FORWARD/REVERSE
37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring
CONTROL VALVE - UNLOADING 56 SERVO PISTON -Swash Plate
6 RELIEF VALVE - CHARGE INLET: SPOOL 38 BI-DIRECTIONAL HYDROSTATIC
360 PSI (24,8 bar) MOTOR – 2 SPEED 57 POSITION SENSOR -Swash Plate
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
With 140 degrees F. (60 degrees C.) Fluid 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 58 CHARGE PRESSURE SENSOR
SPOOL
7 FRONT AUXILIARY MANUAL 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 59 SENSOR – CHARGE PRESSURE – Fan
PRESSURE BLEED-OFF VALVE CONTROL VALVE - BUCKET POSITION Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type VALVE (ON/OFF) 60 SENSOR – HYD. TEMP. – Hyd. Filter
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE 41 CHECK VALVE - BICS CONTROL VALVE
61 HIGH PRESSURE SHUTTLE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD 62 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers 43 CONTROL VALVE – WARM UP
25 FILTER - Bob-Tach Valve
LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE 63 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) 44 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 SPEED
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 64 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH
CONTROL VALVE – HIGH / LO SPEED
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 65 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
CONTROL VALVE - AUXILIARY 46 RESTRICTION - 0.025 inch (0,6 mm)
13 PORT RELIEF/ANTICAVITATION VALVE:
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) 47 RELIEF VALVE - 2000 PSI (137 bar)
3500 PSI (241,3 bar)
14 LOAD CHECK VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
30 RELIEF VALVE: 3300 PSI (228 bar)
15 LIFT CYLINDER SPOOL - MADE TO 49 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE (TWO COIL)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP 50 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR - FAN V-1135legend (1-13-09)
Printed in U.S.A.
109 of 994
(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE COUPLERS) MALE
WITH SJC & 2 SPEED OPTION

(PRINTED JANUARY 2009) Printable Version Click Here INTEGRATED QUICK
23 24 COUPLER BLOCK
(V-1135)
25 MALE
26
DRIVE MOTOR (2 SPEED) 38 MALE
4 29
65 1 30
FEMALE
27
61
P-OUT P-IN T
64 32 BUCKET POSITION VALVE (OPTIONAL)
D
HYDRAULIC FILTER 34
31

60 22
2 COOLER
55
56 A
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
57 14
3 36
10 TILT CYLINDERS
5 56 5
55
59 2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
52
50 LIFT CYLINDERS
51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
DRIVE MOTOR (2 SPEED) 38 BOB-TACH
(OPTIONAL) SPOOL
64 35
39 47
62 15
DR
37 14
54
48 33 41
46 33 16
9
49 45
PP
61 43
P1
44 19
63
4
65
32 V-1135 (1-13-09)
Printed in U.S.A.
110 of 994
WITH SJC AND HIGH FLOW OPTION
V-1136legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 qt. (18,2 L) BRONZE) CONTROL VALVE (TWO COIL)
CONTROL VALVE - BICS CONTROL
2 SPRING LOADED FILTER BY-PASS 50 RELIEF VALVE - 3300 PSI (228 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 51 DUMP VALVE - (ON/OFF)
3 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 52 CHECK VALVE
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE
4 DRIVE MOTOR SHUTTLE VALVE 19 PULL BUTTON ACTIVATED 53 AUXILIARY HYDRAULIC PUMP -
35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 9.5 GPM (36 L/min) at High Engine Idle
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL with 0.016 inch (0,40 mm) orifice
BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 55 SOLENOID ACTIVATED CONTROL
6 RELIEF VALVE - CHARGE INLET: SPOOL 37 SHUTTLE RELIEF VALVE
VALVE - FORWARD/REVERSE
360 PSI (24,8 bar) (Not Adjustable - Factory Set)
21 PILOTED ACTIVATED DIRECTIONAL 56 SERVO PISTON -Swash Plate
at High Engine Idle Dealer Copy -- Not for Resale 65 PSI (4,5 bar)
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL
SPOOL 38 FIXED CAPACITY DISPLACEMENT 57 POSITION SENSOR -Swash Plate
7 FRONT AUXILIARY MANUAL BI-DIRECTIONAL HYDROSTATIC
22 FLOW DIVIDER ADJUSTMENT VALVE MOTOR 58 CHARGE PRESSURE SENSOR
PRESSURE BLEED-OFF VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
23 SOLENOID ACTIVATED DIRECTIONAL 59 CHARGE PUMP -
16.9 GPM (64 L/min.) at High Engine Idle 12.8 GPM (48,5 L/min) at High Engine Idle
CONTROL VALVE - BASE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION 60 FIXED CAPACITY DISPLACEMENT
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD VALVE (ON/OFF) HYDRAULIC MOTOR
at Front Quick Couplers 41 CHECK VALVE - BICS CONTROL VALVE 61 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 26 42 RESTRICTION - 0.343 inch (8,7 mm) 62 PROPORTIONAL RELIEF VALVE –
SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL (Fan Speed Regulator):
43 FILTER - Bob-Tach Valve 1566 - 1784 PSI (108 - 123 bar)
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 44 PILOT ACTIVATED DIRECTIONAL 63 SENSOR – CHARGE PRESSURE – Fan
CONTROL VALVE - AUXILIARY CONTROL VALVE - HYDRAULIC Filter
28 RESTRICTOR - 0.140 inch (3,6 mm) POWERED BOB-TACH
13 PORT RELIEF/ANTICAVITATION VALVE: 64 SENSOR – HYD. TEMP. – Hyd. Filter
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm)
3500 PSI (241,3 bar) 46 RESTRICTION - 0.025 inch (0,6 mm)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar)
47 RELIEF VALVE - 2000 PSI (137 bar)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 48
RESTRICT FLOW DURING BOOM RELIEF VALVE - 1200 PSI (83 bar) NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-1136legend (1-13-09)
Printed in U.S.A.
111 of 994
(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE COUPLERS) MALE
WITH SJC AND HIGH FLOW OPTION


INTEGRATED QUICK
(PRINTED JANUARY 2009) Printable Version Click Here 23 24 COUPLER BLOCK
(V-1136) 25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
38 HYDRAULIC FILTER 34
31

64 22
2 COOLER
55
56 A
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
63 57 14
36
3 10 TILT CYLINDERS
HIGH FLOW VALVE
5 56 5
55 51
2 50
52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
60 LIFT CYLINDERS
62 61 59 10
FAN MOTOR 18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-1136 (1-13-09)
112 of 994
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
V-1137legend
LEGEND
1 RESERVOIR: 17 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 56 SERVO PISTON -Swash Plate
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - TILT CONTROL
36 VARIABLE CAPACITY DISPLACEMENT 57 POSITION SENSOR -Swash Plate
2 SPRING LOADED FILTER BY-PASS 18 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP
VALVE: 45-55 PSI (3,1-3,8 bar) CONTROL VALVE - LIFT CONTROL 58 CHARGE PRESSURE SENSOR
37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring
3 DIFFERENTIAL PRESSURE SWITCH: 19 PULL BUTTON ACTIVATED
36-44 PSI (2,5-3,0 bar) DIRECTIONAL CONTROL VALVE - 59 CHARGE PUMP -
38 BI-DIRECTIONAL HYDROSTATIC
Normally Closed LIFT ARM BY-PASS MOTOR – 2 Speed 12.8 GPM (48,5 L/min) at High Engine Idle
4 DRIVE MOTOR SHUTTLE VALVE 20 PILOTED ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 60 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING HYDRAULIC MOTOR
5 RELIEF/REPLENISHING VALVE - HIGH SPOOL 40 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE: 5075 PSI (350 bar) CONTROL VALVE - BUCKET POSITION 61 ANTICAVITATION VALVE
VALVE (ON/OFF)
6 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - FLOW CONTROL
360 PSI (24,8 bar) SPOOL 41 CHECK VALVE - BICS CONTROL VALVE 62 PROPORTIONAL RELIEF VALVE –
at High Engine Idle (Fan Speed Regulator):
22 FLOW DIVIDER ADJUSTMENT VALVE Dealer Copy 42
-- Not for Resale - 0.343 inch (8,7 mm)
RESTRICTION 1566 - 1784 PSI (108 - 123 bar)
7 FRONT AUXILIARY MANUAL 23 SOLENOID ACTIVATED DIRECTIONAL 43 FILTER - Bob-Tach Valve 63 SENSOR – CHARGE PRESSURE – Fan
PRESSURE BLEED-OFF VALVE CONTROL VALVE - BASE Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type 24 SOLENOID ACTIVATED DIRECTIONAL 64 SENSOR – HYD. TEMP. – Hyd. Filter
16.9 GPM (64 L/min.) at High Engine Idle CONTROL VALVE - ROD
POWERED BOB-TACH
25 LOAD SHUTTLE VALVE - BLEED OFF 45 65 HIGH PRESSURE SHUTTLE
RESTRICTION - 0.089 inch (2,26 mm)
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 bar) 26 SOLENOID ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm) 66 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE - TWO COIL CONTROL VALVE – WARM UP
47 RELIEF VALVE - 2000 PSI (137 bar)
10 PORT RELIEF/ANTICAVITATION VALVE 27 67 SOLENOID ACTIVATED DIRECTIONAL
PILOT ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) CONTROL VALVE - REAR AUXILIARY 48 RELIEF VALVE - 1200 PSI (83 bar) CONTROL VALVE – 2 SPEED
11 ANTICAVITATION VALVE 28 68 PILOT ACTIVATED DIRECTIONAL

RESTRICTOR - 0.140 inch (3,6 mm) 49 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) CONTROL VALVE – HIGH / LO SPEED
12 SOLENOID ACTIVATED DIRECTIONAL 69
29 RESTRICTOR - 0.031 inch (0,8 mm) 50 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
CONTROL VALVE - AUXILIARY RELIEF VALVE - 3300 PSI (228 bar)
13 PORT RELIEF/ANTICAVITATION VALVE: 30 RELIEF VALVE: 3300 PSI (228 bar) 51 DUMP VALVE - (ON/OFF)
. . . . . (Optional)
3500 PSI (241,3 bar) 31 FILTER - HYDRAULIC (CANISTER) 52 CHECK VALVE
14 LOAD CHECK VALVE
32 FILTER - CASE DRAIN (SINTERED 53 AUXILIARY HYDRAULIC PUMP -
15 LIFT CYLINDER SPOOL - MADE TO BRONZE) 9.5 GPM (36 L/min) at High Engine Idle
RESTRICT FLOW DURING BOOM 33 FILTER - BICS CONTROL VALVE 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring NOTE: Unless otherwise specified, springs have
DOWN BUT NOT DURING BOOM UP (SCREEN) with 0.016 inch (0,40 mm) orifice NO significant pressure value.
16 SOLENOID ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 55 SOLENOID ACTIVATED CONTROL
CONTROL VALVE - BICS CONTROL VALVE VALVE - FORWARD/REVERSE V-1137legend (1-13-09)
Printed in U.S.A.
113 of 994
(REAR QUICK
FEMALE COUPLERS)
HYDRAULIC/HYDROSTATIC SCHEMATIC MALE
WITH SJC, 2 SPEED AND HIGH FLOW OPTION

INTEGRATED QUICK
(PRINTED JANUARY 2009) Printable Version Click Here COUPLER BLOCK
23 24
(V-1137)
25 MALE
26
DRIVE MOTOR (2 SPEED) 28 7 (FRONT AUXILIARY
MALE
69 4
29
1 30
FEMALE
27
65
P-OUT P-IN T
68 32 BUCKET POSITION VALVE (OPTIONAL)
D
HYDRAULIC FILTER 34
31

64 22
2 COOLER
55
56 A
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
57 14
3 36
31 10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
63 2 50
52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
62
60 LIFT CYLINDERS
61 59 10
FAN MOTOR 18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
DRIVE MOTOR (2 SPEED) 38
35
68 39 47
66 37
15
DR
14
54
48 33 41
46 33 16
9
49 45
PP
43
P1
44 19
67
4 V-1137 (1-13-09)
69 32
Printed in U.S.A.
114 of 994
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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

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


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

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

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

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

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

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

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


CYLINDER (LIFT) Figure 20-20-2
Testing
WARNING
2
AVOID INJURY OR DEATH 1
N-18786
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and

Figure 20-20-1 tighten.
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the

engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
Repeat the procedure to check the other lift cylinder.
N-18785
WARNING
Lower the lift arms. Stop the engine. Pull up on the lift
arm bypass control and move the lift pedal to release the AVOID INJURY OR DEATH
hydraulic pressure. Raise the seat bar. Always clean up spilled fuel or oil. Keep heat, flames,
Check only one cylinder at a time. Open the rear door. Failure to use care around combustibles can cause
explosion or fire.
Disconnect the negative ground cable to the battery. W-2103-0508
Disconnect the hose (Item 1) [Figure 20-20-1] from the

lift cylinder base end port.

CYLINDER (LIFT) (CONT’D) Figure 20-20-5
Removal And Installation
Figure 20-20-3
P-34048
Remove the retainer bolt (Item 1) [Figure 20-20-5] and

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

Stop the engine. Pull up on the lift arm bypass control to
release the hydraulic pressure.

Open the rear door.
Disconnect the negative ground cable to the battery.

lift cylinder base end port.
Install a plug in the hose and tighten.
Figure 20-20-4
N-18806

nut from the lift arm pin (both sides).
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-4] (both sides).
Roll the lift arm link back.

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

P-34049 nut from the lift cylinder pivot pin.

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

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

cylinder in place.

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

CYLINDER (LIFT) (CONT’D)
Figure 20-20-9

P-34050
Remove the smaller pin (Item 1) [Figure 20-20-7] and lift

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

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

8 5
5
9
6
5
7
14 10
5 11
12
14
5
13
PE2748S

Disassembly And Assembly

4
Use the following tools to service the cylinder:
3
2
MEL1074 - O-ring Seal Hook
Spanner Wrench 1
MEL1033 - Rod Seal Installation Tool
MEL1396 - Seal Installation Tool
Piston Ring Compressor
Wash the cylinder parts in solvent and air dry them. P-48036
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts. Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-11].
Always install new O-rings and seals during assembly.
Assembly: Tighten the nut (Item 1) [Figure 20-20-11] to
Lubricate all O-rings and seals with hydraulic oil during 1152 N•m (850 ft-lb) torque.
installation.

NOTE: Clean and dry the threads before installing the
Hold the hydraulic cylinder over a drain pan and move the nut. Install the new nut from the kit.
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-20-12
Put the base end of the cylinder in a vise.
Figure 20-20-10 2
2
1 1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
20-12] from the piston.
Use a spanner wrench to loosen the head (Item 1) NOTE: If the fiber surface (Item 3) [Figure 20-20-12]
[Figure 20-20-10] from the cylinder case. on the piston head, becomes damaged, the
complete piston head must be replaced.
Assembly: Tighten the head with a spanner wrench until
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-20-10].

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

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

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

compressor can be used on the piston for 3 minutes to
compress the seal into place.
1
Figure 20-20-14
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-20-
3 16].
2
P-48039
Remove the O-ring (Item 1). Remove the O-ring (Item 2)

and the back-up ring (Item 3) [Figure 20-20-14] from the
cylinder head.
NOTE: The O-ring (Item 2) and back-up ring (Item 3)

[Figure 20-20-14] are no longer available
parts. The seal kit will contain a one piece seal
that is used in place of the O-ring and back-up
ring.

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

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

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

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

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

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

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

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

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

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

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

goes to the base end of the tilt cylinder.

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

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

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

the engine. Raise the seat bar.
P-34137
nut from the rod end pin.
Remove the retainer bolt (Item 1) [Figure 20-21-5] from
Installation: Tighten the bolt and nut to standard torque. the tilt cylinder rod end pivot pin.
Installation: Tighten the bolt and nut to 170 - 190 N•m

(125 - 140 ft-lb) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.

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

cylinder.

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

CYLINDER (TILT) (CONT'D) Figure 20-21-9
Rod End Pivot Pin Bushing And Seal Removal And

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

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

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

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

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

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

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

CYLINDER (TILT) (CONT’D)
1. Case 9. Rod seal

2. Plug 10. Wiper
3. O-ring 11. Rod
4. Nut 12. Seal
5. Piston 13. Bushing
6. Seal 14. Back-up Ring
7. Seal
8. Head
3 2
14
7
3
2

3
4
8
5
9
3 10
11
12 12
13
PE-2870S

CYLINDER (TILT) (CONT’D) Figure 20-21-12

3
Use the following tools to service the cylinder: 2
1074 - O-ring Seal Hook

1
1396 - Seal Installation Tool
1033 - Rod Seal Installation Tool
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.

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

Put the base end of the cylinder in a vise. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Figure 20-21-11
Figure 20-21-13
2
P-48034
P-48088 P-48089
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-11] from the cylinder case. Assembly: Mark the end of the shaft and nut. Tighten
the nut an additional 135 degrees or 2-1/4 flats [Figure
Assembly: Tighten the head with a spanner wrench until 20-21-13].
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-11].


1
Figure 20-21-14
2
3
2
1
P-48039

P-48073 and the back-up ring (Item 3) [Figure 20-21-16] from the
cylinder head.
Remove the seal (Item 1), and O-ring (Item 2) [Figure NOTE: The O-ring (Item 2) and back-up ring (Item 3)
20-21-14] from the piston. [Figure 20-21-16] are no longer available

Figure 20-21-15 that is used in place of the O-ring and back-up
ring.
Figure 20-21-17
P7424

P-48040
stretch it until it fits the piston [Figure 20-21-15]. Allow
the seal to stretch for 30 seconds before installing it on
the piston. Remove the wiper seal (Item 1) [Figure 20-21-17] from
the cylinder head.

Figure 20-21-18
1
P-48043 P7427

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

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

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

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

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

Bob-Tach cylinder base end port.
Figure 20-22-3

W-2072-0807 2
Figure 20-22-1
1 P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and

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

N-21401 (Front Accessory Panel).
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the Bob-Tach cylinder
[Figure 20-22-1]. for repair.

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

and 2) [Figure 20-22-4].

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

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

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

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

1
3
2 3
12
11 10 9
3 8
13
3
PE1064S

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

4 3 2
Use the following tools to service the cylinder:
1
1074 - O-ring Seal Hook
Spanner Wrench
1396 - Seal Installation Tool

1033 - Rod Seal Installation Tool
Wash the cylinder parts in solvent and air dry them.

damage. Replace any damaged parts. P16294

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

Assembly: Grease the piston where the nut contacts the
Put the base end of the cylinder in a vise. piston. do not get grease on the threads. Install the new
nut (Item 1) [Figure 20-22-7].
Figure 20-22-6
Assembly: Tighten the nut to 190 N•m (140 ft-lb) torque.
2 Figure 20-22-8
3
2
1
1 4
P-43212
Use a spanner wrench to loosen the head (Item 1) P16295

[Figure 20-22-6].
Assembly: Tighten the head with a spanner wrench until Remove the O-ring (Item 1), and seal (Item 2) from the
the head is seated all of the way into the cylinder (Item 2) piston (Item 3) [Figure 20-22-8].
[Figure 20-22-6].
NOTE: The piston center hole (Item 4) [Figure 20-22-
8] has a bevel on one end. The bevel goes
toward the rod when assembling.

Disassembly And Assembly (Cont’d)
Figure 20-22-9
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-22-11] from

P7424 the cylinder head.
Figure 20-22-12
stretch it until it fits the piston [Figure 20-22-9]. Allow the

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

1
Figure 20-22-10
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
3 2
12].
P-48039

and the back-up ring (Item 3) [Figure 20-22-10] from the
cylinder head.
NOTE: The O-ring (Item 2) and back-up ring (Item 3)

[Figure 20-22-10] are no longer available
that is used in place of the O-ring and back-up
ring.

Figure 20-22-13
P7425

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

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

Figure 20-22-14
P-48043A P7427

[Figure 20-22-14].

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

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

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

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

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1
Testing
2 1
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
WARNING P-37687
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the

loader.

W-2017-0286
The tools listed will be needed to do the following 2

procedure: 1
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position. P-76460C
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and Start the engine and run at low idle.
loaders equipped with SJC option. The main
relief valve is located in the same place on all • Press the AUXILIARY HYDRAULICS Button (Item 1)
of the loaders. [Figure 20-30-2] once to engage the auxiliary
hydraulics.
To release the hydraulic pressure at the front auxiliary
quick couplers push the couplers into the coupler block NOTE: The light (Item 2) [Figure 20-30-2] will be on.
and hold for three seconds.
Lift and block the loader. (See Procedure on Page 10-10-

1.)

MAIN RELIEF VALVE (CONT’D) If the relief pressure is not correct, stop the engine and
adjust the main relief valve.
Testing (Cont’d)
Figure 20-30-3
Right
Steering
Lever
Control
1
P-31833
Figure 20-30-4

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

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

switch (Item 1) [Figure 20-30-3] and [Figure 20-30-
4] a second time.
Watch the flow meter on the hydraulic tester to make sure

the flow is correct. Increase the engine speed to full rpm.
Refer to (See Hydraulic System on Page SPEC-10-3.) for

both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.

MAIN RELIEF VALVE (CONT’D)
Adjusting

loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5
1
2

P-37690
If the pressure is not correct, adjust the main relief valve.

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

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

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

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

of the loaders. Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 47 - 54 N•m
Check the pressure again. (See Testing on Page 20-30-

2.)
P-37690
NOTE: The right side motor cover if removed may

provide better access to the main relief valve
on some machines.
The main relief valve (Item 1) [Figure 20-30-6] is located

at the lower front of the control valve below the lift and tilt
spool connections.
Loosen and remove the main relief valve (Item 1) [Figure

20-30-6].


HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-2
Description
Figure 20-40-1
P-85528
NOTE: The hydraulic control valve can be equipped

P-68082 with two different auxiliary hydraulic
solenoids shown in [Figure 20-40-1] and
[Figure 20-40-2].
The hydraulic control valve is located inside the

mainframe on the right hand side, below the operators
cab.
The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
The lift and tilt functions are operated using mechanical

linkages to connect the foot pedals to the lift and tilt
spools.
The auxiliary function is operated by pilot pressure.

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

which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) Clean the area around the control valve.
(CONT’D)
Drain the hydraulic reservoir. (See Removing And
Removal And Installation Replacing Hydraulic / Hydrostatic Filter on Page 10-120-
2.)
Remove the control panel. (See Removal And Installation

DANGER on Page 50-100-2.)
Figure 20-40-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1

support. Replace if damaged. P-34004
D-1009-0409
Remove the right rear tire.
Locate and remove the access covers (Item 1) [Figure

WARNING 20-40-3] on the right side of the machine.
Never work on a machine with the lift arms up unless Figure 20-40-4
support device can allow the lift arms or attachment 3
W-2059-0598
2
1
IMPORTANT 1
P-66963
damage the system.
I-2003-0888
Mark and disconnect the five electric solenoid connectors
for correct installation (Item 1) [Figure 20-40-4].
1.) Disconnect and cap the supply hose (Item 2). Remove
the supply hose clamp (Item 3) [Figure 20-40-4].
Raise the lift arms and install an approved lift arm
support device (See Installing on Page 10-20-1.)

(CONT’D)
Removal And Installation (Cont'd)
Figure 20-40-5
1
1
P-66969
2 Remove the crossbar linkage bolt (Item 1) [Figure 20-40-

7].
P-66964
Remove the control pedal crossbar linkage and tilt
linkage. (See Linkage Removal And Installation on Page
Disconnect and cap the tubelines (Item 1) [Figure 20-40- 50-90-2.)

5] from the lift arm bypass valve to the hydraulic control
valve. Figure 20-40-8
Disconnect and cap the hose (Item 2) [Figure 20-40-5]

from the lift arm bypass valve to the drive motor case
drain.
Figure 20-40-6 1
P-66965
1
Remove the two lift arm bypass valve bracket mounting
bolts (Item 1) [Figure 20-40-8].
P-66967 Remove the lift arm bypass valve and mounting bracket.
Remove the connector pins (Item 1) [Figure 20-40-6].

HYDRAULIC CONTROL VALVE (STANDARD) Remove the throttle rod (Item 5) [Figure 20-40-10] from
(CONT’D) the engine, then pull the throttle rod out of the loader from
the rear.
Figure 20-40-11
Figure 20-40-9
P-66961
P-66968
Disconnect and cap the supply tubeline (Item 1) [Figure

Remove tubeline clamp screw (Item 1) [Figure 20-40-9] 20-40-11] from the hydraulic control valve.

from the auxiliary tubelines in the left rear upright.
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)

torque.
Figure 20-40-10
3
5
2 1
1
P-66970
Remove and cap both tubelines (Item 1) [Figure 20-40-

10] from the auxiliary section of the control valve.
Disconnect and cap the drain hose (Item 2) [Figure 20-

40-10] from the control valve.
Remove and cap the outlet tubeline (Item 3) [Figure 20-

40-10] from the control valve to the hydraulic oil cooler.
Remove and cap the charge tubeline (Item 4) [Figure 20-

40-10] from the control valve to the charge filter.

(CONT’D)
Figure 20-40-12
1 1
2
P-66957
Mark all tubelines and hoses for correct installation.
P-66973 The fixed end main valve hose (Item 1) [Figure 20-40-
14] is connected to a fixed end fitting on the control valve.
The hose is routed to the back upright where the hose is
Remove the supply tubeline clamp screw (Item 1) connected to a tee fitting that feeds the base end of both

[Figure 20-40-12]. lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
torque. NOTE: Remember the hose routing for ease of
control valve installation.
Remove supply tubeline (Item 2) [Figure 20-40-12] from
loader. Figure 20-40-15
Figure 20-40-13
1
1
3
P-66962
P-66971
Remove any tie-straps (Item 1) [Figure 20-40-15]
securing the fixed end main valve hose.
Disconnect and cap the tubelines (Item 1) and (Item 2)
[Figure 20-40-13] from the tilt section of the control
valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-40-

13] from the lift section of the control valve.

(CONT'D)

1
Figure 20-40-16
P-66972P-
P-66972
P-51713
34004P-
1 51713
Remove the two mounting bolts (Item 1) [Figure 20-40-

18] fastening the control valve and bracket to the side of
P-66960 the loader.
Remove the control valve from the loader.

Remove the fixed-end main valve hose (Item 1) [Figure

20-40-16] from the main control valve fitting. Reverse removal procedure to install the hydraulic control
valve.
Figure 20-40-17
1
1
P-66974
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

40-17] on the control valve.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-19
J2
C2 J4 C3
D5 E3 B3
E3
G1 G2
F2 A3 D3
B2
D4 F4 C4 E2
A2
D1
D2
A1
E1
F1 H2 B1
F3 H3
MR C1

H1 J3
J1 MS1937
ITEM S185 LOADER ITEM S185 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Valve Solenoid
D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 24131,7 H3 BICS™ Lock Valve (Lift)
kPa (241,3 bar) (3500 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 24131,7 J3 Lift Arm Bypass Orifice
kPa (241,3 bar) (3500 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 22752,7 kPa (227,5 bar)
D4 Port Relief / Anti-Cavitation Valve – 24131,7
(3300 psi)
kPa (241,3 bar) (3500 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
24131,7 kPa (241,3 bar) (3500 psi) (Optional)

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

loader. 1
Figure 20-40-20
2
1
2
P-68014
Remove the fitting (Item 1) [Figure 20-40-22] from the

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

3 22].
P-68011

Installation: Lubricate the O-ring and tighten the valve to
75 - 88 N•m (55 - 65 ft-lb) torque.
Remove the two mount bolts (Item 1) [Figure 20-40-20]
and lift eyes (Item 2) from the hydraulic control valve. Figure 20-40-23
Remove the mount bracket (Item 3) from the hydraulic

control valve.
Lift Load Check Valve Removal And Installation

1
Figure 20-40-21
1
P-51439
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-23].
P-68013
Remove the tubeline (Item 1) [Figure 20-40-21] from the

control valve.

HYDRAULIC CONTROL VALVE (STANDARD) Load Check Valve Removal And Installation (Tilt And
(CONT'D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-40-25

(Cont’d)
Figure 20-40-24
1
1
P-68007
P-51440 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-25].

Check for free movement of the load check valve (Item 1) At the front side of the control valve locate the auxiliary
[Figure 20-40-24]. section load check valve (Item 2) [Figure 20-40-25].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
Figure 20-40-26
1
3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-26].
Check the orifice (Item 3) [Figure 20-40-26] in the

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

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

(CONT'D)
Anti-Cavitation Valve Removal And Installation (Lift,

Rod End)
Figure 20-40-27
P-51693
1
Installation: Always use new O-ring (Item 1) [Figure 20-
40-28] on the anti-cavitation valve plug. Tighten the plug
to 47 - 54 N•m (35 - 40 ft-lb) torque.
P-68015
Figure 20-40-29

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-27].
4
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all 3
parts clean. Always use caps and plugs on hoses, 2
damage the system.
I-2003-0888
P-51453

20-40-29].


torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-32

Installation (Lift, Base End)
Figure 20-40-30
P-68015
P-68015 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-40-32] from the base end of the tilt section.

Loosen the lift circuit port relief / anti-cavitation valve Figure 20-40-33
(Item 1) [Figure 20-40-30].
Figure 20-40-31
P-51454
1
P-51451 Replace the O-ring (Item 1) [Figure 20-40-33] before

installation.
Replace the O-ring (Item 1) [Figure 20-40-31] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-36
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-40-34
P-68015
Remove the port relief plug (Item 1) [Figure 20-40-36]

P-68015 from the auxiliary circuit of the control valve.
Figure 20-40-37

Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-40-34] from the rod end of the tilt section.
Figure 20-40-35
P-51695
1
Installation: Always use new O-rings (Item 1) [Figure

P-51694 20-40-37]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Replace the O-ring (Item 1) [Figure 20-40-35] before

installation.

HYDRAULIC CONTROL VALVE (STANDARD) Plug Removal And Installation
(CONT'D)
Figure 20-40-40
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-38
1
1
P-68016
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-40].
The control valve may be equipped with an optional Figure 20-40-41

auxiliary port relief valve (Item 1) [Figure 20-40-38].
Remove the auxiliary port relief valve.
Figure 20-40-39
P-51460

20-40-41]. Tighten to 54 N•m (40 ft-lb) torque.
P-51640

20-40-39]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) Rubber Boot Removal And Installation
(CONT'D)
Figure 20-40-44
Plug Removal And Installation (Cont’d)
1
Figure 20-40-42
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-40-44] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 10 - 11,3 N•m (90 -

(Item 1) [Figure 20-40-42]. 100 in-lb) torque.
Figure 20-40-43 Figure 20-40-45
1
2
1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-40-43]. Tighten to 54 N•m (40 ft-lb) torque. (Item 2) [Figure 20-40-45].

(CONT'D)
End Cap / Spool Lock Block Removal And Installation
Figure 20-40-46
1 1
P-51699A
1
Remove the four end cap / spool lock block mount screws
(Item 1) [Figure 20-40-48].
P-51697
Installation: Tighten the screws to 10 - 11,3 N•m (90 -
100 in-lb) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt

spool lock solenoid (Item 2) [Figure 20-40-46] from the Remove the rubber boots and retainer plate from the lift
end cap / spool lock block. and tilt spools.
Figure 20-40-47 Figure 20-40-49
1 1
P-68017
P-51700
Disconnect the tube line (Item 1) [Figure 20-40-47] from Remove the end cap / spool lock block (Item 1) [Figure
the end cap / spool lock block. 20-40-49] from the control valve.

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

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap / spool lock block from the control
valve.
Figure 20-40-50
P-51513
Remove the end cap (Item 1) [Figure 20-40-52].
Figure 20-40-53
1

P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-50]. 2
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap / spool lock
P-51514
block.
Figure 20-40-51 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-53].
Remove the washer (Item 2) [Figure 20-40-53].
P-51512A
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-51] from the lift spool.

(CONT'D)

(Cont'd)
Figure 20-40-54
1 P-51516
Put a rag around the detent assembly [Figure 20-40-55].

This will prevent the detent balls and spring from being
1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-40-56
Remove the screws (Item 1) [Figure 20-40-54] from the

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-54].
Installation: Lubricate the screws and tighten to 10 -

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

and spring (Item 3) [Figure 20-40-56].

(CONT'D)

(Cont'd)
Figure 20-40-57
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-59].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-60

Remove the lift spool assembly and seal (Item 1) [Figure
20-40-57] from the control valve. 2
Figure 20-40-58
1
3
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-60] over the

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

Remove the lift spool seal (Item 1) [Figure 20-40-58] (Item 2) [Figure 20-40-60] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-60]

is white on all 700 series loaders.

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

(Cont'd)
Figure 20-40-61
N-19009
Remove spring tool (Item 1) [Figure 20-40-63] from the

1 spring assembly.
2
N-18916 Figure 20-40-64

Put a rag around the detent assembly [Figure 20-40-61]. 2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Alan wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-61].
Figure 20-40-62
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-64].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-62]

from the spring assembly.

HYDRAULIC CONTROL VALVE (STANDARD) NOTE: DO NOT USE Loctite® ON THE STUD
(CONT'D) THREADS.
Lift Spool And Detent Removal And Installation Figure 20-40-67

(Cont'd)
Figure 20-40-65
2
1
N-18961
N-18918 Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-67].

Remove the stud from the end of the spool [Figure 20- NOTE: Check the O-ring for damage. The lift spool
40-65]. will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
Figure 20-40-66 recheck the lift spool before the control valve
is replaced.
Figure 20-40-68
N-18920
Removal of the plastic plug:

N-18963
Make a center point in the plug using a 1,6 mm (1/16 in)

drill. Install the plastic plug and O-ring in the spool [Figure 20-
40-68].
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-66] 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.

(CONT'D)

(Cont'd)
2
Figure 20-40-69
O-ring
1 3
2
N-18958
Plastic
Plug
15,2 mm Apply grease on all the detent component surfaces
(0.60 in)
before assembly [Figure 20-40-71].
B-14712 Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-71] and compress
with the detent pliers (Item 1) [Figure 20-40-72].

Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure Figure 20-40-72
20-40-69].
Figure 20-40-70
N-18968
N-18967 Install the detent adapter to the collar [Figure 20-40-72].
NOTE: The collar and the detent adapter are held

Clamp the collar (Item 1) [Figure 20-40-70] in a vice. together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

(CONT'D)

(Cont'd)
Figure 20-40-73
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-75].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the

Install the spring tool (Item 1) [Figure 20-40-73] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 10 - 11,3 N•m (90 - 100 in-lb).
Figure 20-40-74
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-75].
Figure 20-40-76
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-74].
CD-15051
Install the detent balls and spring [Figure 20-40-76].

(CONT'D)

(Cont'd)
Figure 20-40-77
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-79].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-79].
Install the mounting screws (Item 2) [Figure 20-40-79].

Hold the detent balls in place with the detent pliers
[Figure 20-40-77]. Installation: Lubricate the screws and tighten to 10 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-78
Figure 20-40-80
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-78] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-80].

(CONT'D)

(Cont'd)
Figure 20-40-81
2
1
P-51512A
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-83] on the lift spool.
P-51513 Figure 20-40-84

Install the end cap (Item 1) [Figure 20-40-81].
Figure 20-40-82
1
P-51511A
Install the O-ring (Item 1) [Figure 20-40-84] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-82] on the

linkage end of the valve.

(CONT'D)

(Cont'd)
Figure 20-40-85
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 5.5 ± 0.28 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap / spool lock block (Item 1) and the (Item 2) [Figure 20-40-87] lock solenoids and tighten to
mount bolt (Item 2) [Figure 20-40-85]. 52 - 61 N•m (35 - 45 ft-lb) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-85].

100 in-lb) torque.
Figure 20-40-86
P-68017
Connect the tubeline (Item 1) [Figure 20-40-86].

(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap / spool lock block. (See
End Cap / Spool Lock Block Removal And Installation on
Page 20-40-15.)
2
Figure 20-40-88
1
P-68023
Remove the spool centering block (Item 1) [Figure 20-

1 2 40-90] from the control valve.
Check and replace the O-ring (Item 2) [Figure 20-40-90]

before replacing the spool centering block.

P-51521A Figure 20-40-91

20-40-88] from the tilt spool.
Figure 20-40-89
1
1 P-51544A
Remove the tilt spool, centering spring, back-up washer

2
and spool seal [Figure 20-40-91].
P-68019 Installation: Always use a new spool seal.
Remove the two tubelines (Item 1) [Figure 20-40-89].
Remove the three bolts (Item 2) [Figure 20-40-89] from

the spool centering block.
Installation: Tighten the bolts to 10 - 11,3 N•m (90 - 100

in-lb) torque.

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

2 1
Figure 20-40-92
3
4
1
N-18944A
N-18942
Figure 20-40-95
Put the linkage end of the spool in the vice [Figure 20-
2

40-92].
1
Install the spool tool (Item 1) [Figure 20-40-92] over the
centering spring.
Figure 20-40-93
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Installation: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-93] holding the

centering spring to the spool.
Installation: Tighten the bolt to 10 - 11,3 N•m (90 - 100

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

(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-96
2
2
1
1
P-68022

1
20-40-98] from the auxiliary spool.
P-68020
Figure 20-40-99
Remove the three screws (Item 1) [Figure 20-40-96]

from the spool centering block.

in-lb) torque.

2 1
Figure 20-40-97
P-51549A
Remove the spring (Item 1) and center spring retainer

2 (Item 2) [Figure 20-40-99] from the auxiliary spool.
1 NOTE: If the centering spring retainer (Item 2) [Figure

20-40-99] must be replaced, replace the
retainer on the opposite end also.
P-68021

(Item 2) [Figure 20-40-97] from the auxiliary spool.
Note: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end also.

HYDRAULIC CONTROL VALVE (STANDARD)
(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-100
1 2
P-51550A

Figure 20-40-101
P-51551A
Remove the spool (Item 1) [Figure 20-40-101].

(CONT'D)
Auxiliary Solenoid Removal And Installation (S/N

A3L934999 & Below And A3LH34999 & Below)
Figure 20-40-102 1
1
1
P-68008
Remove the solenoid stem (Item 1) [Figure 20-40-104].
Installation: Tighten the stem to 14 - 19 N•m (10 - 14 ft-

P-68007 lb) torque.
Figure 20-40-105

Remove the nut (Item 1) [Figure 20-40-102] from both
solenoids.
Installation: Tighten the nut to 5 - 8 N•m (48 - 72 in-lb)

torque.
Figure 20-40-103 1
1
2
2
P-51555
Remove the O-rings (Item 1) [Figure 20-40-105] from the

solenoid stem.
Check and clean the screen (Item 2) [Figure 20-40-105].

P-51553
Remove the nut (Item 1) and solenoid coil (Item 2)

[Figure 20-40-103].
Use an ohmmeter to measure the solenoid coil

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

HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)

A3L935001 & Above And A3LH35001 & Above)
Figure 20-40-106
2
1
2 1
P-85528

Remove the screws (Item 1) [Figure 20-40-106] from
both solenoids.
Remove the solenoids (Item 2) [Figure 20-40-106] from

the control valve.
Installation: Tighten the nut to 2,44 - 2,98 N•m (21.6 -

26.4 in-lb) torque.
Figure 20-40-107
P-85556
Check and remove the O-rings (Item 1) [Figure 20-40-

107] from the solenoid stem.

resistance.

(CONT’D)
Solenoid Removal And Installation
Figure 20-40-108
2
P-68009
P-68006 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-108] from the Figure 20-40-111

solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-108]. 3

2
Figure 20-40-109
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-111] from the cartridge.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-109] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-111] may be
cleaned with solvent. If it is torn or worn it
Use an ohmmeter to measure the solenoid coil needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.79 ± 0.29 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-109] and

[Figure 20-40-111] and new back-up rings (Item 2)
[Figure 20-40-111] on the solenoid stem.

(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-112 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-40-114] from the lift lock valve, and replace
P-68010 with new.
Locate the two BICS™ lock valves, (Item 1) is for the tilt

circuit and (Item 2) [Figure 20-40-112] is for the lift
circuit.
Figure 20-40-113
P-51443
Remove the lift lock valve (Item 1) [Figure 20-40-113]

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

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

(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-115
1
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-40-117]

from the front of the control valve.
P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

115]. Figure 20-40-118
Figure 20-40-116
2 1
1
1
1 2
2
2
P-51564
P-51697P-
51504
[Figure 20-40-118] from the tilt lock valve, and replace
Remove the lift spool lock solenoid (Item 1) [Figure 20- with new.
40-116].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-116].
Installation: Lubricate the O-rings and tighten the spool

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

HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-121
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-119
1
P-51707
2
P-68010 Remove the main relief valve (Item 1) [Figure 20-40-
121].
Remove the tubeline (Item 1) and fitting (Item 2) [Figure Figure 20-40-122

20-40-119] from the valve.
Figure 20-40-120
P-51463
P-51437 Remove the O-rings (Item 1) [Figure 20-40-122] from the

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

casting.

(CONT'D)
Check Valve Removal And Installation
Figure 20-40-123
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

125] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-68013 torque.
Figure 20-40-126
Remove the tubeline (Item 1) [Figure 20-40-123].

Figure 20-40-124
P-68870
P-68010 Inspect the screen (Item 1) [Figure 20-40-126].
Remove the BICS™ check valve fitting (Item 1) [Figure

20-40-124] from the top of the lift load check valve.
Installation: Lubricate the O-ring and tighten the fitting to

27 - 33 N•m (20 - 24 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-2
Description
Figure 20-41-1
P-85528
NOTE: The hydraulic control valve can be equipped

P-68082 with two different auxiliary hydraulic
solenoids shown in [Figure 20-41-1] and
[Figure 20-41-2].
The hydraulic control valve is located inside the

mainframe on the right hand side, below the operators
cab.
The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
The lift and tilt functions in the ACS or SJC hydraulic

control valve are operated using electronic control handle
/ levers or foot pedals that send an electronic signal to the
electronic actuators to move the lift and tilt spools in the
control valve.
The auxiliary function is operated by pilot pressure.

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

valve which is adjustable.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Clean the area around the control valve.
(CONT’D)
Removal And Installation Replacing Hydraulic / Hydrostatic Filter on Page 10-120-
2.)

DANGER on Page 50-100-2.)
Figure 20-41-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1

support. Replace if damaged. P-34004
D-1009-0409
Remove the right rear tire.
Locate and remove the access covers (Item 1) [Figure

WARNING 20-41-3] on the right side of the machine.
Never work on a machine with the lift arms up unless Figure 20-41-4
to fall and cause injury or death. 3
W-2059-0598
IMPORTANT
1
P-68204
damage the system.
I-2003-0888
Mark and disconnect the three electric solenoid
connectors for correct installation (Item 1) [Figure 20-41-
Lift and block the loader. (See Procedure on Page 10-10- 4].
1.)
Disconnect and cap the supply hose (Item 2). Remove
Raise the lift arms and install an approved lift arm the supply hose clamp (Item 3) [Figure 20-41-4].
support device (See Installing on Page 10-20-1.)

(CONT’D)
Figure 20-41-5
1
P-66965
2
Remove the two lift arm bypass valve bracket mounting
P-68206
Remove the lift arm bypass valve and mounting bracket.
Disconnect and cap the tubelines (Item 1) [Figure 20-41- Figure 20-41-8

5] from the lift arm bypass valve to the hydraulic control
valve.
Disconnect and cap the hose (Item 2) [Figure 20-41-5]

from the lift arm bypass valve to the drive motor case 1
drain.
Figure 20-41-6
P-66968
1 Remove tubeline clamp screw (Item 1) [Figure 20-41-8]

from the auxiliary tubelines in the left rear upright.

torque.
P-68205
Disconnect the connectors for the hydraulic control valve

actuators (Item 1) [Figure 20-41-6].

(CONT’D)
Figure 20-41-9
1
3 2
5
2
1 1 4
P-66973
Remove the supply tubeline clamp screw (Item 1)

[Figure 20-41-11].
P-68203
torque.
Remove and cap both tubelines (Item 1) [Figure 20-41-

9] from the auxiliary section of the control valve. Remove supply tubeline (Item 2) [Figure 20-41-11] from
loader.
Disconnect and cap the drain hose (Item 2) [Figure 20-
41-9] from the control valve. Figure 20-41-12
Remove and cap the outlet tubeline (Item 3) [Figure 20-

41-9] from the control valve to the hydraulic oil cooler.
1
Remove and cap the charge tubeline (Item 4) [Figure 20-
41-9] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-41-9] from 2

the engine, then pull the throttle rod out of the loader from
the rear.
Figure 20-41-10 3
P-66971
1
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-41-12] from the tilt section of the control
valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-41-

12] from the lift section of the control valve.
P-66961
Disconnect and cap the supply tubeline (Item 1) [Figure

20-41-10] from the hydraulic control valve.

(CONT’D)
Figure 20-41-13
P-66960
1
Remove the fixed-end main valve hose (Item 1) [Figure
20-41-15] from the main control valve fitting.
P-66957
Mark all tubelines and hoses for correct installation.

The fixed end main valve hose (Item 1) [Figure 20-41-
13] is connected to a fixed end fitting on the control valve.
The hose is routed to the back upright where the hose is
connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
NOTE: Remember the hose routing for ease of

control valve installation.
Figure 20-41-14
P-66962
Remove any tie-straps (Item 1) [Figure 20-41-14]

securing the fixed end main valve hose.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out Of Loader)
(CONT’D)
Figure 20-41-18
Figure 20-41-16
1 1
P-68028
P-68202

Connect a hoist to the lifting brackets (Item 1) [Figure 20- from the lift actuator.

41-16] on the control valve.
Installation: Tighten the mounting bolts to 10 - 11,3 N•m
Figure 20-41-17 (90 - 100 in-lb) torque.
Figure 20-41-19
1
P-66972P-
P-66972
P-51713
34004P-
51713
P-68029
17] fastening the control valve and bracket to the side of
the loader. Slide the actuator mount bracket (Item 1) [Figure 20-41-
19] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
Reverse removal procedure to install the hydraulic control 41-19].
valve.

(CONT’D)
Actuator Removal And Installation (Out of Loader) 1

(Cont’d)
Figure 20-41-20
1
P-68032
1 Remove the two mount bolts (Item 1) [Figure 20-41-22]

from the tilt actuator.
P-68030 Installation: Tighten the mounting bolts to 10 - 11,3 N•m

(90 - 100 in-lb) torque.

Using a drift pin and a hammer, remove the actuator Figure 20-41-23
linkage pin (Item 1) [Figure 20-41-20] from the actuator
and the lift spool.
Remove the actuator and linkage pin from the valve.

1
Figure 20-41-21
P-68033
Slide the actuator mount bracket (Item 1) [Figure 20-41-

2 23] away from the control valve.
P-68031 Pull the actuator away from the control valve [Figure 20-
41-23].
Inspect the O-ring (Item 1) [Figure 20-41-21] on the

nose of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-21] and

replace as needed.

(CONT’D)
Actuator Removal And Installation (Out of Loader) 3

(Cont’d)
Figure 20-41-24
1
2
P-68035
1 NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2) to
the control valve.
P-68034 The two shorter mount bolts (Item 3) are used
to mount the tilt actuator (Item 4) [Figure 20-
41-26] to the end cap.

Using a drift pin and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-41-24] from the actuator Installation: Tighten the mounting bolts to 10 - 11,3 N•m
and the tilt spool. (90 - 100 in-lb) torque (Item 1) [Figure 20-41-26]
Remove the actuator and linkage pin from the valve.
Figure 20-41-25
P-68031

nose of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-25] and

replace as needed.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-27
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3
B2 D3
D4 C4 E2
A2
D1
D2
A1
E1
F1 H2 B1
H3

MR C1
H1 J3
J1 MS1972
ITEM S185 LOADER ITEM S185 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 LIft Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS™ Valve Solenoid
C3 Load Check Valve Auxiliary Function H2 BICS™ Lock Valve (Tilt)
C4 Check Valve
H3 BICS™ Lock Valve (Lift)
D1 Anti-Cavitation Valve
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief / Anti-Cavitation Valve – 24131,7 J2 Outlet Fluid Flow (Return to Tank)
kPa (241,3 bar) (3500 psi) J3 Lift Arm Bypass Orifice
Lift (Base End) J4 Drain (Case)
D3 Port Relief / Anti-Cavitation Valve – 24131,7 MR Main Relief Valve – 22752,7 kPa (227,5 bar)
kPa (241,3 bar) (3500 psi) (3300 psi)
Tilt (Base End)
D4 Port Relief / Anti-Cavitation Valve – 24131,7
kPa (241,3 bar) (3500 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
24131,7 kPa (241,3 bar) (3500 psi) (Optional)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Figure 20-41-29
Mount Bracket Removal And Installation
Remove the control valve and mount bracket from the

loader.
Figure 20-41-28
1 1
P-68013

control valve.
3
P-68011 Figure 20-41-30

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

control valve.
P-68014

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

30].
Installation: Lubricate the O-ring and tighten the valve to

75 - 88 N•m (55 - 65 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-33

(Cont’d)
Figure 20-41-31
1
2
2
P-68007
P-51439 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-33].

Remove and install new O-rings (Item 1) and back-up At the front side of the control valve locate the auxiliary
ring (Item 2) [Figure 20-41-31]. section load check valve (Item 2) [Figure 20-41-33].
Figure 20-41-32 NOTE: The tilt and auxiliary load check valves are
interchangeable.
1
Figure 20-41-34
1
3
2
P-51440
Check for free movement of the load check valve (Item 1)

P-51453
[Figure 20-41-32].

20-41-34].


torque.

(CONT’D)
Anti-Cavitation Valve Removal And Installation (Lift,

Rod End)
Figure 20-41-35
1
1
P-51452
Always use new O-ring (Item 1) [Figure 20-41-36] on the

anti-cavitation valve plug.
P-68037 Figure 20-41-37

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-35]. 4
IMPORTANT 1
3
damage the system.
I-2003-0888 P-51453

20-41-37].


torque.

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

Installation (Lift, Base End)
Figure 20-41-38
P-68037
P-68037 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-41-40] from the base end of the tilt section.

Loosen the lift circuit port relief / anti-cavitation valve Figure 20-41-41
(Item 1) [Figure 20-41-38].
Figure 20-41-39
1
1
P-68039
P-68038 Replace the O-ring (Item 1) [Figure 20-41-41] before

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

61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-44
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-41-42 1
P-68037
Remove the port relief plug (Item 1) [Figure 20-41-44]

P-68037 from the auxiliary circuit of the control valve.
Figure 20-41-45

Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-42] from the rod end of the tilt section.
Figure 20-41-43
P-51801
1

P-51455 20-41-45]. Lightly lubricate with oil and tighten to 52 - 61
N•m (38 - 45 ft-lb) torque.
Replace the O-ring (Item 1) [Figure 20-41-43] before

installation.
Installation: Lightly lubricate with oil and tighten to 52 -


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Plug Removal And Installation
(CONT’D)
Figure 20-41-48
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-46
1
1
P-68016
P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-48].
The control valve may be equipped with an optional Figure 20-41-49

auxiliary port relief valve (Item 1) [Figure 20-41-46].
Remove the auxiliary port relief valve.
Figure 20-41-47
1
P-51460

P-51640

20-41-47]. Lightly lubricate with oil and tighten to 52 - 61

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) End Cap Block Removal And Installation
(CONT’D)
Remove the lift and tilt actuators from the control valve.
Plug Removal And Installation (Cont’d) (See Actuator Removal And Installation (Out Of Loader)
on Page 20-41-6.)
Figure 20-41-50
Figure 20-41-52
1 P-51461
P-68040
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-50]. Disconnect the tube line (Item 1) [Figure 20-41-52] from
the end cap block.
Figure 20-41-51
Remove the two end cap block mount screws (Item 2)
[Figure 20-41-52].

100 in-lb) torque.
Figure 20-41-53
1
P-51462 1

P-68041
Remove the end cap block (Item 1) [Figure 20-41-53]

from the control valve.

(CONT’D)
1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-54 1
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-56] from
the lift spool end cap.
Installation: Lubricate the screws and tighten to 10 -

11,3 N•m (90 - 100 in-lb) torque.

Figure 20-41-57
P-68042
Remove the O-ring (Item 1) [Figure 20-41-54].
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-41-55 1
P-68044
2 Remove the lift spool end cap (Item 1) [Figure 20-41-57]

1 from the control valve.
P-68047

20-41-55] from the lift spool.

(CONT’D)

(Cont'd)
Figure 20-41-58
P-51772
1
Clamp the linkage end of the spool in a vise [Figure 20-
41-60].
P-68045 NOTE: Protect spool before clamping in vise.
Figure 20-41-61

Remove the lift spool assembly and seal (Item 1) [Figure
20-41-58] from the control valve.
Figure 20-41-59
1
P-51773

P-68046 centering spring.
Remove the lift spool seal (Item 1) [Figure 20-41-59]

from the linkage end of the valve.

(CONT’D)

(Cont'd)
Figure 20-41-62
1
1
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in)

drill.
N-190146
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill

Remove the bolt (Item 1) [Figure 20-41-62] holding the Turn a 6-32 tap (Item 1) [Figure 20-41-64] into the plug.
centering spring to the spool. Pull the tap and plug out of the spool. Be careful, do not
break the tap.
in-lb) torque. Clean all the debris from inside the spool bore.
Remove spring tool from the spring assembly. NOTE: DO NOT USE Loctite® ON THE STUD
THREADS.
Figure 20-41-63 Figure 20-41-65
3
2
2
1
4 1
P-51776
P-74183
Inspect the adapter (Item 1), collar (Item 2), spring (Item Install the O-ring (Item 1) over the nipple on the plastic
3) and washer (Item 4) [Figure 20-41-63]. plug (Item 2) [Figure 20-41-65].
NOTE: Check the O-ring for damage. The lift spool

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

(CONT’D)

(Cont'd) 1
Figure 20-41-66
2
3
3
P-68044
Install the lift spool assembly (Item 1) [Figure 20-41-68]

in the spool bore.
P-74184 Install the end cap (Item 2) [Figure 20-41-68].
Install the mounting screws (Item 3) [Figure 20-41-68].

Install the plastic plug and O-ring in the spool [Figure 20-
41-66]. Installation: Lubricate the screws and tighten to 10 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-67
2
1
P-51771 P-51775


(CONT’D)

(Cont'd) 1
Figure 20-41-69
1
P-68042
Install the O-ring (Item 1) [Figure 20-41-71] on the

control valve.
P-68048 Figure 20-41-72

Install the spool seal (Item 1) [Figure 20-41-69] on the
actuator end of the valve.
Figure 20-41-70 3
1 P-68040
Install the end cap block (Item 1) and the two mount bolts
2
(Item 2) [Figure 20-41-72].
P-68049 Installation: Tighten the screws to 10 - 11,3 N•m (90 -

100 in-lb) torque.
Install the O-ring (Item 1) and spacer (Item 2) [Figure 20- Connect the tube line (Item 3) [Figure 20-41-72] to the
41-70] on the lift spool. end cap block.
Install the lift and tilt actuators to the control valve.

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

Figure 20-41-73 2
P-68051

1 2
Check and replace the O-ring (Item 2) [Figure 20-41-75]
before replacing the spool centering block.
P-68049

Figure 20-41-76

20-41-73] from the tilt spool.
Figure 20-41-74
1
1
2 1
P-68052
2 Remove the tilt spool, centering spring, back-up washer

and spool seal (Item 1) [Figure 20-41-76].
P-68050
Disconnect the tubeline (Item 1) [Figure 20-41-74].


in-lb) torque.

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

2 1
Figure 20-41-77
3
4
1
N-18944A
N-18942
Figure 20-41-80
Put the linkage end of the spool in the vice [Figure 20-
2

41-77].
1
centering spring.
Figure 20-41-78
1
1
P-51545 N-18943

N-19014
Remove the bolt (Item 1) [Figure 20-41-78] holding the

centering spring to the spool.

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

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-81
1
1
2
P-68054
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

P-68050
Figure 20-41-84
Disconnect the tubelines (Item 1) [Figure 20-41-81] from

the spool centering block.


in-lb) torque.
2
Remove the spool centering block from the control valve. 1
Figure 20-41-82
P-68076

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

2 20-41-84] must be replaced, replace the
retainer on the opposite end of the spool,
also.
1
P-68053

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

retainer on the opposite end of the spool also.

(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-85
P-68077

Figure 20-41-86
P-68078
Remove the auxiliary spool (Item 1) [Figure 20-41-86].

(CONT’D)

Figure 20-41-87
1 1
P-68083
Installation: Tighten the stem to 14 - 19 N•m (10 - 14 ft-

P-68082 lb) torque.
Figure 20-41-90

Remove the nut (Item 1) [Figure 20-41-87] from both
solenoids.
Installation: Tighten the nut to 5 - 8 N•m (48 - 72 in-lb)

torque.
Figure 20-41-88 1
1
2
2
P-51555
Remove the O-rings (Item 1) [Figure 20-41-90] from the

solenoid stem.
Check and clean the screen (Item 2) [Figure 20-41-90].

P-51553
Remove the nut (Item 1) and solenoid coil (Item 2)

[Figure 20-41-88].

resistance.

(CONT’D)

Figure 20-41-91
2
1
2 1
P-85528

Remove the screws (Item 1) [Figure 20-41-91] from both
solenoids.
Remove the solenoids (Item 2) [Figure 20-41-91] from

the control valve.

26.4 in-lb) torque.
Figure 20-41-92
P-85556
Check and remove the O-rings (Item 1) [Figure 20-41-

92] from the solenoid stem.

resistance.

(CONT’D)
Solenoid Removal And Installation
Figure 20-41-93
P-68085
2
P-68084 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-93] from the Figure 20-41-96

solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-93]. 3

2
Figure 20-41-94
1
1
N-18694

[Figure 20-41-96] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-94] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-96] may be
cleaned with solvent. If it is torn or worn it
Use an ohmmeter to measure the solenoid coil needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.79 ± 0.29 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-94] and

[Figure 20-41-96] and new back-up rings (Item 2)
[Figure 20-41-96] on the solenoid stem.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-97 1
1
1
2
1
1
2
2
2
P-51564

[Figure 20-41-99] from the lift lock valve, and replace
P-68079 with new.
Figure 20-41-100
Locate the two BICS™ lock valves, (Item 1) is for the tilt

circuit, and (Item 2) [Figure 20-41-97] is for the lift circuit.
Figure 20-41-98
1 P-68080
Remove the tilt lock valve (Item 1) [Figure 20-41-100]

P-68081 from the back of the control valve.

Remove the lift lock valve (Item 1) [Figure 20-41-98] tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.
from the back of the control valve.


(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-101
1
1
1
1
2
2
2
P-51564

[Figure 20-41-101] from the tilt lock valve, and replace
with new.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-104
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-102
P-68088
P-68087 Remove the main relief valve (Item 1) [Figure 20-41-

104].
Remove the fitting (Item 1) [Figure 20-41-102] from the Figure 20-41-105

valve.
Figure 20-41-103
1
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-41-105].
Check the lift arm bypass orifice (Item 1) [Figure 20-41- Installation: Always use new O-rings. Tighten to 52 - 61
103]. N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-41-106
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

108] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-68013 torque.
Figure 20-41-109
Remove the tubeline (Item 1) [Figure 20-41-106].

Figure 20-41-107
P-68870
P-68010 Inspect the screen (Item 1) [Figure 20-41-109].
Remove the check valve fitting (Item 1) [Figure 20-41-

107] from the hydraulic control valve.

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

side of the machine close to the engine speed control.
DANGER
The lift arm bypass control valve is manually operated by
pulling up on the valve knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise a 1/4 turn. The valve
releases the hydraulic fluid from the base end of the lift
cylinder(s) which allows the lift arm to slowly come down
to the transport position.
Testing P-90328
Figure 20-50-1 AVOID DEATH

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

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

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

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

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

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

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

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

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

20-50-3].

HYDRAULIC PUMP (STANDARD) Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
the front auxiliary quick couplers.
Description
This procedure will require a operator in the cab and one
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
The hydraulic gear pump has a dedicated charge pump. rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about a 6895
A seal kit is available to service the hydraulic pump. If any kPa (68,9 bar) (1000 psi).
of the main components of the pump are damaged, the
entire pump must be replaced. NOTE: DO NOT EXCEED 22752,7 kPa (227,5 bar) (3300
psi).
Pump Test At Quick Couplers
Turn the restrictor control (Item 2) [Figure 20-60-1] on
The tools listed will be needed to do the following the tester counterclockwise to obtain free flow, the flow
procedure: should be approximately 60,6 - 64,4 L/min (16 - 17 U.S.

gpm). Start turning the restrictor clockwise, causing more
10003 - In-Line Hydraulic Tester restriction on the flow. The L/min (U.S. gpm) should drop
10006 - Flow Meter Fitting Kit off slightly until the pressure reaches approximately
19305 kPa (193,1 bar) (2800 psi). At approximately
Figure 20-60-1 19305 kPa (193,1 bar) (2800 psi) the flow should start
decreasing rapidly until the pressure reaches 22408 -
22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi). At
1 22408 -22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi)
the flow should be at 0 L/min (0 U.S. gpm). Turn the
restrictor (Item 2) [Figure 20-60-1] counterclockwise to
free flow. Shut the front auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to Direct

Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full rpm.
P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).

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

procedure: 2
1563 - Remote Start Tool Kit

10003 - Hydraulic Tester
10006 - Hydraulic Test Kit
WARNING 1
P-68163
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
tubeline on the control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

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

P-48256A
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-1.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-3] from the tester to the tubeline (Item 2) [Figure
Connect the remote start tool. (See REMOTE START 20-60-2] on the control valve.
TOOL KIT-1563 on Page 10-60-1.) or (See REMOTE
START TOOL (SERVICE TOOL) KIT - 7003031 on Page
10-61-1.)
IMPORTANT
I-2024-0284

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

BH-196
Sample tester connection shown [Figure 20-60-4].
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
rpm*.
Warm the fluid to 60°C (140°F) by turning the restrictor

control (Item 1) [Figure 20-60-4] on the tester to about
6895 kPa (68,9 bar) (1000 psi). DO NOT exceed system
relief pressure. Open the restrictor control and record the
free flow (L/min [U.S. gpm]) at full rpm*.
Push the maximum / variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (psi)
and flow (L/min [U.S. gpm]). The high pressure flow must
be at least 80% of free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm) X 100

%=
FREE FLOW (L/min [U.S. gpm)
A low percentage may indicate a failed pump.


Direct Pump Test (Charge Section)

procedure:
1563 or 7003031 - Remote Start Tool Kit

10003 - Hydraulic Tester 2
10006 - Hydraulic Test Kit 1
WARNING
P-69182
Failure to use jackstands can allow the machine to Disconnect the proportioning valve electrical connector
fall or move and cause injury or death. (Item 1) [Figure 20-60-5].
W-2017-0286
Remove the tie-strap (Item 2) [Figure 20-60-5] from the

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

Figure 20-60-6
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
P-69184
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1) [Figure 20-60-6].
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-1.) for system relief pressure and full rpm.
Connect the remote start tool. (See REMOTE START

10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)

IMPORTANT
Figure 20-60-7
3 position before you start the engine.
4 I-2024-0284
rpm*.

4137 kPa (41,4 bar) (600 psi). DO NOT exceed 8274 kPa
2 1 (82,7 bar) (1200 psi). Open the restrictor control and
P-69185 record the free flow (L/min [U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

Connect the filter inlet hose (Item 1) to the inlet side of
approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
the tester (Item 2) [Figure 20-60-7].
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to

Hydraulic Schematics for flow. The high pressure flow
Connect the OUTLET hose (Item 3) from the hydraulic
must be at least 80% of free flow.
tester to the inlet fitting (Item 4) of the charge filter
HIGH PRESSURE FLOW (L/min [U.S. gpm) X 100
[Figure 20-60-7]. %=
FREE FLOW (L/min [U.S. gpm))
Figure 20-60-8
*Refer to the Hydraulic Schematics for pump flow and

rpm.
P-48256A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-60-8].

DANGER
1
P-66880
P-90328
AVOID DEATH Disconnect and cap the outlet hoses (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 60-9] from the back of the hydraulic pump.
WARNING

D-1009-0409
IMPORTANT to fall and cause injury or death.
W-2059-0598

clean the work area before disassembly and keep all Figure 20-60-10
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Installing on

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

P-66882
Checking And Adding Fluid on Page 10-120-1.)
Open the rear door of the loader. Disconnect and cap the inlet hoses (Item 1) [Figure 20-
60-10] from the front of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

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

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

Figure 20-60-12 pump.

1
P-66898

11] and [Figure 20-60-12] from the hydraulic pump.

Remove the hydraulic pump from the loader.

Hydraulic Pump Startup
NOTE: This procedure is necessary to prevent a dry 1

start up of the hydraulic pump.
Figure 20-60-14
2
P100352
Attach a push button starter switch (1712) (Item 1)

Inlet Hose [Figure 20-60-15] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-16].
P-66897 Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.

Disconnect the pump inlet hose connection at the front of
the hydrostatic pump. Fill the pump inlet and hose
Start the loader from the operators cab and run the
completely with hydraulic fluid. Reconnect the hose
engine at low idle for 1 - 2 minutes without operating the
[Figure 20-60-14].
hydraulics.
Figure 20-60-15
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
1 With the loader parked on a level surface and lift arms
down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.
P100685

15
14
7 5
13
8
5 6
4
12 3

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

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

60-17].

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

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

Figure 20-60-19 1
P-64511
2
Figure 20-60-22
P-64509
1
Figure 20-60-20

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

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

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

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

Figure 20-60-23
P-64515
Figure 20-60-26
P-64513
Figure 20-60-24

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

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

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


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

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

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

toward gears.

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

damage and replace as needed. 4

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

needed.

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

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

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

1
P-64531
P-64529

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

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

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

the end of the drive gear.

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

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

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


Figure 20-60-43
3
2
1
P-64540

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

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

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

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

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


HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
Description
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
The hydraulic gear pump has a dedicated charge pump. rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
The high flow hydraulic pump has an additional pump kPa (68,9 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 22752,7 kPa (227,5 bar) (3300
from a button on the panel in the cab. psi).
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 60,6 - 64,4 L/min (16 - 17 U.S.

Pump Test At Quick Couplers restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately
The tools listed will be needed to do the following 19305 kPa (193,1 bar) (2800 psi). At approximately
procedure: 19305 kPa (193,1 bar) (2800 psi) the flow should start
10003 - In-Line Hydraulic Tester 22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi). At
10006 - Flow Meter Fitting Kit 22408 -22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi)
Figure 20-61-1 restrictor (Item 2) [Figure 20-61-1] counterclockwise to
1 If flow and pressure specs are not obtained, go to Direct

on Page 20-61-2.)

P-16903 P-66894


HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Figure 20-61-2
(CONT’D)

procedure:

1
WARNING
P-68163

Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
that comes from the gear pump, and connects to the
W-2017-0286
Figure 20-61-3

1.)

2
WARNING 1

P-48256A
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-61-3] from

Raise the operator cab. (See Raising on Page 10-30-1.) the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Open the rear door of the loader. 20-61-3] from the tester to the tubeline (Item 2) [Figure
20-61-2] on the control valve.
10-61-1.)

HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
(CONT’D)
Direct Pump Test (Standard Section) (Cont’d)
Figure 20-61-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
rpm*.


HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

%=
FREE FLOW (L/min [U.S. gpm])


(CONT’D)

procedure:
1563 - Remote Start Tool Kit 2

WARNING
P-69182

Disconnect the proportioning valve electrical connector
(Item 1) [Figure 20-61-5].
W-2017-0286
electrical harness.

1.) Figure 20-61-6

WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-69184

filtered after it passes through the Hydraulic Disconnect the filter inlet hose (Item 1)[Figure 20-61-6].
Tester, to prevent any contamination to the
Hydrostatic Pumps.

10-61-1.)

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Start the engine and run at low idle rpm. Make sure the
(CONT’D) tester is connected correctly. If no flow is indicated on the
Direct Pump Test (Charge Section) (Cont’d) connected correctly, increase the engine speed to full
rpm*.
Figure 20-61-7
4 3 control (Item 1) [Figure 20-61-8] on the tester to about
(82,7 bar) (1200 psi). Open the restrictor control and
record the free flow (L/min [U.S. gpm]) at full rpm*.


1 %=
2 FREE FLOW (L/min [U.S. gpm])
P-69185


rpm.
[Figure 20-61-7].
Figure 20-61-8
P-48256A
[Figure 20-61-8].
IMPORTANT
I-2024-0284

(CONT’D)
Direct Pump Test (High Flow Section)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-61-9] onto the

front auxiliary quick couplers.

Figure 20-61-10
W-2059-0598
IMPORTANT
I-2024-0284 1

procedure: 2
P-48235
10006 - Hydraulic Test Kit Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow valve INLET fitting (Item 2) [Figure 20-
Lift and block the loader. (See Procedure on Page 10-10- 61-10].
1.)

10-61-1.)

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Warm the fluid to 60°C (140°F) by turning the restrictor
(CONT’D) control (Item 1) [Figure 20-61-12] on the tester to about
6895 kPa (68,9 bar) (1000 psi).
Direct Pump Test (High Flow Section) (Cont'd)
NOTE: DO NOT EXCEED 22752,7 kPa (227,5 bar)
Figure 20-61-11 (3300 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm. Turn the restrictor control on the
tester to 22752,7 kPa (227,5 bar) (3300 psi) and the flow
should go to 0 L/min (0 U.S. gpm).
2 1 If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-3.)
Record the highest pressure (psi) and flow (L/min [U.S.

gpm]). The high pressure flow must be at least 80% of
free flow.
P-48256A HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

%=
Connect the INLET hose (Item 1) [Figure 20-61-11] from


the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-10]. Connect the OUTLET hose (Item 2)
[Figure 20-61-11] from the tester, to the high flow valve *Refer to Hydraulic Schematics Legend for system relief
INLET fitting (Item 2) [Figure 20-61-10] on the High Flow pressure and full rpm.
valve.
Lower the cab.
Figure 20-61-12
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
High Flow Valve
1
B-16277
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

(CONT’D)
DANGER
1
P-64545
P-90328
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
AVOID DEATH 61-13] from the back of the hydraulic pump.
WARNING

D-1009-0409 Never work on a machine with the lift arms up unless
IMPORTANT W-2059-0598
When repairing hydrostatic and hydraulic systems, Figure 20-61-14

damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.) 1

Drain the hydraulic fluid from the reservoir. (See P-66882

Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
Disconnect and cap the inlet hoses (Item 1) [Figure 20-
Remove the Power Bob-Tach block if equipped. (See


(CONT’D)
Figure 20-61-15
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-61-17] on the

hydraulic pump.
P-66897
pump.
Figure 20-61-16

1
P-66898

15] and [Figure 20-61-16] from the hydraulic pump.

Remove the hydraulic pump from the loader.

(CONT’D)

1
NOTE: This procedure is necessary to prevent a dry
Figure 20-61-18 2
P100352

[Figure 20-61-19] to the starter terminal S (Item 1) and
Inlet Hose the positive battery cable (Item 2) [Figure 20-61-20].
Crank the engine for 15 seconds, then stop for at least 30

P-66897 seconds. Again, crank the engine for 15 seconds.

the hydrostatic pump. Fill the pump inlet and hose Start the loader from the operators cab and run the
completely with hydraulic fluid. Reconnect the hose engine at low idle for 1 - 2 minutes without operating the
[Figure 20-61-18]. hydraulics.
Figure 20-61-19 After operating the engine at low idle, remove the lift arm
of cylinder stroke.
With the loader parked on a level surface and lift arms

1
P100685

(CONT’D)
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7

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

(CONT’D)
1
Figure 20-61-21
1
P-64553
P-64554
1
1 Remove the high flow end section (Item 1) [Figure 20-
61-22].
P-64552

61-21].

20-61-21].

IMPORTANT
damage the system.
I-2003-0888

(CONT’D)

1
Figure 20-61-23
P-64556
2 Figure 20-61-26
P-64554
1
Figure 20-61-24

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

61-25] and [Figure 20-61-26] from the charge center
P-64555 section.
NOTE: Inspect the high flow pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-26]. If excessive wear or
[Figure 20-61-23] and [Figure 20-61-24] from the high damage is visible, the pump must be
flow end section. replaced.

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


(CONT’D)
Figure 20-61-27
P-64560
Figure 20-61-30
P-64558
Figure 20-61-28

1
P-64561

[Figure 20-61-30] from the charge center section.
P-64559
Remove the drive gear (Item 1) [Figure 20-61-27] and pump must be replaced.
[Figure 20-61-28].


(CONT’D)
Figure 20-61-31
1
P-64564
2 Figure 20-61-34
P-64562
2
Figure 20-61-32

1
2 1
P-64565

P-64563 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-34].

[Figure 20-61-31] and [Figure 20-61-32] from the
charge center section. Inspect for damage and replace
as needed.

toward gears.

(CONT’D)

2
Figure 20-61-35
3
1
1 P-64569
Figure 20-61-38
P-64567 3

4

damage and replace as needed.
NOTE: Inspect the charge center section (Item 2) and

Figure 20-61-36
2
P-64571
1

as needed.

toward gears.

P-64568 bushings (Item 4) [Figure 20-61-38]. If
Remove the charge center section (Item 1) [Figure 20-
61-36].

(CONT’D)
Figure 20-61-39
1
1
P-64574

the auxiliary center section.
P-64572
Figure 20-61-42
Figure 20-61-40

1
P-64575
P-64573
Remove the charge pump section (Item 1) [Figure 20- pump must be replaced.
61-39] and [Figure 20-61-40] from the auxiliary pump
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-61-40]. If excessive wear or
damage is visible, the pump must be
replaced.

(CONT’D)
Figure 20-61-43
1
2
1
2
P-64578
Figure 20-61-46
P-64576

the end of the drive gear. Inspect for damage and replace
as needed.
1
2
Figure 20-61-44
P-64579
1 Remove the wear plate (Item 1) and O-ring (Item 2)

auxiliary center section. Inspect for damage and replace
as needed.

toward gears.
P-64577


(CONT’D)
2
Figure 20-61-47
1 1
P-64521

P-64519
NOTE: Inspect the auxiliary center section (Item 2)
and bushings (Item 3) [Figure 20-61-49]. If
Figure 20-61-48 excessive wear or damage is visible, the

2 Figure 20-61-50
1
P-64520

P-64525
needed.
Remove the auxiliary center section (Item 1) [Figure 20-
Remove the pre-load seal (Item 2) [Figure 20-61-48]. 61-50].

(CONT’D)
Figure 20-61-51
P-64528
1
Figure 20-61-54
P-64526
Figure 20-61-52

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

2
61-53] and [Figure 20-61-54] from the pump flange
P-64527 section.
NOTE: Inspect the auxiliary pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-54]. If excessive wear or
[Figure 20-61-51] and [Figure 20-61-52] from the damage is visible, the pump must be
auxiliary center section. Inspect for damage and replace replaced.
as needed.

toward gears.


(CONT’D)
Figure 20-61-55
1
2
P-64532

P-64530
Remove the drive gear (Item 1) [Figure 20-61-55] from Figure 20-61-58

Figure 20-61-56
1
1
P-64534
P-64531 Remove the idler gear (Item 1) [Figure 20-61-58] from

NOTE: Inspect the drive gear (Item 1) [Figure 20-61- NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
56]. If excessive wear or damage is visible, the 58]. If excessive wear or damage is visible, the
pump must be replaced. pump must be replaced.

(CONT’D)
Figure 20-61-59
P-64537
Figure 20-61-62
P-64535
Figure 20-61-60

2
P-64538
1

2 [Figure 20-61-62]. Inspect for damage and replace as
P-64536 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-62].

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

toward gears.

(CONT’D)
Figure 20-61-63
3
2
1
P-64540


Figure 20-61-64
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-61-64] from


pump.


HYDRAULIC PUMP (SJC) This procedure will require a operator in the cab and one
operator running the tester.
Description
Start the engine and run at low idle rpm. Press the Front
The hydraulic gear pump is attached to the end of the Auxiliary button. Engage the front auxiliary with the
hydrostatic pumps and is located on the right side of the trigger on the right handle. Make sure the tester is
loader between the hydraulic control valve and the connected correctly. If no flow is indicated on the tester,
engine. the hoses are connected wrong. With the hoses
The hydraulic gear pump is a combination of gear pumps rpm*.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about a 6895
This supplies flow to the hydraulic fan motor and charge kPa (68,9 bar) (1000 psi).
pressure to the hydrostatic pump.
A seal kit is available to service the hydraulic pump. If any (3300 psi).
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-70-1] on
the tester counterclockwise to obtain free flow, the flow
Pump Test At Quick Couplers should be approximately 60,6 - 34,4 L/min (16 - 17 U.S.
The tools listed will be needed to do the following restriction on the flow. The L/min (U.S. gpm) should drop
procedure: off slightly until the pressure reaches approximately

10003 - In-Line Hydraulic Tester 19305 kPa (193,1 bar) (2800 psi) the flow should start
10006 - Flow Meter Fitting Kit decreasing rapidly until the pressure reaches 22408 -
22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi). At
Figure 20-70-1 22408 -22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi)
1 If flow and pressure specs are not obtained, go to Direct

on Page 20-70-2.)

P-16903 P-66894
Install a hydraulic tester (Item 1) [Figure 20-70-1] onto



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

procedure: 2

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

WARNING 2 1

P-48256A
W-2059-0598
10-61-1.)

HYDRAULIC PUMP (SJC) (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Figure 20-70-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
rpm*.



%=



procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-70-6
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-1.) for system relief pressure and full rpm.

10-61-1.)

HYDRAULIC PUMP (SJC) (CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-70-7 rpm*.
4 3 Warm the fluid to 60°C (140°F) by turning the restrictor


2 1 HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

%=
P-69185 FREE FLOW (L/min [U.S. gpm])


rpm.
[Figure 20-70-7].
Figure 20-70-8
P-48256A
[Figure 20-70-8].
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (SJC) (CONT'D)
Removal And Installation WARNING

DANGER the lift arms are secured by an approved lift arm
W-2059-0598
Figure 20-70-9
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1
2

D-1009-0409
P-64546
IMPORTANT Open the rear door of the loader.
When repairing hydrostatic and hydraulic systems, Disconnect and cap the outlet hose (Item 1) [Figure 20-
clean the work area before disassembly and keep all 70-9] from the back of the hydraulic pump.
tubelines and ports to keep dirt out. Dirt can quickly Remove the Power Bob-Tach block (Item 2) [Figure 20-
damage the system. 70-9] if equipped. (See Removal And Installation on Page
I-2003-0888 20-130-1.)
Lift and block the rear of the loader. (See Procedure on Figure 20-70-10
Page 10-10-1.)


1
Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 20-


HYDRAULIC PUMP (SJC) (CONT'D) Remove the hydraulic pump (Item 3) [Figure 20-70-12]
from the hydrostatic pump.
Figure 20-70-13
Figure 20-70-11
P-64446
P-64549
Replace the O-ring (Item 1) [Figure 20-70-13] in the

hydrostatic pump.
11] from the hydraulic pump.

pump.
Figure 20-70-12
3
1
P-64343
Remove the bracket mounting bolt (Item 1) from the

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

Only replace with original Bobcat Parts.
Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 122 - 136 N•m (90 - 100 ft-
lb) torque.
Remove the mounting bracket (Item 2) [Figure 20-70-

12].


Figure 20-70-14
2
P100352


[Figure 20-70-14].
hydraulics.
Figure 20-70-15
of cylinder stroke.
P100685

HYDRAULIC PUMP (SJC) (CONT’D)
15
14
7 5
13
8
5 6
4
12 3

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

HYDRAULIC PUMP (SJC) (CONT’D) Figure 20-70-18
Figure 20-70-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-70-
P-64508 18].

70-17].

20-70-17].

IMPORTANT
damage the system.
I-2003-0888

Figure 20-70-19 1
P-64511
2
Figure 20-70-22
P-64509
1
Figure 20-70-20

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

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

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

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

Figure 20-70-23
P-64515
Figure 20-70-26
P-64513
Figure 20-70-24

1
P-64516

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



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

1
2 1
P-64520

needed.
needed.

toward gears.

Figure 20-70-31
2
1
1
P-64526
Figure 20-70-34
P-64521
3


NOTE: Inspect the pump center section (Item 2) and
Figure 20-70-32
2
1
P-64527

needed.

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

Remove the pump center section (Item 1) [Figure 20-70- pump must be replaced.
32].

Figure 20-70-35
1
P-64530
1
P-64528 the pump flange section.
Figure 20-70-38
Figure 20-70-36

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
70-35] and [Figure 20-70-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

70-36]. If excessive wear or damage is visible,
the pump must be replaced.

Figure 20-70-39
2
P-64535
Figure 20-70-42
P-64532


Figure 20-70-40
2
P-64536

1 [Figure 20-70-41] and [Figure 20-70-42] from the pump
needed.

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


Figure 20-70-43
3
2
1
P-64540


Figure 20-70-44 bushings (Item 3) [Figure 20-70-45]. If

Figure 20-70-46
1
2
2
1 P-30188A
P-64538

P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-70-44]. Remove the shaft seal (Item 1) [Figure 20-70-46] from

pump.


HYDRAULIC PUMP (SJC) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description diameter and connected directly to the
The hydraulic gear pump is attached to the end of the “quick coupler” on the connection to the
hydrostatic pumps and is located on the right side of the tester. Also make sure your hydraulic tester is
loader between the hydraulic control valve and the capable of at least 189,3 L/min (50 U.S. gpm).
engine.
The hydraulic gear pump is a combination of gear pumps operator running the tester.
that provide hydraulic flow to several hydraulic systems.
Start the engine and run at low idle rpm. Press the Front
The hydraulic gear pump has a dedicated charge pump. Auxiliary button. Engage the front auxiliary with the
This supplies flow to the hydraulic fan motor and charge trigger on the right handle. Make sure the tester is
pressure to the hydrostatic pump. connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
The high flow hydraulic pump has an additional pump connected correctly, increase the engine speed to full
section that provides an additional amount of flow that is rpm*.
controlled by an external valve. The valve is switched
from a button on the panel in the cab. Warm the fluid to 60°C (140°F) by turning the restrictor
A seal kit is available to service the hydraulic pump. If any kPa (68,9 bar) (1000 psi).
entire pump must be replaced. NOTE: DO NOT EXCEED 22752,7 kPa (227,5 bar)

(3300 psi).
Pump Test At Quick Couplers
Turn the restrictor control (Item 2) [Figure 20-71-1] on
The tools listed will be needed to do the following the tester counterclockwise to obtain free flow, the flow
procedure: should be approximately 60,6 - 34,4 L/min (16 - 17 U.S.
10003 - In-Line Hydraulic Tester restriction on the flow. The L/min (U.S. gpm) should drop
10006 - Flow Meter Fitting Kit off slightly until the pressure reaches approximately
Figure 20-71-1 19305 kPa (193,1 bar) (2800 psi) the flow should start
2 22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi). At
22408 -22752,7 kPa (224,1 - 227,5 bar) (3250 - 3300 psi)
If flow and pressure specs are not obtained, go to Direct

on Page 20-71-2.)
2
P-16903 P-66894
Install a hydraulic tester (Item 1) [Figure 20-71-1] onto


HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D) Figure 20-71-2

procedure: 2

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

1
WARNING 2

P-48256A
W-2059-0598
10-61-1.)

HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Figure 20-71-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
rpm*.



%=



procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-71-6
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.

10-61-1.)

HYDRAULIC PUMP (SJC) (HIGH FLOW)(CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-71-7 rpm*.
4 3 Warm the fluid to 60°C (140°F) by turning the restrictor


2 1 HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

%=
P-69185 FREE FLOW (L/min [U.S. gpm])


rpm.
[Figure 20-71-7].
Figure 20-71-8
P-48256A
[Figure 20-71-8].
IMPORTANT
I-2024-0284

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-71-9] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:
1563 - Remote Start Too Kit


1.)

10-61-1.)

Direct Pump Test (High Flow Section) (Cont'd) EXAMPLE: TESTER

CONNECTION
Reservoir
Figure 20-71-10
Hydraulic Pump
Out In
High Flow Valve
1 1
B-16277
2 Sample tester connection shown [Figure 20-71-12].

P-48235
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
Disconnect the high flow pump OUTLET hose (Item 1) button (on the right control lever) for fluid flow to the quick
from the high flow valve INLET fitting (Item 2) [Figure 20- coupler. Make sure the tester is connected correctly. If no

71-10]. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-71-11 engine speed to full rpm*.

6895 kPa (68,9 bar) (1000 psi).

2 1 (3300 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm. Turn the restrictor control on the
tester to 22752,7 kPa (227,5 bar) (3300 psi) and the flow
should go to 0 L/min (0 U.S. gpm).
If pressure readings are not obtained go to the High Flow

P-48256A Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-3.)
Connect the INLET hose (Item 1) [Figure 20-71-11] from Record the highest pressure (psi) and flow (L/min [U.S.
the tester, to the high flow pump OUTLET hose (Item 1) gpm]). The high pressure flow must be at least 80% of
[Figure 20-71-10]. Connect the OUTLET hose (Item 2) free flow.
[Figure 20-71-11] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-71-10] on the High Flow
valve. %=
Lower the cab.

*Refer to Hydraulic Schematics Legend for system relief

pressure and full rpm.

HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT’D) Figure 20-71-13
DANGER
P-64545
P-90328
AVOID DEATH Figure 20-71-14


D-1009-0409
1
2
Page 10-10-1.)
P-64546
Drain the hydraulic fluid from the reservoir. (See Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Removing And Replacing Hydraulic Fluid on Page 10- 71-13] and [Figure 20-71-14] from the back of the
120-2.) hydraulic pump.
Open the rear door of the loader. Remove the Power Bob-Tach block (Item 2) [Figure 20-
71-14] if equipped. (See Removal And Installation on
Page 20-130-1.)
WARNING
W-2059-0598

Figure 20-71-15
3
1
1
2
1 P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64544 pump mounting bracket (Item 2) [Figure 20-71-17].
NOTE: The mounting bolt is a special purpose bolt.

Disconnect and cap the inlet hoses (Item 1) [Figure 20- Only replace with original Bobcat Parts.

Installation: Apply a medium strength threadlocker to
Figure 20-71-16 mounting bolt and tighten to 122 - 136 N•m (90 - 100 ft-
lb) torque.
Remove the mounting bracket (Item 2) [Figure 20-71-

17].
Remove the hydraulic pump (Item 3) [Figure 20-71-17]

from the hydrostatic pump.
1
Figure 20-71-18
P-64549

16] from the hydraulic pump.

P-64446
Replace the O-ring (Item 1) [Figure 20-71-18] in the

hydrostatic pump.

pump.


Figure 20-71-19
2
P100352


[Figure 20-71-19].
hydraulics.
Figure 20-71-20
of cylinder stroke.
P100685

HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT’D)
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7
12

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

Figure 20-71-22
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 71-23].

71-22].

20-71-22].

IMPORTANT
damage the system.
I-2003-0888

Figure 20-71-24 1
P-64556
2
Figure 20-71-27
P-64554
1
Figure 20-71-25

3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 71-26] and [Figure 20-71-27] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-71-24] and [Figure 20-71-25] from the high [Figure 20-71-27]. If excessive wear or
flow end section. damage is visible, the pump must be
replaced.
toward gears.
NOTE: Inspect the high flow end section (Item 3) and


Figure 20-71-28
P-64560
Figure 20-71-31
P-64558
Figure 20-71-29

1
P-64561

P-64559 [Figure 20-71-31] from the charge center section.



Figure 20-71-32
P-64564
2
Figure 20-71-35
P-64562
2
Figure 20-71-33

1
2
1
P-64565

needed.
as needed.

toward gears.

Figure 20-71-36 2
3
1
1
P-64569
Figure 20-71-39
P-64567
3


1
Figure 20-71-37
2
1 P-64571

as needed.

toward gears.
P-64568 NOTE: Inspect the charge center section (Item 3) and

Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
71-37].

Figure 20-71-40
1 1
P-64574

P-64572 the auxiliary center section.
Figure 20-71-43
Figure 20-71-41

1
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 43]. If excessive wear or damage is visible, the
71-40] and [Figure 20-71-41] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-71-41]. If excessive wear or
damage is visible, the pump must be
replaced.

Figure 20-71-44
1 2
2
P-64578
Figure 20-71-47
P-64576

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

as needed.
Remove the idler gear (Item 2) [Figure 20-71-44]. 1
Figure 20-71-45 2
P-64579
1
auxiliary center section. Inspect for damage and replace
as needed.

P-64577 toward gears.


Disassembly And Assembly (Cont'd) 2
Figure 20-71-48
1
1
P-64521


Figure 20-71-49 and bushings (Item 3) [Figure 20-71-50]. If

2
Figure 20-71-51
1
P-64520

P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-71-49]. Remove the auxiliary center section (Item 1) [Figure 20-
71-51].

Figure 20-71-52
P-64528
1
Figure 20-71-55
P-64526
Figure 20-71-53

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

P-64527 71-54] and [Figure 20-71-55] from the pump flange
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-71-52] and [Figure 20-71-53] from the [Figure 20-71-55]. If excessive wear or
auxiliary center section. Inspect for damage and replace damage is visible, the pump must be
as needed. replaced.

toward gears.


Figure 20-71-56
1
1
P-64532

P-64530 the end of the drive gear.

the pump flange section. Figure 20-71-59

Figure 20-71-57
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-71-59] from
57]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-71-
pump must be replaced. 59]. If excessive wear or damage is visible, the

Figure 20-71-60
P-64537
Figure 20-71-63
P-64535
Figure 20-71-61

2
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-71-63].
needed.

toward gears.

HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT’D)
Figure 20-71-64
3
2
1
P-64540


Figure 20-71-65
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-71-65] from


pump.


HYDRAULIC / HYDROSTATIC FILTERS Disconnect the tubeline (Item 3) [Figure 20-80-1] from
the filter housing.
Description
Figure 20-80-2
The hydraulic / hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

gear pump filter and one fan / charge pressure filter.
The gear pump hydraulic / hydrostatic filter removes 1

contaminants after the oil cooler.
2
The charge pressure filter removes contaminants before
the oil enters the hydrostatic pump.
P-68220
IMPORTANT
Disconnect the temperature sender connector (Item 1)
When repairing hydrostatic and hydraulic systems, [Figure 20-80-2] from the filter housing.

parts clean. Always use caps and plugs on hoses, Disconnect the wire connector (Item 2) [Figure 20-80-2]
tubelines and ports to keep dirt out. Dirt can quickly from the differential pressure switch on the filter housing.
damage the system.
I-2003-0888
Housing Removal And Installation
Figure 20-80-1
2
P-68234
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)
Remove the mounting bolt (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-80-1].

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-80-3
P-48257
Using MEL 1558 tool disconnect the oil cooler tubeline

(Item 1) [Figure 20-80-3] from the filter housing.

Figure 20-80-4
P-48258
Remove the two mounting screws (Item 1) [Figure 20-

80-4] from the filter housing mounting bracket.
Installation: Tighten the mounting screws to 20 - 27 N•m

Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D) Figure 20-80-7
Charge Filter Housing Removal And Installation
Figure 20-80-5 2
2 1
2
1 P-68127
Remove filter inlet hose (Item 1) [Figure 20-80-7].

P-66884
Remove the four mounting screws (Item 2) [Figure 20-
80-7].
Remove filter outlet hose (Item 1) [Figure 20-80-5].
Installation: Tighten the mount screws to 20 - 27 N•m

Disconnect the electrical connector (Item 2) [Figure 20- (15 - 20 ft-lb) torque.
80-5] from the charge pressure sender.
Remove filter assembly from the loader.
Figure 20-80-6
Figure 20-80-8
2
1
P-66884
P-66609
Disconnect the charge pressure tubeline (Item 1) [Figure

20-80-6] that connects to the control valve. Remove the four mounting bolts (Item 1) [Figure 20-80-
8].
Disconnect the electrical connector from the filter sensor
(Item 2) [Figure 20-80-6]. Installation: Tighten the mount bolts to 34 N•m (25 ft-lb)
torque.


HYDRAULIC FLUID RESERVOIR
Description
IMPORTANT
The hydraulic fluid reservoir is a storage container for the
loaders hydraulic / hydrostatic fluid. The reservoir When repairing hydrostatic and hydraulic systems,
contains a vented fill cap with a fluid screen to prevent clean the work area before disassembly and keep all
contaminants from entering the reservoir while adding parts clean. Always use caps and plugs on hoses,
fluid. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The hydraulic fluid reservoir is located below the I-2003-0888
operators cab on the left side of the loader.
Stop the engine.
1.) Remove the fluid from the hydraulic reservoir.
Start the engine. Raise the lift arms and install an Remove the control panel. (See Removal And Installation
approved lift arm support device. (See Installing on Page on Page 50-100-2.)
10-20-1.)
Remove bucket position valve if so equipped. (See
DANGER

Remove the crossbar linkage, if so equipped. (See
Linkage Removal And Installation on Page 50-90-2.)
Figure 20-90-1
2
P-90328
AVOID DEATH
1
D-1009-0409 P-34113
Remove the left rear tire assembly (Item 1) [Figure 20-

90-1].
WARNING
Remove the two access panels (Item 2) [Figure 20-90-
1].
W-2059-0598

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-4
Figure 20-90-2
1 3
1 2
2 P-68132
Remove the drive motor drain hose (Item 1) [Figure 20-

P-68130 90-4] at the drain filter
Remove the auxiliary pressure relief drain hose (Item 2)

Remove the two mounting screws (Item 1) and remove [Figure 20-90-4] at the drain filter.
the plate (Item 2) [Figure 20-90-2] from the loader.

Remove the drive motor supply hose (Item 3) [Figure 20-
Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb) 90-4] from the drive motor and the hydrostatic pump.
torque.
Figure 20-90-5
Figure 20-90-3
2
1
1
P-68131
P-66831
Remove the control valve drain hose (Item 1) [Figure 20-

Remove the hose clamp (Item 1) [Figure 20-90-3] from 90-5].
the fill hose.
Remove the hydraulic fill hose (Item 2) [Figure 20-90-3] reservoir.
from the hydraulic reservoir.

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-8
Figure 20-90-6
2
P-34044
Remove the hose clamp (Item 1) [Figure 20-90-8] from

P-34042 the fitting.
Remove the breather hose (Item 2) [Figure 20-90-8]

Remove the hose clamp (Item 1) [Figure 20-90-6] from from the hydraulic reservoir.
the tank outlet.

Figure 20-90-9
Remove the hydrostatic supply hose (Item 2) [Figure 20-
90-6] from the bottom of the reservoir.
Figure 20-90-7
1
1
2
P-34052
Remove the hydraulic reservoir (Item 1) [Figure 20-90-9]

P-34043 from the loader.
Remove the bolt and nut (Item 1) [Figure 20-90-7].
Loosen the bolt and nut (Item 2) [Figure 20-90-7] to

allow the hydraulic reservoir mount to drop down.

HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Figure 20-90-10
P-68128

Remove the hose clamp (Item 1) and remove the
hydraulic fill hose (Item 2) [Figure 20-90-10] from the
hydraulic reservoir.
Figure 20-90-11
P-68129
Remove the hydraulic fluid screen (Item 1) [Figure 20-

90-11] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER Figure 20-100-2
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
The oil cooler is located underneath the rear grille

between the A/C condenser (if so equipped) and the
radiator.
N-19346
IMPORTANT Figure 20-100-3


damage the system.
I-2003-0888
Remove the rear grille from the loader. (See Removal

And Installation on Page 50-60-1.)
Figure 20-100-1
P-45242
1
2 Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 20-100-2] and [Figure 20-
100-3].
N-19345
Install tool MEL 1558 (Item 1) to outside of rubber sleeve

(Item 2) [Figure 20-100-1].

OIL COOLER (CONT’D)
Figure 20-100-4
1
2
1
P-45101
Disconnect the inlet and outlet hoses (Item 1) from the oil
cooler (Item 2) [Figure 20-100-4].

NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.

BUCKET POSITION VALVE Figure 20-110-2
Description
The Bucket Position Valve is an option that allows the

loader to meter the lift and tilt circuits. The metering of the
lift and tilt circuits allows the operator to hold the
attachment at the same angle from the ground to 2
maximum lift height without using the tilt function.
The bucket position valve is located below the operators

cab on the right side of the hydraulic fluid reservoir.
See Hydraulic Schematic for more circuit information. 1
Solenoid Removal And Installation P-26311A
Figure 20-110-1
Remove the solenoid nut (Item 1) [Figure 20-110-2].
Installation: Tighten the solenoid nut to a maximum of 5

- 8 N•m (4 - 6 ft-lb) torque. Overtightening may cause
valve failure.

Remove the solenoid coil (Item 2) [Figure 20-110-2].
1 2
Figure 20-110-3
P-68162
Disconnect the wire harness connector (Item 1) [Figure

20-110-1] from the bucket position shut-off solenoid.
NOTE: Loosening the two mounting screws (Item 2)

[Figure 20-110-1] on the Bucket Positioning
Valve Bracket may aid in the solenoid 1
removal. P-26312A
Remove the solenoid stem (Item 1) [Figure 20-110-3]

from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 40,8 - 47,6 N•m (30 - 35 ft-lb)
torque.

BUCKET POSITION VALVE (CONT'D) Solenoid Testing
Solenoid Removal And Installation (Cont’d) Figure 20-110-5
Figure 20-110-4
1
2
P9175
N-18191
Use a test meter to measure coil resistance [Figure 20-
110-5]. Coil wires do not have polarity. Correct resistance
Inspect the solenoid stem and replace the O-rings (Item for the coil is 9.8 ohm.
1) and the back-up washer (Item 2) [Figure 20-110-4].

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

BUCKET POSITION VALVE (CONT'D) Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
Removal And Installation 10-20-1.)
Stop the engine.
DANGER Raise the operator cab. (See Raising on Page 10-30-1.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-110-6].
Figure 20-110-7
P-90328
AVOID DEATH
2

1
D-1009-0409
P-26311A

W-2059-0598 1
Figure 20-110-6
P-26312A
1 Remove the solenoid nut (Item 1) [Figure 20-110-7].
Installation: Tighten the nut to a maximum of 5 - 8 N•m

(4 - 6 ft-lb) torque. Overtightening may cause valve
failure.
Remove the solenoid (Item 2) [Figure 20-110-7] and the

P-68162 solenoid stem (Item 1) [Figure 20-110-8].
Installation: Put oil on the O-rings and back-up washers

and tighten the solenoid stem to 40,8 - 47,6 N•m (30 - 35
ft-lb) torque.

BUCKET POSITION VALVE (CONT'D) Remove the bucket position valve and bracket from the
loader.
Figure 20-110-9
Figure 20-110-11
1 1
P-68158
N-19069
Disconnect the tubeline (Item 1) [Figure 20-110-9] from

the fitting under the solenoid on the bucket position valve. Remove the solenoid nut (Item 1) [Figure 20-110-11].

Figure 20-110-10 Installation: Tighten the solenoid nut to maximum 8 N•m
(6 ft-lb) torque.
Figure 20-110-12
1 4
2
2
3 P-68157 1
Remove the tubeline (Item 1) [Figure 20-110-10] from

N-19070
the B port to the control valve.
Disconnect the tubeline (Item 2) [Figure 20-110-10] from Remove the solenoid (Item 1) and the solenoid stem
the C port (tilt rod end) on the BPV. (Item 2) [Figure 20-110-12].
Disconnect the tubeline (Item 3) [Figure 20-110-10] from Installation: Put oil on O-rings and back-up washers and
the D port (tilt base end) on the BPV. tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Remove the mounting screws (Item 4) [Figure 20-110-
10].


BUCKET POSITION VALVE (CONT'D) Figure 20-110-15
Figure 20-110-13
N-18339
1 Remove the plug (Item 1), and flow control spool (Item 2)
N-19072 [Figure 20-110-15].
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

Remove the flow adjustment valve and O-ring (Item 1) ft-lb) torque.
[Figure 20-110-13].

Inspect the flow control spool for wear, inspect the O-ring
Installation: Tighten the flow adjustment valve to 20,3 - on the plug and replace as needed.
40,7 N•m (15 - 30 ft-lb) torque.
Figure 20-110-16
NOTE: Always install new O-rings before any parts
are installed into the valve. Inspect the parts
for wear or damage and replace as needed.
Figure 20-110-14
3
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

1 2) and plug (Item 3) [Figure 20-110-16]. Inspect for wear,
N-19041 inspect the O-ring and replace as needed.

Remove the plug (Item 1) [Figure 20-110-14]. ft-lb) torque.

ft-lb) torque.

BUCKET POSITION VALVE (CONT'D)
Figure 20-110-17
N-19045
Remove the plug [Figure 20-110-17].

ft-lb) torque.
Figure 20-110-18
N-19046
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-110-18].
Inspect all parts and replace as needed. Install a new O-

ring on the plug before installing.
Assembly: Tighten the plug to torque.

REAR AUXILIARY DIVERTER VALVE Solenoid Testing
Description Figure 20-120-1
The rear auxiliary diverter valve is an optional valve that

diverts oil from the front auxiliary circuit to two sets of
rear auxiliary couplers or the right side auxiliaries. The
couplers are used for rear mounted attachments.The
right side auxiliaries are used for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
The right side auxiliaries are located on the inside of the

right side lift arm at the front of the machine.
The rear auxiliary valve is located on the right side of the

machine behind the blower housing. The valve is P9137
accessed by remove a panel on the right side of the
machine.
See Hydraulic Schematic for more circuit information. 120-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm @ 20°C (68°F).


REAR AUXILIARY DIVERTER VALVE (CONT'D) Disconnect the negative battery cable. (See Removal
Remove the speed control lever. (See Lever Removal
DANGER Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
Remove the right rear tire. (See TIRE MAINTENANCE

on Page 10-160-1.)
Figure 20-120-2
P-90328
AVOID DEATH
• Keep out of this area when lift arms are raised 1

D-1009-0409
P-48301
WARNING The rear auxiliary valve (Item 1) [Figure 20-120-2] is

located between the control valve and the gear pump on
the right side of the loader.
W-2059-0598 IMPORTANT
WARNING parts clean. Always use caps and plugs on hoses,
damage the system.
AVOID INJURY OR DEATH I-2003-0888
explosion or fire.
W-2103-0508

1.)


REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-120-5
Figure 20-120-3
1
1
P-48300
2 Disconnect the four solenoid connectors (Item 1) [Figure

P-48302 20-120-5] from the rear auxiliary valve.
Figure 20-120-6
Disconnect the base and rod end tubelines (Item 1)
[Figure 20-120-3].

Remove the fittings (Item 2) [Figure 20-120-3] from the
valve.
Figure 20-120-4
1
P-48304
Disconnect the drain tubeline (Item 1) [Figure 20-120-6]

from the lift arm by pass valve.
P-48872
Remove the three access covers (Item 1) [Figure 20-

120-4] on the right side of the machine.

Figure 20-120-7
1
P-48869
Loosen and remove the two bolts and nuts (Item 1)

P-48303 [Figure 20-120-9] that hold the rear auxiliary valve.
Figure 20-120-10
Disconnect and remove the drain tubeline (Item 1)
[Figure 20-120-7] from the rear auxiliary valve.

Figure 20-120-8
2
P-48870
1
Remove the rear auxiliary valve (Item 1) [Figure 20-120-
P-48305 10] by moving the valve to the rear access hole which
allows enough room for the valve to be removed from the
loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-
120-8] from the rear auxiliary valve. The valve needs to be tilted as shown in [Figure 20-120-
10] for it to be removed through the hole.
Disconnect the tubeline (Item 2) [Figure 20-120-8] from
the bottom of the control valve and the rear auxiliary
valve.

IMPORTANT
damage the system.
I-2003-0888 1
P-76791
Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
assembly. There are 11 #4 SAE hex head plugs (Item 1) [Figure
20-120-12] located on all sides of the diverter valve and
Figure 20-120-11 can be removed for clean out purposes.
Assembly: Put oil on O-rings. Tighten to 13,6 N•m (10 ft-

lb) torque.

2
Figure 20-120-13
1
P-76747
Remove the two mount bolts (Item 1) from the diverter

valve mount plate (Item 2) [Figure 20-120-11] and
remove the mount plate. P-48752
Inspect O-ring (Item 1) [Figure 20-120-13].
Assembly: Put oil on O-ring.

Figure 20-120-14
1
1
P-76789A
Remove the differential sensing valve (Item 1) [Figure

P-76789A 20-120-16].
Assembly: Put oil on O-rings and back-up washers.

Remove the shuttle valve (Item 1) [Figure 20-120-14]. Tighten to 115,25 N•m (85 ft-lb) torque.

Assembly: Put oil on the O-rings and back-up washers. Figure 20-120-17
Tighten to 10,8 N•m (8 ft-lb) torque.
Figure 20-120-15
1
1 1
2 P-48757
P-48756 Inspect the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-120-17] for damage.
Inspect the O-rings (Item 1) and back-up washers (Item



1
Figure 20-120-18
1 P-76794
NOTE: Before removing the solenoid coils, mark the

P-48753 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-120-20] from the

Remove the relief valve (Item 1) [Figure 20-120-18]. solenoid valve stem.

Assembly: Put oil on O-rings and back-up washers. Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
Tighten to 34 N•m (25 ft-lb) torque. torque.
Figure 20-120-19 Figure 20-120-21
2
2
1
P-48754 P-76796
Inspect the O-rings (Item 1) and back-up washer (Item 2) Remove the metal shields (Item 1) and solenoid valve
[Figure 20-120-19] for damage. coils (Item 2) [Figure 20-120-21].

Figure 20-120-22
1
P-48761
NOTE: Before removing the solenoid coils, mark the

P-48763A coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-120-24] from the

Remove the solenoid valve stem (Item 1) [Figure 20- solenoid valve stems.
120-22]

Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
Assembly: Put oil on the O-rings and back-up washers. torque.
Tighten to 34 N•m (25 ft-lb) torque.
Figure 20-120-25
Figure 20-120-23
1
1
P-48762
2 P-48764
Remove the solenoid valve stems (Item 1) [Figure 20-

Inspect the O-rings (Item 1) and back-up washers (Item 120-25].
Assembly: Put oil on the O-rings and back-up washers.
Tighten to 34 N•m (25 ft-lb) torque.

Figure 20-120-26
1 1
P-48752
2
Inspect O-ring (Item 1) [Figure 20-120-28].

P-76833
Inspect the O-rings (Item 1) and back-up washer (Item 2) Figure 20-120-29
[Figure 20-120-26].

Figure 20-120-27
1
P-48766
P-48765 Remove and inspect the orifice (Item 1) [Figure 20-120-

29] for dirt and debris.
Remove the #8 SAE hex head plug (Item 1) [Figure 20- Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
120-27]. torque.
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.


1
Figure 20-120-30
1
2
P-76798
Remove the #4 SAE hex head plug (Item 1) and the #6

P-48765 SAE hex head plugs (Item 2) [Figure 20-120-32].
Assembly: Tighten the #4 SAE hex head plug to 13,6

Remove the #4 SAE hex head plug (Item 1) [Figure 20- N•m (10 ft-lb) torque.
120-30].

Assembly: Tighten the #6 SAE hex head plugs to 19
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. N•m (14 ft-lb) torque.
Figure 20-120-31 Figure 20-120-33
1
1
P-48786 P-48752
Remove the orifice (Item 1) [Figure 20-120-31] and Inspect O-ring (Item 1) [Figure 20-120-33].
inspect for dirt and debris.
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)
torque.

BOB-TACH (POWER) BLOCK
Description
The power Bob-Tach block is an option that allows the

IMPORTANT
operator to hydraulically control the Bob-Tach levers for
mounting and dismounting the attachments. When repairing hydrostatic and hydraulic systems,
The power Bob-Tach is operated by a switch on the front parts clean. Always use caps and plugs on hoses,
console. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The power Bob-Tach block is mounted on the right side of
the machine in front of the engine on the backside of the
hydraulic gear pump. Figure 20-130-1

3
WARNING 1


support device. Failure to use an approved lift arm 3
W-2059-0598
P-66869

DANGER 1.)

Open the rear door.

P-90328 Replacing Hydraulic Fluid on Page 10-120-2.)
AVOID DEATH Remove the nut from the speed control linkage (Item 1)
• Disconnecting or loosening any hydraulic and unplug the rear lights electrical connector (Item 2)
tubeline, hose, fitting, component or a part failure [Figure 20-130-1].
• Keep out of this area when lift arms are raised Remove the fuel fill bracket mounting bolts (Item 3)
unless supported by an approved lift arm [Figure 20-130-1].
D-1009-0409

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-130-4
Figure 20-130-2
P-48227
Remove the four mounting bolts (Item 1) [Figure 20-130-

P-48230 4].

Installation: The harness connectors are marked with (25 - 28 ft-lb) torque.
Red or Black tie straps. Be sure the connectors with the

same color are connected. Remove the power Bob-Tach block.
Disconnect the power Bob-Tach harness from the NOTE: There is an O-ring in-between the power Bob-
solenoid connectors (Item 1) [Figure 20-130-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-130-3
P-48226

“DR” port fitting on the block.

power Bob-Tach cylinder rod end fitting on the block.

power Bob-Tach cylinder base end fitting on the block.
Disconnect the outlet hose (Item 4) [Figure 20-130-3]

from the fitting on top of the block.

Figure 20-130-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-130-6].
Inspect the O-ring (Item 4) [Figure 20-130-6] on the plug

Clean the block (Item 1) [Figure 20-130-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-130-7
Remove the plug (Item 2) [Figure 20-130-5].
Assembly: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-7].
Assembly: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.

Figure 20-130-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-130-10].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-130-8]. will be altered.

Assembly: Oil the check valve and O-rings and tighten Figure 20-130-11
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-130-9
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-130-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Assembly: Tighten the plug (Item 1) [Figure 20-130-11]
(Item 2) [Figure 20-130-9]. to 16,3 - 19 N•m (12 - 14 ft-lb) torque.
Inspect the O-rings and back up washers (Item 3)

[Figure 20-130-9] on the check valve and piston
assembly and replace as needed.

Figure 20-130-12 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-130-14].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-130-11] and [Figure 20-130-

12]. Figure 20-130-15
Assembly: Tighten the orifice screw (Item 2) [Figure 20-

130-12] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.
Figure 20-130-13
1
2 P-48386
P-48127 Assembly: Tighten the solenoid stem to 27,1 - 34 N•m

NOTE: This plug is a zero leak plug and should not be

removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-13].
Remove the solenoid nut (Item 2) [Figure 20-130-13].
Assembly: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.

Figure 20-130-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 130-18].
Assembly: Tighten the screened orifice plug to 14,9 -

Remove the armature rod assembly (Item 1) [Figure 20- 16,3 N•m (11 - 12 ft-lb) torque.
130-16].

Figure 20-130-19
Figure 20-130-17
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 130-19] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
130-17].
Inspect the O-ring (Item 2) [Figure 20-130-19] and
NOTE: If the solenoid stem is damaged (Item 1) replace as needed.
inspect the armature assembly (Item 2) for
damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-130-
17].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
The front auxiliary hydraulic coupler block is the

connection block that houses the two main auxiliary
1
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm. 2
4
3
IMPORTANT P-34661
When repairing hydrostatic and hydraulic systems, Figure 20-140-3

damage the system. 1

I-2003-0888
Figure 20-140-1
6 2
4
5 3
1 P-34760
3
Remove the male coupler (Item 1) [Figure 20-140-2] and
[Figure 20-140-3].
Assembly: Tighten the male coupler (Item 1) [Figure 20-

140-2] and [Figure 20-140-3] to 80 N•m (59 ft-lb)
P-48464
Remove the drain coupler (Item 2) [Figure 20-140-2] and
[Figure 20-140-3].
Disconnect the auxiliary tubelines (Item 1) and drain
tubeline (Item 2) from the coupler block [Figure 20-140- Assembly: Tighten the drain coupler (Item 2) [Figure
1]. 20-140-2] and [Figure 20-140-3] to 50 N•m (37 ft-lb)
Remove the two mounting bolts (Item 3) [Figure 20-140- Remove the female coupler (Item 3) [Figure 20-140-2]
1]. and [Figure 20-140-3].
Assembly: Tighten the female coupler (Item 3) [Figure

20-140-2] and [Figure 20-140-3] to 80 N•m (59 ft-lb)
Remove the fittings (Item 4) [Figure 20-140-2] and

[Figure 20-140-3]. Inspect the O-rings (Item 5) [Figure
20-140-3] and replace as needed.
Remove the springs (Item 6) [Figure 20-140-3].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-140-6
(CONT’D)

1
Figure 20-140-4
1
2
P-34665
Inspect the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-140-6].
P-34663
Figure 20-140-7
Inspect the O-ring (Item 1) [Figure 20-140-4] for damage

and replace as needed. 1
Figure 20-140-5
P-34664
Inspect the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-140-7].
P-34701
Press center of male couplers down and inspect the O-

ring (Item 1) [Figure 20-140-5] for damage and replace
as needed.

HIGH FLOW VALVE
Description WARNING
The high flow valve is an optional valve with a 12 volt
solenoid that diverts flow from a dedicated high flow Put jackstands under the front axles and rear corners
section on the gear pump. of the frame before running the engine for service.
The valve is in plumbed in series with the female coupler fall or move and cause injury or death.
side on the front auxiliary circuit. W-2017-0286
High Flow Relief Valve Testing Figure 20-150-2
Figure 20-150-1
1
2

2
1 P-76460C
Start the engine and run at low idle rpm.

P-34480
Press the HIGH FLOW button (Item 1) [Figure 20-150-
2].
procedure: The light (Item 2) [Figure 20-150-2] will be ON.
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit

1.)
NOTE: Check the Main Relief Valve (See MAIN

RELIEF VALVE on Page 20-30-1.) for proper
flow and pressure before checking the High
Flow Relief Valve.
Connect the IN port of the hydraulic tester to the female

quick coupler (Item 1) [Figure 20-150-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-150-1] on the loader.
IMPORTANT
I-2024-0284

HIGH FLOW VALVE (CONT'D) High Flow Relief Valve Adjustment
High Flow Relief Valve Testing (Cont’d) NOTE: The high flow relief valve is located between
the control valve and the hydraulic reservoir.
Figure 20-150-3
Figure 20-150-4
Right
Steering
Lever
Control
1
P-31833
P-48231
• Push the front switch (Item 1) [Figure 20-150-3] to

give the front quick couplers a constant flow of fluid. If the relief pressure is not correct, stop the engine and

raise the operator cab. (See Raising on Page 10-30-1.)
• To release from continuous operation, press the front
switch (Item 1) [Figure 20-150-3] a second time. Remove the high flow relief valve adjustment plug (Item
1) [Figure 20-150-4].
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full rpm.

control on the tester to about 6895 kPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure.

(3300 psi).
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 102,2 L/min (27
U.S. gpm). Start turning the restrictor clockwise, causing
more restriction on the flow. The L/min (U.S. gpm) should
drop off slightly until the pressure reaches approximately
21374 kPa (213,7 bar) (3100 psi) the flow should start
23097 kPa (224,1 - 231 bar) (3250 - 3350 psi). At 22408 -
23097 kPa (224,1 - 231 bar) (3250 - 3350 psi) the flow
should be at 0 L/min (0 U.S. gpm). Turn the restrictor
control counter clockwise to free flow. Shut the front
auxiliary hydraulics off.
If the specs from above are reached, the high flow relief
valve is OK.
If the high flow relief pressure is not correct, stop the

engine and adjust the high flow relief valve. (See High
Flow Relief Valve Adjustment on Page 20-150-3.)

HIGH FLOW VALVE (CONT'D) Solenoid Testing
High Flow Relief Valve Adjustment (Cont’d) Figure 20-150-6
Figure 20-150-5
P9175
P-45469
150-6]. Coil terminals do not have polarity. Correct
To increase the high flow relief valve psi turn the screw resistance for the pressure relief coil is 7.5 ohm.
(Item 1) [Figure 20-150-5] 90° clockwise and recheck the

high flow relief valve. (90° equals approximately 1379 Replace the test meter with 12 volt power. You can see
kPa [13,8 bar] [200 psi].) and hear the spool shift.
To decrease the high flow relief valve psi turn the screw
(Item 1) [Figure 20-150-5] 90° counterclockwise turn and
recheck the high flow relief valve. (90° equals
approximately 1379 kPa [13,8 bar] [200 psi].)
NOTE: If the relief screw (Item 1) [Figure 20-150-5]

has been turned in 1/4 turn and the pressure
remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.

HIGH FLOW VALVE (CONT'D) Figure 20-150-8
Figure 20-150-7
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 150-8] from the solenoid.
Figure 20-150-9

steering shaft on the control panel.

[Figure 20-150-7].
2
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 34 -
The high flow valve is located between the control valve

1
and the hydraulic reservoir.
P-48238
IMPORTANT Mark all tubelines and hoses for correct installation.
When repairing hydrostatic and hydraulic systems, Disconnect and cap the hose (Item 1) [Figure 20-150-9]
clean the work area before disassembly and keep all from the pump outlet to the high flow valve.
tubelines and ports to keep dirt out. Dirt can quickly Disconnect and cap the hose (Item 2) [Figure 20-150-9]
damage the system. from the high flow valve to the pump inlet.
I-2003-0888

HIGH FLOW VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-150-11
Figure 20-150-10
2 1
1
2
P-48108
P-48232
Remove the solenoid nut (Item 1) and solenoid (Item 2)
[Figure 20-150-11] from the solenoid valve.
Disconnect and cap the tubelines (Item 1) [Figure 20-
150-10] to the tilt cylinders. Assembly: Tighten to 5 - 8 N•m (4 - 6 ft-lb) torque.

Remove the two mounting bolts (Item 2) [Figure 20-150- Figure 20-150-12
10].

P-48109
Remove the solenoid valve (Item 1) [Figure 20-150-12]

from the valve.
Assembly: Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.

HIGH FLOW VALVE (CONT'D) Figure 20-150-15
Figure 20-150-13
2 2
P-48112
Inspect the relief valve and replace the two O-rings (Item
1
P-48110 1) and washer (Item 2) [Figure 20-150-15].
Figure 20-150-16
Inspect O-rings (Item 1) and back-up washer (Item 2) on
the solenoid stem [Figure 20-150-13].

Assembly: Put oil on O-rings and back-up washer. Install
and tighten to 39,9 N•m (25 ft-lb) torque.
Figure 20-150-14
1
P-45469

relief valve adjustment plug for damage and replace as
needed.
P-48111 Assembly: Tighten to 27,1 N•m (20 ft-lb) torque.
Remove the relief valve (Item 1) [Figure 20-150-14].
Assembly: Apply to oil to the O-rings and back-up

washers. Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.

HIGH FLOW VALVE (CONT'D)
Figure 20-150-17
P-48113
Remove the check valve (Item 1) [Figure 20-150-17]

from the high flow valve.

Figure 20-150-18
P-48114
Inspect the check valve, O-rings and back-up washers for

wear and replace as needed [Figure 20-150-18].
Assembly: Apply oil to the O-rings (Item 1) and back-up

washers (Item 2) [Figure 20-150-18]. Tighten to 41 - 47


HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removal And Installation (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Removal And Installation (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-19
HYDROSTATIC MOTOR CARRIER

(SINGLE AND TWO-SPEED WITH MANUAL CONTROLS) . . . . . . . . . . . . . . . . . . . . . 30-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-2
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing (S/N A3L929999 & Below And A3LH29999 & Below) . . . . . . . . . . . . . . . . . 30-40-2
Sender Removal And Installation
(S/N A3L929999 & Below And A3LH29999 & Below) . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Testing (S/N A3L390001 & Above And A3LH30001 & Above) . . . . . . . . . . . . . . . . . 30-40-4
Sender Removal And Installation
(S/N A3L930001 & Above And A3LH30001 & Above) . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-12
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-7
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-10
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-27
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-31

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-6
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-7
TWO-SPEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.

HYDROSTATIC DRIVE MOTOR Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

DANGER
the hydrostatic pumps.
In this system there is a case drain filter for each motor to

filter the excess low pressure oil before the oil enters the
hydraulic reservoir.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission tub which houses the drive chains. P-90328
The hydrostatic motors do not have an internal brake. AVOID DEATH

Inside the endcap of the hydrostatic motor, there is a tubeline, hose, fitting, component or a part failure
shuttle valve. The shuttle valve helps to keep the motor can cause lift arms to drop.
cool by mixing case drain oil with cooled low pressure oil • Keep out of this area when lift arms are raised
from the charge circuit. The shuttle valve is shifted by the unless supported by an approved lift arm
high pressure oil coming from the hydrostatic pumps. If support. Replace if damaged.
D-1009-0409
the shuttle valve sticks, a delay or lack of drive may or
may not be felt in the controls and / or an overheated

hydrostatic motor will result.

W-2059-0598
WARNING
P-68211
explosion or fire.
W-2103-0508


1.)
Remove the front and rear wheel / tire assemblies. (See

TIRE MAINTENANCE on Page 10-160-1.)

HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-3

3
Figure 30-20-2
2
1
1 P-68208
Mark the two hoses (Item 1) [Figure 30-20-3] before

P-34004 disconnecting them from the hydrostatic motor for correct
installation.
Remove the four motor cover mounting screws (Item 1) Remove the two hoses (Item 1) [Figure 30-20-3] from
[Figure 30-20-2]. the hydrostatic motor.

Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb) Remove the drain hose and case drain filter (Item 2)
torque. [Figure 30-20-3] from the hydrostatic motor.
NOTE: The hydraulic fitting (Item 3) [Figure 30-20-3]

on the hydrostatic motor must be tightened to
IMPORTANT 156 - 170 N•m (115 - 125 ft-lb) torque.
Figure 30-20-4
damage the system.
I-2003-0888
P-68208
Remove the four hydrostatic motor mounting bolts (Item

1) [Figure 30-20-4] that fasten the hydrostatic motor to
the hydrostatic motor carrier.
Installation: Tighten the hydrostatic motor mounting

bolts to 122 - 136 N•m (90 - 100 ft-lb) torque.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-5
P-82716
Remove the hydrostatic motor from the access hole in

the loader frame [Figure 30-20-5].

Inspect hydrostatic motor O-ring (Item 1) and carrier
shaft seal (Item 2) [Figure 30-20-5].
Reverse the removal procedure to install the hydrostatic

motor.

HYDROSTATIC DRIVE MOTOR (CONT’D)
16
14
20 3
15
14
19 14
16 18
3 13
18
19
17 3 5
12
11
10
5
9

8
7 10
6 3
3
5
4
2
1
PE2620T
Ref. Description Ref. Description

1. SHAFT, drive 11. GEROLER®
2. SEAL, face 12. PLATE, valve
3. O-RING 13. END CAP
4. FLANGE, mounting 14. POPPET
5. SEAL, square cut 15. SPRING
6. RING, back-up 16. PLUG
7. SPRING, belleville 17. BOLT
8. PLATE, outer balance 18. SLEEVE
9. PLATE, inner balance 19. SPRING
10. BALL 20. VALVE, shuttle


1
IMPORTANT
damage the system.
I-2003-0888
P-68211
Figure 30-20-6
Remove the nine tie bolts (Item 1) [Figure 30-20-7] from

the motor.
Figure 30-20-8
3
8

6
5
9
2
P-64267
1
7
Drain the oil from the motor. 4
Seal all open ports and clean the motor with solvent.
P-68211
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-6]. Assembly:
1. Tighten the bolts to 61 - 75 N•m (45 - 55 ft-lb) torque

in the order shown in figure [Figure 30-20-8].
2. Re-tighten the bolts to 75 - 88 N•m (55 - 65 ft-lb)

torque in the order shown in figure [Figure 30-20-8].
NOTE: To prevent damage to the balance plate, never

lift or support the motor by the drive shaft.

Figure 30-20-9
3
1
2
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet

P-64267 (Item 3) [Figure 30-20-11] that make up the relief valve
assembly. Inspect for scoring on poppet. Ensure it can
operate freely in the bore. Inspect O-ring on plug.
Once the tie bolts have been removed and the motor
begins to separate, the drive shaft (Item 1) [Figure 30- Installation: Lubricate relief valve assembly with

20-9] can be removed. hydraulic oil and tighten plug to 41 N•m (260 in-lb) torque.
Assembly: Install drive shaft before tightening tie bolts. Figure 30-20-12
Figure 30-20-10
2
1
P-68213
P-68212
Remove the plug (Item 1) and shuttle valve assembly
(Item 2) [Figure 30-20-12]. Inspect for scoring on shuttle
Lift and remove the end cap (Item 1) [Figure 30-20-10] valve. Ensure it can operate freely in the bore. Inspect O-
from the motor. ring on plug.
NOTE: Do not scratch or damage the surfaces of the Installation: Lubricate shuttle valve assembly with
motor sections. Always put them on a soft hydraulic oil and tighten plug to 41 N•m (260 in-lb) torque.
surface.


3
Figure 30-20-13
2
P-64274
Remove and inspect / replace seal (Item 1) [Figure 30-

P-39897 20-15].
Remove the Geroler® section as an assembly (Item 2)

Remove the remaining pieces to the shuttle valve [Figure 30-20-15].
assembly (Item 1) [Figure 30-20-13] from the inside of

the end cap. Inspect for broken or damaged parts. Parts NOTE: There are two check balls on the backside of
should move freely in bore. the Geroler® section. Be careful not to lose
these check balls. See [Figure 30-20-16]. Note
Assembly: Apply grease to shuttle valve parts to help location of case drain hole (Item 3) [Figure 30-
hold in place during assembly. 20-15]. Align hole with other sections on
hydrostatic motor.
Figure 30-20-14
2 3
P-39898
Remove and inspect / replace seals (Item 1) [Figure 30-

20-14].
Remove the valve plate (Item 2) [Figure 30-20-14].
Assembly: Apply grease to seals. Note location of case

drain hole (Item 3) [Figure 30-20-14]. Align hole with
other sections on hydrostatic motor.


1
4
Figure 30-20-16 2
3
1
P-64268
Remove the center piece of the balance plate (Item 1)

P-39901 [Figure 30-20-17].
Remove and inspect / replace the seal (Item 2) [Figure

Remove the two check balls (Item 1) [Figure 30-20-16] 30-20-17].
from the Geroler®.

Remove the balance plate (Item 3) [Figure 30-20-17].
Assembly: Check for scoring and wear on the Geroler®
assembly. Apply grease to check balls to keep them from Assembly: Apply grease to seals. Note location of case
falling out of there seats when assembling. drain hole (Item 4) [Figure 30-20-17]. Align hole with
other sections on hydrostatic motor.
NOTE: Care should be taken to keep the Geroler®
assembly together.
NOTE: If rollers are removed, put them back in their

original bore.


1
Figure 30-20-18
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-20].

P-64270
Assembly: If the belleville spring is no longer cone
shaped, replace with new.
Remove the back up ring (Item 1) [Figure 30-20-18].
Figure 30-20-21

Assembly: Apply grease to back up ring. One side of the
back up ring is grooved to fit against the O-ring
underneath.
Figure 30-20-19
1
1
P-64273
1
Carefully turn the mounting flange over and remove the

1 seal (Item 1) [Figure 30-20-21].
P-64271
Assembly: Replace the seal.
Remove and inspect / replace the seals (Item 1) [Figure

30-20-19] from the Geroler®.
Assembly: Apply grease to seals.


HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
In this system there is a case drain filter for filtering the

excess low pressure oil before the oil enters the hydraulic
reservoir.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing drive
loop return oil with cooled low pressure oil from the
charge circuit. The shuttle valve is shifted by the high
pressure oil coming from the hydrostatic pumps. If the
shuttle valve sticks, a delay or lack of drive may or may
not be felt in the controls and / or an overheated
hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Remove the front and rear wheel / tire assemblies. (See
(CONT'D) TIRE MAINTENANCE on Page 10-160-1.)
Removal And Installation (Left Side) Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.)
DANGER Remove the linkage on foot control loaders. (See Linkage

Drain the hydraulic reservoir. (See Removal And

Figure 30-21-1
P-90328
AVOID DEATH
can cause lift arms to drop. 1 1

D-1009-0409
P-45492
WARNING
Remove the motor cover mount bolts (Item 1) [Figure 30-
Never work on a machine with the lift arms up unless 21-1].
support device. Failure to use an approved lift arm Remove the motor cover from the loader.
to fall and cause injury or death. Figure 30-21-2
W-2059-0598
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P-73665
1.)
Loosen the bolts (Item 1) [Figure 30-21-2] holding the
Raise the lift arms and install an approved lift arm lower motor bolt access panel and swing the panel open.
support device. (See Installing on Page 10-20-1.) The panel is located under the loader frame directly
Raise the operator cab. (See Raising on Page 10-30-1.) below the motor.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-5
(CONT'D)
Removal And Installation (Left Side) (Cont'd)

1
Figure 30-21-3
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

5] from the motor.
P-76164
Installation: Tighten the mounting bolt to 285 N•m (210
ft-lb) torque.
Mark the hoses and tubeline for correct installation.

Figure 30-21-6
Disconnect both high pressure hydraulic tubelines (Item
1) [Figure 30-21-3] from the motor.
Disconnect the pre-warming tubeline (Item 2) [Figure 30- 1

21-3] from the motor.
Figure 30-21-4
P-76146
1 Remove two mounting bolts (Item 1) [Figure 30-21-6]

from the motor.
3 Installation: Tighten the mounting bolts to 285 N•m (210

P-76159 ft-lb) torque.
Remove the motor from the access hole in the loader

Mark the hose and tubelines for correct installation. frame.
Disconnect the case drain tubeline (Item 1) [Figure 30-

Disconnect the shift pressure tubeline (Item 2) [Figure

30-21-4] from the motor.

motor.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
1
2
P-82716
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-7].
Inspect the hydrostatic motor carrier shaft seal (Item 2)

[Figure 30-21-7].
Figure 30-21-8
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

shaft seal (Item 1) [Figure 30-21-8] in the mounting
flange cavity with the convex surface facing outward.
Reverse the removal procedure to install the two-speed

hydrostatic motor.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Remove the front and rear wheel / tire assemblies.
(CONT'D)
Remove the control panel. (See CONTROL PANEL on
Removal And Installation (Right Side) Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.)
Remove the linkage on foot control loaders. (See Linkage

DANGER Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-21-9
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1 1

D-1009-0409
P-45492
WARNING Remove the motor cover mount bolts (Item 1) [Figure 30-
21-9].
the lift arms are secured by an approved lift arm Remove the motor cover from the loader.
support device can allow the lift arms or attachment Figure 30-21-10
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888
P-73665

1.) Loosen the bolts (Item 1) [Figure 30-21-10] holding the
lower motor bolt access panel and swing the panel open.
Raise the lift arms and install an approved lift arm The panel is located under the loader frame directly
support device. (See Installing on Page 10-20-1.) below the motor.

(CONT'D)
Removal And Installation (Right Side) (Cont'd)

2
Figure 30-21-11
P-76127
2
Mark the hose and tubelines for correct installation.
P-76153 Disconnect the case drain tubeline (Item 1) [Figure 30-

Mark the hoses and tubeline for correct installation. Disconnect the shift pressure tubeline (Item 2) [Figure

30-21-13] from the motor.
Disconnect both high pressure hydraulic tubelines (Item
1) [Figure 30-21-11] from the motor. Figure 30-21-14
Disconnect the pre-warming tubeline (Item 2) [Figure 30-

1
Figure 30-21-12
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

14] from the motor.
P-76152
Installation: Tighten the mounting bolt to 285 N•m (210
ft-lb) torque.
Mark the hose and tubelines for correct installation.
Disconnect the hoses (Item 1) [Figure 30-21-12] from

the motor.

(CONT'D)
Removal And Installation (Right Side) (Cont'd)

1
Figure 30-21-15
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

shaft seal (Item 1) [Figure 30-21-17] in the mounting
P-76145 flange cavity with the convex surface facing outward.
Reverse the removal procedure to install the two-speed

Remove two mounting bolts (Item 1) [Figure 30-21-15] hydrostatic motor.

from the motor.
Installation: Tighten the mounting bolts to 285 N•m (210

ft-lb) torque.
Remove the motor from the access hole in the loader

frame.
Figure 30-21-16
1
2
P-82716
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-16].
Inspect the hydrostatic motor carrier shaft seal (Item 2)

[Figure 30-21-16].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
1. Shaft Seal 10
2. Mounting Flange 11
12 15
3. O-ring 13 14
4. Main Drive
5. Geroler® 16
6. O-ring
7. Valve Drive
8. Selector Plate
9. Gasket 17
9 18
10. Plug
11. Compression Spring
12. Compression Spring 8
13. Control Spool
14. Plug
15. Cap Screw 7
16. Spool Housing 6
17. Plug
18. O-ring
19. Valve 5
20. Outer Balance Ring

21. Back-up Ring
22. O-ring
23. Back-up Ring 3 4
24. Inner Balance Ring
25. Back-up Ring
26. O-ring 2
27. Dowel Pin
28. Plug
29. Compression Spring
30. Plug
31. Valve Housing 33
32. Shuttle Valve Assembly
33. 12 Point Screw 28
34. Plug 32
35. Plug 31
36. Ball Seat
37. Ball
1
32
28
34
35
27
25 37 36
24 29
23
20 21 26 30
19
22
MS2315SA

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Drain the oil from the motor casing.
(CONT'D)
Place the mounting flange (Item 1) [Figure 30-21-19] on
Disassembly a protective material built up 57,15 mm (2-1/4 in) to allow
room for main drive.
Figure 30-21-18
Figure 30-21-20
1
2
1
P-76142
P-73524
Remove the tubeline (Item 1) and relief valve (Item 2)

[Figure 30-21-18] from the motor. Remove the nine mounting bolts (Item 1) [Figure 30-21-
20] from the valve housing.
Remove the fittings [Figure 30-21-18] from the motor.
Figure 30-21-21
Figure 30-21-19
1
1
P-73529
P-73525
Remove the valve housing from the motor assembly and

NOTE: The motor is connected to the carrier for place on a clean work surface.
photo purposes [Figure 30-21-19]. Install a
mark on the valve housing, selector plate, Remove and discard the O-ring (Item 1) [Figure 30-21-
Geroler®, and mounting flange for correct 21].
assembly.
NOTE: Always protect any sealing surfaces. Any

scratches or marks will cause premature
failure.
NOTE: It is not recommended to remove any plugs

unless they are leaking.

(CONT'D)
Disassembly (Cont'd)
1
Figure 30-21-22
P-73532
Remove four compression springs (Item 1) [Figure 30-

21-24] and inspect for damage.
P-73530
Figure 30-21-25
Remove the dowel pin (Item 1) [Figure 30-21-22] and

1

inspect for wear.
Figure 30-21-23
P-73534
Remove the outer balance ring (Item 1) [Figure 30-21-

25] from the valve housing. Tap the ring lightly with a
P-73531 wooden dowel or hammer handle if binding. Inspect the
face of the outer balance ring for wear.
Remove the inner balance ring (Item 1) [Figure 30-21-

23] from the valve housing and inspect face for wear.

(CONT'D)
Figure 30-21-26
P-73539
Remove and discard the back-up ring (Item 1) [Figure

1
30-21-28] from the valve housing.
P-73535
Figure 30-21-29
Remove and discard the O-ring and two back-up rings

(Item 1) [Figure 30-21-26] from the outer balance ring.
Figure 30-21-27
P-73538
Remove and discard the O-ring (Item 1) [Figure 30-21-

29] from the valve housing.
P-73536
Remove the six compression springs (Item 1) [Figure 30-

21-27] and inspect for damage.

(CONT'D)
Figure 30-21-30
1
1
P-76390
Remove the plug (Item 1) [Figure 30-21-32] from the

valve housing.
P-76387
Figure 30-21-33

valve housing.
Figure 30-21-31
P-76389
1
Remove O-ring (Item 1) [Figure 30-21-33] on plug.
P-76389

(CONT'D)
Figure 30-21-34
1
2
1 P-76395

valve housing.
P-76392
Figure 30-21-37
Remove the ball seat (Item 1) and ball (Item 2) [Figure

30-21-34] from the valve housing.
NOTE: To remove the ball seat, use a long allen

wrench to reach down into the valve housing.
Figure 30-21-35
P-76389
P-76394A

(CONT'D)
Figure 30-21-38
1
1
1
1
1
1
1
1 P-76400
Remove the shuttle valve assembly (Item 1) [Figure 30-

1 21-40] from the valve housing.
P-76397
Figure 30-21-41
Remove the plugs (Item 1) [Figure 30-21-38] from both

sides of the valve housing.
Figure 30-21-39
P-73526
1
Remove the valve (Item 1) [Figure 30-21-41] and inspect
for wear.
P-76389
Remove O-ring (Item 1) [Figure 30-21-39] on plugs.

(CONT'D)
Figure 30-21-42
2
1
P-73528
Remove and discard the O-ring (Item 1) [Figure 30-21-

44].
P-73527
Remove the Geroler® assembly (Item 2) [Figure 30-21-
44] and inspect for wear.
Remove the selector plate (Item 1) [Figure 30-21-42]

and inspect for wear. Figure 30-21-45
Figure 30-21-43
1
1
2
P-73540
P-73543
Remove the main drive (Item 1) [Figure 30-21-45] and
inspect for wear.
Remove the valve drive (Item 1) [Figure 30-21-43] and
inspect for wear. Remove and discard the O-ring (Item 2) [Figure 30-21-
45].

(CONT'D)
Figure 30-21-46
1
1
P-73549
Mount the spool housing in a vise taking care to protect it

from damage. Remove the spool retaining plug (Item 1)
P-73546 [Figure 30-21-48].
NOTE: The plug is under slight spring pressure.

Remove the ten screws (Item 1) [Figure 30-21-46] from Remove the plug carefully.

the selector spool housing.
Figure 30-21-49
Figure 30-21-47
2 1
1
P-73550
P-73547
Remove the two nested springs (Item 1) [Figure 30-21-

Remove and discard the gasket (Item 1) [Figure 30-21- 49] from the spool housing.
47].
Inspect the selector plate (Item 2) [Figure 30-21-47] for

wear.
NOTE: Clean any old thread sealer from the threaded

holes before assembly.

(CONT'D)
Figure 30-21-50
P-73552
Inspect the spool for wear or damage [Figure 30-21-52].
P-73523 Clean the spool and spool housing.
Figure 30-21-53
Inspect springs for wear and deformation [Figure 30-21-

50].
Figure 30-21-51
P-73550A
1 Remove the plug (Item 1) [Figure 30-21-53] from the

P-73551 spool housing.
Remove the spool (Item 1) [Figure 30-21-51] from the

spool housing.

(CONT'D)
Figure 30-21-54
P-76389
1
Remove O-ring (Item 1) 23 on plug.
P-76389

Figure 30-21-55
P-76438

spool housing.

(CONT'D)
Assembly
NOTE: Always use new O-rings and back up washers

during assembly and lubricate them with
clean petroleum jelly.
Figure 30-21-57
P-76389
Install new O-ring (Item 1) [Figure 30-21-59] on plug.
Figure 30-21-60
1

P-76389
Figure 30-21-58 1
1
P-73550A
Install the plug (Item 1) [Figure 30-21-60] in the spool

housing with a light coat of oil.
Tighten the plug to 19 - 24 N•m (14 - 18 ft-lb) torque.
P-76438
Install the plug (Item 1) [Figure 30-21-58] in the spool

housing with a light coat of oil.

(CONT'D)
Assembly (Cont’d)
Figure 30-21-61
P-73549
1
Install the plug (Item 1) [Figure 30-21-63] with a light

coat of oil.
P-73551
Lubricate with hydraulic oil and insert the spool (Item 1)

[Figure 30-21-61] into the spool housing.
Figure 30-21-62
P-73550
Install two nested springs (Item 1) [Figure 30-21-62] on

the spool shaft.

(CONT'D)
Assembly (Cont'd)
Figure 30-21-64
Apply Loctite® 262 Here
P-73774
Install the new gasket (Item 1) [Figure 30-21-65] onto

the selector plate.
P-73775
Figure 30-21-66
NOTE: Before assembling the new gasket, the spool

housing, or the screws, remove any old
thread sealer from the threaded holes.
Put a VERY SMALL amount of Loctite® 262 into each of

the ten threaded holes of the selector plate. DO NOT put
Loctite® on the screw threads [Figure 30-21-64].
Remove any trapped air from below the Loctite®. Wipe

any excess Loctite® from the selector plate surface.
NOTE: If too much Loctite® is applied and any

trapped air is not removed, it can pool in the
bottom of the threaded holes. This can
P-73776
prevent the screws from reaching full thread
contact and the correct torque may not be
reached. Install the ten screws [Figure 30-21-66] through the
spool housing and into the selector plate.
NOTE: Installing the screws can force some of the
Loctite® out of the holes and onto the selector
plate surface. If any Loctite® gets between the
new gasket and the selector plate it will create
a poor seal. Be sure to wipe excess Loctite®
from the surface.

(CONT'D)
Assembly (Cont'd)
2 1
Figure 30-21-67
10 4 1 6 7
3
P-73528
9 5 2 3 8 Install the Geroler® assembly (Item 1) with the groove in

the ring facing up. The star groove (Item 2) must be
MS2316S facing up. Take care to line up the shuttle flow hole (Item
3) [Figure 30-21-69].
Tighten the ten screws to 8 - 9 N•m (70 - 80 in-lb) torque
using the sequence shown [Figure 30-21-67]. Lubricate and install the new O-ring (Item 4) [Figure 30-

21-69].
Repeat the tightening sequence to insure the correct
torque. Motor Timing
Put the selector plate assembly aside until needed for Figure 30-21-70
installation. Let the Loctite® cure for six hours after
assembly.
4
Figure 30-21-68
2
1
2
3
1
P-73544
P-73540
Locate a tooth (Item 1) [Figure 30-21-70] that lines up
with a star tip.
Install the main drive (Item 1) [Figure 30-21-68]. Ensure
Install the valve drive (Item 2) [Figure 30-21-70] in the
it is supported from beneath until assembly is complete.
Geroler®.
Lubricate and install the new O-ring (Item 2) [Figure 30-
21-68]. Mark the spline (Item 3) in the Geroler® star that is 11.25
degrees counter-clockwise. Mark the corresponding
NOTE: Two 203,2 mm (8 in) long steel rods installed tooth (Item 4) on the small end of the valve drive that
in the mounting bolt holes will help align the aligns with the spline mark (Item 3) [Figure 30-21-70].
bolt holes in each section of the motor during
assembly.

(CONT'D)
Assembly (Cont’d)
Motor Timing (Cont’d)
Figure 30-21-71
1
1
P-76389
2 Install new O-rings (Item 1) [Figure 30-21-73] on both

plugs.
Figure 30-21-74
P-73527

Install the selector plate (Item 1) with the slotted holes
facing up. Be sure to line up the shuttle flow hole (Item 2)
[Figure 30-21-71].
1
Figure 30-21-72 1
1
1
1
1
1
1 P-76400
3
Assemble the shuttle valve assembly (Item 1) [Figure 30-
2 21-74] and insert into the valve housing.
P-73545
Install the valve (Item 1) [Figure 30-21-72] on the valve

drive. The round holes and four grooves must be facing
up.
Align any one of the four grooves (Item 2) in the valve

with the marked tooth on the valve drive (Item 3) [Figure
30-21-72].

(CONT'D)
Assembly (Cont’d)
Figure 30-21-75
2
1
P-76392
Install the ball (Item 1) and ball seat (Item 2) [Figure 30-
1 21-77] into the valve housing.
P-76397
Tighten the ball seat to 2 - 3 N•m (18 - 22 in-lb) torque.
Install the plugs (Item 1) [Figure 30-21-75] with a light NOTE: To install the ball seat, use a long allen

coat of oil on both sides of the valve housing. wrench to reach down into the valve housing.
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque. Figure 30-21-78
Figure 30-21-76
1
P-76389
P-76394A

(CONT'D)
Assembly (Cont’d)
Figure 30-21-79
1
P-76395

1 coat of oil.
P-76390
Install the plug (Item 1) [Figure 30-21-79] with a light Figure 30-21-82

coat of oil.
Figure 30-21-80
P-76389
1
P-76389

(CONT'D)
Assembly (Cont’d)
Figure 30-21-83
1
1
P-73539
Lubricate and install the back-up ring (Item 1) [Figure 30-

21-85] on the valve housing.
P-76387
Figure 30-21-86

coat of oil.

1
Figure 30-21-84
P-73536
Install the six compression springs (Item 1) [Figure 30-

21-86].
1
P-73538
Lubricate and install new O-ring (Item 1) [Figure 30-21-

84] on the valve housing.

(CONT'D)
Assembly (Cont’d)
1
Figure 30-21-87
P-73532
Install four compression springs (Item 1) [Figure 30-21-

1
89].
P-73535
Figure 30-21-90
Lubricate and install the O-ring and two back-up rings

(Item 1) [Figure 30-21-87] on the outer balance ring.
Figure 30-21-88
1
1
P-73531
Install the inner balance ring (Item 1) [Figure 30-21-90]

in the valve housing.
P-73534
Install the outer balance ring (Item 1) [Figure 30-21-88]

in the valve housing.

(CONT'D)
Assembly (Cont’d)
1
Figure 30-21-91
P-73773
Install the valve housing (Item 1) [Figure 30-21-93] on

the assembly taking care to maintain correct alignment.
P-73529
NOTE: Be careful when installing the valve housing
so the balance rings and springs remain in
Install the dowel pin (Item 1) [Figure 30-21-91]. position.

Figure 30-21-92 Figure 30-21-94
P-73529
P-73525
Lubricate and install new O-ring (Item 1) [Figure 30-21- Verify correct assembly with the marks that were made
92]. prior to disassembly [Figure 30-21-94].

(CONT'D)
Assembly (Cont'd)
Figure 30-21-95
2
P-76142
Install the relief valve (Item 1) and tubeline (Item 2) and

[Figure 30-21-97] on the motor.
P-73524
Install the fittings [Figure 30-21-97] on the motor.
Lubricate the nine bolts (Item 1) [Figure 30-21-95] with

hydraulic oil and install them into the assembly. Hand
tighten the bolts.
Figure 30-21-96
5 8
2 3
7 6
4 9
1 MS2317S
Tighten the nine bolts to 68 - 95 N•m (50 - 70 ft-lb) torque

using the sequence shown in [Figure 30-21-96].
Perform a final tightening of the nine bolts to 149 N•m

(110 ft-lb) torque using the same sequence shown in
[Figure 30-21-96].


HYDROSTATIC MOTOR CARRIER (SINGLE AND Figure 30-30-2
TWO-SPEED WITH MANUAL CONTROLS)
Single / Two-Speed
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission case.
2
The hydrostatic motor carrier contains a shaft that rotates
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
1
P-82710
A brake disk is installed on each hydrostatic motor
carrier. The brake disk is mounted to the shaft in the
motor carrier. The motor carrier hydrostatic motor mounting holes (Item
1) [Figure 30-30-1] and [Figure 30-30-2] are the only
The hydrostatic motor carriers are made to fit on both the difference between the single, two-speed and single /
right or left hand side of the loader. There are two sets of two-speed motor carriers with manual controls. The
mounting holes on each hydrostatic motor carrier to disassembly and assembly procedures are the same.
fasten the hydrostatic motors. One set for the left hand

side and another set for the right hand side of the loader. The single / two-speed motor carrier has a notch (Item 2)
[Figure 30-30-2] removed from one side of the carrier.
Figure 30-30-1
Single Speed Two-Speed
1 1
P-73920
P-68214

TWO-SPEED WITH MANUAL CONTROLS) (CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

DRIVE MOTOR on Page 30-20-1.) or (See
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) on Page
30-21-1.)
WARNING P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-30-4].
Figure 30-30-5

• Tools are being used.
W-2019-0907
Figure 30-30-3
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-30-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-30-3] is

located on the outside of the motor carrier shaft.

Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-6
1 2
P-82716
Photo [Figure 30-30-8] shows the motor carrier seal

correctly installed.
P-82713
Inspect the O-ring (Item 1) [Figure 30-30-8] and replace
if needed.
Installation: Install a new seal over the motor carrier

shaft [Figure 30-30-6]. NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 2) [Figure 30-30-8]
Figure 30-30-7 located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
motor can leak into the chaincase.
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-30-7].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-30-7].


2
WARNING 1

W-2059-0598
P-54227
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-30-
9]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or
Lift and block the loader. (See Procedure on Page 10-10- (See BRAKE (TWO-SPEED) on Page 40-11-1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising on Page 10- [Figure 30-30-9] from the inside of the chaincase.

30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing And 170 - 190 N•m (125 - 140 ft-lb) torque.
Replacing Oil on Page 10-130-1.)
Figure 30-30-10
Remove the engine speed control. (See Removal And
1
on Page 50-100-2.) or (See Removal And Installation on
Page 50-101-1.)
2
Remove the lift arm bypass control valve. (See Removal
Remove the traction lock assembly. (See Removal And

Remove the center chaincase cover. (See Center Cover

Removal And Installation on Page 40-30-2.) P-54226
Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-1.) For ease of removal, fasten the front drive chain
(previously removed) to the chaincase as shown (Item 1)
Remove the front axle and sprocket. (See Axle, Sprocket [Figure 30-30-10].
And Bearings Removal And Installation on Page 40-20-
4.) Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-30-
Remove the hydrostatic motor. (See HYDROSTATIC 10] from the sprocket.
30-21-1.)

HYDROSTATIC MOTOR CARRIER (SINGLE AND
Figure 30-30-11
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

30-11].
Installation: Ensure both motor carrier sealing surface

and transmission sealing face is clean and apply
polyurethane sealant to both surfaces.
Figure 30-30-12
P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-30-12] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

SINGLE SPEED
1
5
2
6
3
7
8

TWO-SPEED
&
SINGLE / TWO-SPEED
TWO-SPEED
1
5
6 2
7
8 3
4
P-76446
P-76445
1. SHAFT 5. RACE
2. BEARING 6. BEARING
3. RACE 7. SNAP RING
4. HOUSING 8. SEAL

Figure 30-30-13
76,2 mm O.D. Diameter

(3.000 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
P-39816
( 7.000 in)
Put the motor carrier in the hydraulic press as shown

[Figure 30-30-15].
MC-2102
Use 57,15 mm (2 - 1/4 in) driver tool and press the
sprocket shaft out of the motor carrier housing [Figure
It is necessary to locate or fabricate a press tool for this 30-30-15].

procedure. Refer to [Figure 30-30-13] for the correct
dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-30-14
Figure 30-30-16
2
1
P-82709
P-4365
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-30-16] on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal
Removal And Installation on Page 30-30-2.) Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-30-14] from 30-16] from the shaft.
the motor carrier shaft using the snap ring pliers.

Figure 30-30-17
P-39820
Put the motor carrier housing in the press as shown

[Figure 30-30-19].
P-39817
Use 109,5 mm (4 - 5/16 in) driver tool and press the new
inner bearing race into the motor carrier housing [Figure
Fasten the carrier motor housing to the work surface 30-30-19].

securely with the inner bearing race (Item 1) [Figure 30-
30-17] facing up. Press the bearing race in until it is fully seated in the
carrier housing.
Install the slide hammer with puller end (Item 2) [Figure
30-30-17] on the bottom side of the bearing race. Figure 30-30-20
Remove the bearing race from the carrier housing

[Figure 30-30-17].
Figure 30-30-18
P-39819
Turn the motor carrier housing over as shown [Figure 30-

30-20].
P-39818
Use 109,5 mm (4 - 5/16 in) driver tool and press the new
outer bearing race into the motor carrier housing [Figure
Put the motor carrier housing in the hydraulic press as 30-30-20].
shown [Figure 30-30-18].
Press the bearing race in until it is fully seated in the
Use a 98,4 mm (3 - 7/8 in) driver tool and press the outer carrier housing.
bearing race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

Figure 30-30-21

P-4371
P-4366 Put the motor carrier housing (Item 1) [Figure 30-30-22]

over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 76,2 mm (3.0 Put the outer bearing over the end of the sprocket shaft
in) driver tool, install the new inner bearing (Item 2) and press the bearing on with the press tool and driver
[Figure 30-30-21] on the sprocket shaft as shown. tool [Figure 30-30-22].
Remove the press and drive tools from the sprocket Remove the press and driver tools from the sprocket
shaft. shaft.

Figure 30-30-23
P-82708
Put the snap ring (Item 1) [Figure 30-30-23] over the end P-4375

of the sprocket shaft.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-30-
NOTE: Use the snap ring pliers to spread the snap 25] and install the shaft seal.
ring so it will fit over the sprocket shaft.
Using the press and driver tools, press the snap ring the carrier shaft [Figure 30-30-25].
(Item 1) [Figure 30-30-23] over the sprocket.
Figure 30-30-26
Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-30-24
P-39821
1
Use a rubber mallet [Figure 30-30-26], tap down on the

P-82707 cluster shaft.
Put a new shaft seal (Item 1) [Figure 30-30-24] on the

sprocket shaft.

Figure 30-30-27

N-15087
Install a dial indicator as shown in Photo [Figure 30-30-

27].
Use a pry bar (Item 1) [Figure 30-30-27] to lift the carrier

shaft and read the end play on the dial indicator.
The carrier shaft must turn freely with end play not to
exceed 0,17 mm (0.007 in).


TWO-SPEED WITH SJC CONTROLS)
Single / Two-Speed
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission case.
2
The hydrostatic motor carrier contains a shaft that rotates
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
1
P-82710
Loaders equipped with Selectable Joystick Controls
(SJC) use a speed sensor installed in the motor carrier
housing. The speed sensor senses a disk that is fixed to The motor carrier hydrostatic motor mounting holes (Item
the shaft in the motor carrier. If the loader does not have 1) [Figure 30-31-1] and [Figure 30-31-2] are the only
(SJC), a plate covers the hole where the sensor would difference between the single, two-speed and single /
be. two-speed motor carriers with SJC controls. The
disassembly and assembly procedures are the same.
A brake disk is installed on each hydrostatic motor

carrier. The brake disk is mounted to the shaft in the The single / two-speed motor carrier has a notch (Item 2)
motor carrier. [Figure 30-31-2] removed from one side of the carrier.
The hydrostatic motor carriers are made to fit on both the

right or left hand side of the loader. There are two sets of
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
side and another set for the right hand side of the loader.
Figure 30-31-1
Single Speed Two-Speed
1 1
P-73920
P-68214

TWO-SPEED WITH SJC CONTROLS) (CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

30-21-1.)
WARNING P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-31-4].
Figure 30-31-5

W-2019-0907
Figure 30-31-3
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-31-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-31-3] is

located on the outside of the motor carrier shaft.

Shaft Seal Removal And Installation (Cont’d)
Figure 30-31-6
2 1
P-82716
Photo [Figure 30-31-8] shows the motor carrier seal

correctly installed.
P-82713
Inspect the O-ring (Item 1) [Figure 30-31-8] and replace
if needed.
Installation: Install a new seal over the motor carrier

shaft [Figure 30-31-6]. NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 2) [Figure 30-31-8]
Figure 30-31-7 located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
motor can leak into the chaincase.
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-31-7].

WARNING 2

W-2059-0598
P-39781
support device. (See Installing on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-31-
9]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or
Lift and block the loader. (See Procedure on Page 10-10- (See BRAKE (TWO-SPEED) on Page 40-11-1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising on Page 10- [Figure 30-31-9] from the inside of the chaincase.

30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing And 170 - 190 N•m (125 - 140 ft-lb) torque.
Replacing Oil on Page 10-130-1.)
Figure 30-31-10
1
on Page 50-100-2.)
Remove the lift arm bypass control valve. (See Removal 2



P-54226
Remove the front chaincase cover. (See Front Cover
For ease of removal, fasten the front drive chain
Remove the front axle and sprocket. (See Axle, Sprocket (previously removed) to the chaincase as shown (Item 1)
And Bearings Removal And Installation on Page 40-20- [Figure 30-31-10].
4.)
Tip the end of the sprocket toward the rear of the loader
Remove the hydrostatic motor. (See HYDROSTATIC and remove the rear drive chain (Item 2) [Figure 30-31-
DRIVE MOTOR on Page 30-20-1.) or (See 10] from the sprocket.
30-21-1.)

Figure 30-31-11
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

31-11].
Installation: Ensure both motor carrier sealing surface

and transmission sealing face is clean and apply
polyurethane sealant to both surfaces.
Figure 30-31-12
P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-31-12] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

SINGLE SPEED
1
6
2
7 3
4
8
9

TWO-SPEED
&
TWO-SPEED
SINGLE / TWO-SPEED
1
6
7
2
8 4 3
9
5
P-76448
P-76447
1. SHAFT 6. RACE
2. SENSOR DISC 7. BEARING
3. BEARING 8. SNAP RING
4. RACE 9. SEAL
5. HOUSING

Figure 30-31-13
76,2 mm O.D. Diameter

(3.000 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
P-39816
( 7.000 in)
Put the motor carrier in the hydraulic press as shown

[Figure 30-31-15].
MC-2102
Use 57,15 mm (2-1/4 in) driver tool and press the
sprocket shaft out of the motor carrier housing [Figure
It is necessary to locate or fabricate a press tool for this 30-31-15].

procedure. Refer to [Figure 30-31-13] for the correct
dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-31-14
Figure 30-31-16
P-82709
P-76462
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal
Removal And Installation on Page 30-31-2.) Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 1) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-31-14] from 31-16] from the shaft.
the motor carrier shaft using the snap ring pliers.

Figure 30-31-17
P-39820
Put the motor carrier housing in the press as shown

[Figure 30-31-19].
P-39817
Use 109,5 mm (4-5/16 in) driver tool and press the new
inner bearing race into the motor carrier housing [Figure
Fasten the carrier motor housing to the work surface 30-31-19].

securely with the inner bearing race (Item 1) [Figure 30-
31-17] facing up. Press the bearing race in until it is fully seated in the
carrier housing.
Install the slide hammer with puller end (Item 2) [Figure
30-31-17] on the bottom side of the bearing race. Figure 30-31-20
Remove the bearing race from the carrier housing

[Figure 30-31-17].
Figure 30-31-18
P-39819
Turn the motor carrier housing over as shown [Figure 30-

31-20].
P-39818
Use 109,5 mm (4-5/16 in) driver tool and press the new
outer bearing race into the motor carrier housing [Figure
Put the motor carrier housing in the hydraulic press as 30-31-20].
Press the bearing race in until it is fully seated in the
Use a 98,4 mm (3-7/8 in) driver tool and press the outer carrier housing.
bearing race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

Figure 30-31-21
2 1
P-76462
Use the fabricated press tool and 76,2 mm (3.0 in) driver
tool, install the new inner bearing (Item 1) [Figure 30-31-
P-76464 23] on the sprocket shaft as shown.
Remove the press and drive tools from the sprocket

Figure 30-31-22 shaft.

2
1
P-76466
Install the sensor disc (Item 1) on the shaft (Item 2)

[Figure 30-31-21] and [Figure 30-31-22].
NOTE: Protrusion on disc to be aligned with pin area

on sprocket.

Figure 30-31-24
1 P-82708
Put the snap ring (Item 1) [Figure 30-31-25] over the end
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap

ring so it will fit over the sprocket shaft.

Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-25] over the sprocket.
Press the snap ring on until it snaps into the groove on

the shaft.
P-4371 Figure 30-31-26
Put the motor carrier housing (Item 1) [Figure 30-31-24]

over the sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft
and press the bearing on with the press tool and driver
tool [Figure 30-31-24].
Remove the press and driver tools from the sprocket

shaft. 1
P-82707
Put a new shaft seal (Item 1) [Figure 30-31-26] on the

sprocket shaft.

Figure 30-31-27
P-76467
1 Install a dial indicator as shown in Photo [Figure 30-31-

29].
Use a pry bar (Item 1) [Figure 30-31-29] to lift the carrier

shaft and read the end play on the dial indicator.

The carrier shaft must turn freely with end play not to
exceed 0,17 mm (0.007 in).
P-4375
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-31-

27] and install the shaft seal.
Figure 30-31-28
P-76463
Use a rubber mallet [Figure 30-31-28], tap down on the

cluster shaft.


CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender can be located on the

charge filter housing mounted next to the blower housing
or on the hydraulic fan motor depending on the style of
fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

CHARGE PRESSURE (CONT’D)
Testing (S/N A3L929999 & Below And A3LH29999 &

Below)
WARNING
Figure 30-40-1 Never work on a machine with the lift arms up unless
W-2059-0598
Place the loader on jackstands. (See Procedure on Page

2 4 10-10-1.)
1 3
P-43196 Figure 30-40-3
The tools needed to check charge pressure, hydraulic

hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6895 kPa (68,9 bar) (1000 psi) (Item 3) and
adapter fitting (P/N 93F-5) (Item 4) [Figure 30-40-1].
Figure 30-40-2 1
P-66884
3 Remove the hydraulic tubeline (Item 1) [Figure 30-40-8]

2
from the charge pressure sender adapter fitting and the
hydraulic control valve.
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-40-2].
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to

the adapter fitting. Tighten all connections.

CHARGE PRESSURE (CONT’D) Sender Removal And Installation (S/N A3L929999 &
Below And A3LH29999 & Below)
Testing (S/N A3L929999 & Below And A3LH29999 &
Below (Cont’d) Figure 30-40-5
Figure 30-40-4 1
3 2
P-66884
P-68256
Disconnect the charge pressure sender connector (Item
1) [Figure 30-40-5] from the sender.
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].

Remove the sender (Item 2) [Figure 30-40-5] from the
Install a hose (Item 2) [Figure 30-40-4], to replace the adapter fitting.
tubeline that was there.
Installation: Tighten the charge pressure sender to 10 -
Install the hose (Item 3) [Figure 30-40-4], that is 11 N•m (7.4 - 8.1 ft-lb) torque.
attached to the pressure gauge, to the T fitting.
NOTE: Inspect the O-ring on the sender and replace
Tighten the hydraulic fittings. if necessary before installation.

TOOL KIT-1563 on Page 10-60-1.)
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 60°C (140°F).
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2309,7 - 2654,5 kPa (23,1 - 26,5 bar) (335 - 385 psi) with
the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 2309,7 -
2723,4 kPa (23,1 - 27,2 bar) (335 - 395 psi) at
60°C (140°F) fluid @ High idle.

CHARGE PRESSURE (CONT’D)
Testing (S/N A3L390001 & Above And A3LH30001 &

Above)
WARNING
Figure 30-40-6 Never work on a machine with the lift arms up unless
W-2059-0598

2 4 10-10-1.)
1 3
P-43196 Figure 30-40-8
The tools needed to check charge pressure, hydraulic

hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6895 kPa (68,9 bar) (1000 psi) (Item 3) and 1
adapter fitting (P/N 93F-5) (Item 4) [Figure 30-40-1].
Figure 30-40-7
P-76947
3 Disconnect the hydraulic hose (Item 1) [Figure 30-40-8].

2
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-40-2].
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to

the adapter fitting. Tighten all connections.

CHARGE PRESSURE (CONT’D) Sender Removal And Installation (S/N A3L930001 &
Above And A3LH30001 & Above)
Testing (S/N A3L930001 & Above And A3LH30001 &
Above) (Cont’d) Figure 30-40-10
Figure 30-40-9
1
2
2
P-76947
P-76948
Disconnect the wire (Item 1) [Figure 30-40-5] from the
sender.
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].

Remove the sender (Item 2) [Figure 30-40-5] from the
Install the hose (Item 2) [Figure 30-40-4], that was motor.
disconnected from the motor, to the T fitting.
Installation: Tighten the charge pressure sender to 10 -
Install the hose (Item 3) [Figure 30-40-4], that is 10,9 N•m (7.4 - 8.1 ft-lb) torque.
attached to the pressure gauge, to the T fitting.
NOTE: Inspect the O-ring on the sender and replace
Tighten the hydraulic fittings. if necessary before installation.
Connect the remote start tool. (See Remote Start Tool -

1563 on Page 10-60-1.)
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 60°C (140°F).
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2309,7 - 2654,5 kPa (23,1 - 26,5 bar) (335 - 385 psi) with
the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 2309,7 -
2654,5 kPa (23,1 - 26,5 bar) (335 - 385 psi) at
60°C (140°F) fluid @ High idle.

CHARGE PRESSURE (CONT’D) Figure 30-40-12
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-40-11 Remove the plug, spring and poppet [Figure 30-40-12].
1 Check the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.

Figure 30-40-13
N-19567
If the charge pressure is not correct loosen the charge 1

relief valve plug (Item 1) [Figure 30-40-11].
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque. N-19568
There are several different thickness of the shims (Item 1)

[Figure 30-40-13] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is 55,2 kPa (0,55 bar) (8

psi) increase in pressure.
The charge pressure should be set at 2309,7 - 2654,5

kPa (23,1 - 26,5 bar) (335 - 385 psi).

CHARGE PRESSURE (CONT'D) Figure 30-40-15
Adjusting (Cont’d)
SJC Machines
IMPORTANT
damage the system.
P-64435
I-2003-0888
Figure 30-40-14 Check the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-15] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim (Item 1) [Figure 30-40-15] = 299,9

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2309,7 - 2654,5

kPa (23,1 - 26,5 bar) (335 - 385 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-14].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.


HYDROSTATIC PUMP Figure 30-50-2
Description
1
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic drive motors.
The pump flow and direction are controlled by two hand
levers, one for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement 2
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure P-66670
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump contains the charge pressure Remove the replenishing / high pressure relief valve
relief. The charge pressure relief is adjustable with shims. (Item 1) [Figure 30-50-2] from the pump.
The hydrostatic pump is located in the center of the Assembly: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
mainframe mounted to the engine flywheel housing. torque.

Replenishing / High Pressure Relief Valve Removal Check for damage and replace as needed.
And Installation
Check the O-ring (Item 2) [Figure 30-50-2] for damage
Figure 30-50-1 and replace as needed.
If the replenishing / high pressure relief valve must be

1 replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing / high

pressure relief valve is 34473,8 kPa (344,7 bar) (5000
psi).
N-19565
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-50-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-4

1
IMPORTANT
2
damage the system.
I-2003-0888
P-34567B
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-8.) Loosen the drive belt tensioner (Item 1) [Figure 30-50-4]
and remove the drive belt.
Remove the control handle linkage from the hydrostatic
pump. (See Linkage Removal And Installation on Page Remove the hydrostatic pump drive pulley mounting nut
50-100-7.) (Item 2) [Figure 30-50-4] and washer.

Remove the hydraulic pump from the hydrostatic pump. Installation: Tighten the pump pulley mounting nut to
(See HYDRAULIC PUMP (STANDARD) on Page 20-60- 237 - 271 N•m (175 - 200 ft-lb) torque.
1.)
Figure 30-50-5
Figure 30-50-3
1 P-34567A
P-34568
Install a puller on the hydrostatic pump drive pulley and

Remove the hydrostatic pump mounting bolt (Item 1) remove the pulley from the pump shaft [Figure 30-50-5].
[Figure 30-50-3] and washer(s).
Installation: Tighten the mounting bolt to 125 - 135 N•m

NOTE: Mounting bolt (Item 1) [Figure 30-50-3] is a

special purpose bolt, replace with genuine
Bobcat parts only.

HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-8.)
Figure 30-50-6
WARNING
1
explosion or fire.
W-2103-0508
P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-50-6] before installing the pump drive

pulley.
Figure 30-50-7
P-28850
Hold the nut (Item 1) [Figure 30-50-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-50-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 88 - 95

Reverse the removal procedure to install the hydrostatic

pump assembly.

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

HYDROSTATIC PUMP (CONT'D) Figure 30-50-10
Disassembly
1
Figure 30-50-8
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-50-10].

N-19550
Check the valve plate for wear. (Both Sides.)
Remove the four bolts (Item 1) [Figure 30-50-8] from the

pump housing end cap.

Figure 30-50-9
N-19551
Remove the pump housing end cap (Item 1) [Figure 30-

50-9].
Remove the gasket (Item 2) [Figure 30-50-9].

1
Figure 30-50-11
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-50-13] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-50-13] for wear

Check the valve plate locating pin (Item 1) [Figure 30-50- and replace the rotating group as needed.
11] for wear and replace if needed.

Figure 30-50-14
Check the needle bearing (Item 2) [Figure 30-50-11] for
wear and replace if needed. 1
Figure 30-50-12
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-50-

N-17197 14] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-50-12]

from the pump.

Figure 30-50-15
1
3 3
2
3 3 2 1
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)

N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-50-17].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-50-18
2) for wear and replace as needed [Figure 30-50-15].

Remove the four pins (Item 3) [Figure 30-50-15] from the
cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-50-15] to see if they are

all the same length.
Figure 30-50-16
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-50-18] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-50-16] from

the pump housing.

Figure 30-50-19 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-50-21] for

N-17240 wear and replace if needed.
Figure 30-50-22
Remove the snap ring (Item 1) [Figure 30-50-19] from
the pump housing and remove the driveshaft and bearing

from the housing.
Figure 30-50-20
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-50-22]
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

Figure 30-50-23
2
2
1 1
1 N-17246
Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-50-25].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-50-26
from the pump housing [Figure 30-50-23].

Figure 30-50-24
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-50-

26].
Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-24] for wear and replace as needed.

Figure 30-50-27
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-50-29] and replace as needed.
Figure 30-50-30
Inspect the seal (Item 1) [Figure 30-50-27] in the upper
trunnion cover and replace if needed.

Figure 30-50-28
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-50-30] from
the swash plate shaft.
Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-28] from the pump housing.

Assembly
Figure 30-50-31
N-17252
Install the swash plate and bearing into the pump

N-17252 housing [Figure 30-50-33].
Tilt the swash plate (Item 1) [Figure 30-50-31] and

remove the swash plate and lower bearing from the pump

housing.
Figure 30-50-32
N-17253
Install the lower bearing (Item 1) [Figure 30-50-32] on

the swash plate.

Assembly (Cont'd)
Figure 30-50-34
1 1
2
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-50-36]
N-17249 and cover.
Figure 30-50-37
Install the tapered bearing (Item 1) [Figure 30-50-34] on
the swash plate shaft.

Figure 30-50-35
2
N-17246
3
Install the linkage bracket (Item 1) [Figure 30-50-37] and
N-17248 the four mounting bolts and tighten to 24 - 30 N•m (18 -
22 ft-lb) torque.
Install the bearing race (Item 2) and O-ring (Item 3) as

shown in [Figure 30-50-34] and [Figure 30-50-35].

Assembly (Cont'd)
Figure 30-50-38
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-50-40].
Install the four mounting bolts and tighten to 24 - 30 N•m

Figure 30-50-39 (18 - 22 ft-lb) torque.

Figure 30-50-41
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-50-38] and O-
ring (Item 2) [Figure 30-50-38] at the lower trunnion as
shown in [Figure 30-50-39]. Install the snap ring (Item 1) [Figure 30-50-41] on the
pump shaft.

Assembly (Cont'd) 1 1
Figure 30-50-42
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-50-44]

N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the bearing and snap ring (Item 1) [Figure 30-50- and install into the ball guide retainer (Item 3) [Figure 30-
42] on the pump shaft. 50-44].

Figure 30-50-43 Figure 30-50-45
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
50-43]. 30-50-45] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-50-43].

Assembly (Cont'd)
1
2
Figure 30-50-46
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-48] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-49
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
50-46].
Figure 30-50-47
2 1
N-17196
The bearing cage (Item 1) [Figure 30-50-49] will

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
N-17197 surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

Lay the pump housing on its side and install the cylinder 50-49] will protrude from 4,19 - 4,70 mm (1.65 - 0.185 in)
block, piston assembly into the housing. from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-50-47].

Assembly (Cont'd)
1 1
Figure 30-50-50
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-52] to 47 - 61
Coat the backside of the valve plate with petroleum jelly Figure 30-50-53
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-50-50].
The notch (Item 1) [Figure 30-50-50] on the valve plate

must engage the locating pin.
Figure 30-50-51 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-50-53].
Install the large new O-ring (Item 2) [Figure 30-50-53].
N-19551 Install the pump coupler (Item 3) [Figure 30-50-53].
Coat a new end cap gasket (Item 1) [Figure 30-50-51]

with petroleum jelly and install onto the end cap.

Assembly (Cont'd)
Figure 30-50-54
N-19570
Install the two pumps together [Figure 30-50-54].

Figure 30-50-55
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-50-55] to

torque.

HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The endcaps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1

P-64943
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the 1

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install and approved lift arm P-64460
Place the loader on jack stands. (See Procedure on Page Disconnect all of the electrical harness connectors (Item
10-10-1.) 1) [Figure 30-51-3] from the loader harness.
Removal:
WARNING

Put jackstands under the front axles and rear corners IMPORTANT
Failure to use jackstands can allow the machine to When repairing hydrostatic and hydraulic systems,
fall or move and cause injury or death. clean the work area before disassembly and keep all
W-2017-0286 parts clean. Always use caps and plugs on hoses,
Raise the operator cab. (See Raising on Page 10-30-1.) damage the system.
I-2003-0888
Figure 30-51-2
Figure 30-51-4
1
P-64425
P-64426
Locate the two hydraulic controllers (Item 1) [Figure 30-

51-2] on the hydrostatic pumps. Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.

Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-51-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4
N•m (7.7 ft-lb) torque. Ensure bolts are tight to
P-64427 specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-51-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-51-31.)
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump. Figure 30-51-8
Installation:
Figure 30-51-6
P-64978
With the engine running and the loader on jack stands:

P-64444 Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
the center of the servo piston groove (Item 1) [Figure 30- torque.
51-6].
Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].
Be sure the pump surface is clean.

Remove the hydrostatic pump / engine assembly from

Page 70-10-8.)
IMPORTANT 1

P-64345
damage the system.
I-2003-0888 Loosen the washer and nut (Item 1) [Figure 30-51-10] on
the hydrostatic pump drive shaft.
Figure 30-51-9
Installation: Tighten the nut to 237 - 271 N•m (175 - 200
ft-lb) torque

1 Figure 30-51-11
P-64344
1
Loosen the tensioner mount bolt (Item 1) [Figure 30-51-

9]. P-64346
Remove the drive belt (Item 2) [Figure 30-51-9].

Use a puller (Item 1) [Figure 30-51-11] to loosen the
Installation: (See Belt Removal And Installation on Page pulley from the pump drive shaft.
30-60-3.)
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.

Figure 30-51-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-51-14] at

P-64348 the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 125 - 135 N•m (90

Figure 30-51-13 - 100 ft-lb)

NOTE: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
1 1 Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-51-7.)
P-64337 P-64338

12] and nuts (Item 1) [Figure 30-51-13].
Installation: Tighten the mounting bolts and nuts to 88 -

Make sure the key (Item 2) [Figure 30-51-12] is installed.

HYDROSTATIC PUMP (SJC) (CONT'D)
Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.
Figure 30-51-15

1
P-64458
Remove the air bleed plugs (Item 1) [Figure 30-51-15].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

3
1. O-ring 5
4 1
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt 14
15
16
19 17
21 25
24 23 22 26

20
18
26
18
27 29
19
32 28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
6 21. Bolt
2 7 22. Plug
23. Screen
24. Plug
25. Plug
30 26. Dowel Pin
4 27. Charge Pressure Relief
28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
P-90241

High Pressure Relief And Bypass Valve
Figure 30-51-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-51-18]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-16].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 34990,9 kPa (349,9
Figure 30-51-17 bar) (5075 psi).
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-51-17] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-51-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-51-21] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-51-19] is Inspect the sealing ring (Item 3) [Figure 30-51-21] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 70 N•m (52 ft- shims (Item 5) [Figure 30-51-21].
lb) torque.
NOTE: 1,0 mm shim (Item 5) [Figure 30-51-21] = 299,9
Figure 30-51-20 kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-51-20].

Remove the hydrostatic pump / engine assembly from

2
Page 70-10-8.)
Figure 30-51-22
1
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers

(Item 2) [Figure 30-51-24].
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.
P-64458 Figure 30-51-25

Remove the hydraulic controllers (Item 1) [Figure 30-51-
22]. (See Hydraulic Controller Removal And Installation 1
on Page 30-51-2.)
Figure 30-51-23
2 2
1 1
1
P-64440
Remove the mounting bolts and washers for the swash

plate angle sensor (Item 1) [Figure 30-51-25].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

P-64438
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-23].
Note the connectors facing each other.
Note the steel covers facing direction.

Figure 30-51-26
P-64442
Both swash plate angle sensors and associated

P-64441 hardware removed from the hydrostatic pump. [Figure
30-51-28].
Assembly: Note the slotted portion (Item 1) of the

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-51-
26].
Note the machined section of the swash plate angle

sensor shaft faces the center of the hydrostatic pump.
Figure 30-51-27
P-64453
NOTE: Improperly installing the swash plate angle

sensor, with the shaft facing toward the
outside of the hydrostatic pump, will make it
hard to install the sensor mounting bolts and
also destroy the seal (Item 1) [Figure 30-51-
27].

Right End Housing
Figure 30-51-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
51-31].
1
P-64445

Left End Housing
Figure 30-51-30
3 1
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-29] and [Figure 30-51-30].
Assembly: Alternately, tighten mount bolts to 130 N•m

(96 ft-lb) torque.

Figure 30-51-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole

P-64465 in case housing (Item 2) [Figure 30-51-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-32].

Figure 30-51-33
P-64466
Ensure servo follower (Item 2) [Figure 30-51-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-33].

Figure 30-51-35
RIGHT SIDE
P-64454
Figure 30-51-36

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-35] and

[Figure 30-51-36] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-35] and [Figure 30-51-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-51-37
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-51-40
P-64455
LEFT SIDE
Figure 30-51-38 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64502 37] and [Figure 30-51-38] in the case housing with the
notch (Item 1) [Figure 30-51-39] and [Figure 30-51-40]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-51-37] and [Figure 30-51-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-39] and [Figure
30-51-40].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

Figure 30-51-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-43].

B25012
Figure 30-51-44
Right Side Rotating Group [Figure 30-51-41].

Figure 30-51-42
1
P-64475
Remove the pistons (Item 1) [Figure 30-51-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-42].


1
Figure 30-51-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 47].
Figure 30-51-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-45] in the
1

slippers, are not plugged.
Figure 30-51-46
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-48]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-46].


3
Figure 30-51-49
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-51-51].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-51].
1) [Figure 30-51-49].

Remove the slide ring (Item 3) [Figure 30-51-51], ensure
Figure 30-51-50 it pivots freely.
Figure 30-51-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-50] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-52].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-51-50] are not bent or damaged.

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-55] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-53]. the outside of the endcap housing

Figure 30-51-54 Inspect bearing surfaces for scratches or scoring.
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-51-54] on swash plate.

Disassembly And Assembly (Cont'd) LEFT SIDE

Figure 30-51-56
1
2
1
P-64486
Figure 30-51-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-51-56].

Figure 30-51-57
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-51-58] and

[Figure 30-51-59] from the end housing.
Figure 30-51-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-51-57].
Inspect wear surfaces (Item 2) [Figure 30-51-57] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
1
P-64524
The pump seal (Item 1) [Figure 30-51-60] is removed by

inserting a screw into the seal and prying out.

HYDROSTATIC PUMP (SJC) (CONT'D) The Servo Piston Assembly [Figure 30-51-62] cannot be
removed unless the hydraulic controller and rotating
Disassembly And Assembly (Cont'd) group is removed first.
Figure 30-51-61 Figure 30-51-63
1 1 1
P-64488 P-64489
The drive shaft can be tapped out of the end housing with Remove servo piston mounting bolts (Item 1) [Figure 30-
a rubber mallet. 51-63].

Inspect wear surfaces for scratches, and inspect splines Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-61] and remove
bearing.
Figure 30-51-62
B25013
Servo Piston Assembly [Figure 30-51-62].

Figure 30-51-64
P-64492
Slide the servo piston assembly out of the bore. [Figure

P-64490 30-51-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-64].

Figure 30-51-65
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-65].

Figure 30-51-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item 2)

P-64467 [Figure 30-51-69] from the pump housing.
Figure 30-51-70
Figure 30-51-68

1
3
P-64494
P-64466
Each servo has a pair of bushings (Item 1), O-rings (Item

Assembly: Align the servo piston so the guide slot 2) and square-cut seals (Item 3) [Figure 30-51-70].
(Item 1) [Figure 30-51-68] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-51-
67].

Figure 30-51-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-73] from the
P-64495 servo piston.
Figure 30-51-74
Remove the lock nut (Item 1) [Figure 30-51-71] from the
servo piston.
1

Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque. 2
Figure 30-51-72
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-51-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-51-74]

Remove the servo cover (Item 1) [Figure 30-51-72] from
the servo piston.

Figure 30-51-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure

P-64461 30-51-77] at the top of the case housing.
Replace O-rings on plugs.

Remove the plug (Item 1) from the top center of the case
housing. Replace O-ring (Item 2) [Figure 30-51-75]. Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

Assembly: Tighten plug to 10 N•m (45 ft-lb) torque.
Remove internal screen (Item 3) [Figure 30-51-75].
Assembly: Tighten internal screen to 62 N•m (7.4 ft-lb)

torque.
Figure 30-51-76
P-64462
Ensure screen is clean [Figure 30-51-76].

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-78 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.

10-10-1.)
2
1
WARNING
P-64502
W-2017-0286
Bearings (Item 1) [Figure 30-51-78] in case housing are
replaced by using a press and bearing driver. Raise the lift arms, and install an approved lift arm

Inspect center coupler (Item 2) [Figure 30-51-78].

Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
WARNING
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-79
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-81] from the

P-64973 MA ports on the bottom of the pump, and install 51710,7
kPa (517,1 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-79] Figure 30-51-82

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-51-80
1
1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-82]. Plug the ports with metal caps. The
P-64425 caps must be able to handle at least 51710,7 kPa (517,1
bar) (7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-51-80] from the pump mechanical neutral setting.
MB ports on the front side of the pump, and install
51710,7 kPa (517,1 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-83
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-51-85]

P-64457 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-83]. Figure 30-51-86

Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
Figure 30-51-84 1
P-64457

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-64457

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-87 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
2 NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
1 pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-64457
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-51-87] to 30 N•m

(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-51- Connect the remote start tool. (See REMOTE START
31.) TOOL KIT-1563 on Page 10-60-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-88
2
1
P-64975
1
Install 3447,3 kPa (34,5 bar) (500 psi) pressure gauges

P-64460 in the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-51-91

[Figure 30-51-88] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-51-89
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-51-91].

P-64458
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-89] pertaining to the side of the
hydrostatic pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-92
P-64459

P-64459 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-95

in system pressure. Mark the position of the adjustment
screw.
2
Figure 30-51-93
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-51-95] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-93] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See Lift And

Tilt Calibration (ACS) on Page 60-160-11.)


DRIVE BELT Shield Removal And Installation
The drive belt makes the mechanical connection from the

engine flywheel to the hydrostatic pump pulley.
The belt is a cord-reinforced rubber design.
Constant tension is applied to the drive belt by the use of

a spring-loaded belt tensioner.
The drive belt is protected by a plastic shield fastened to 1

the flywheel housing by metal clips. The shield is also in
place to protect the operator.
P-66811
Remove the three drive belt shield mounting clips

(Item 1) [Figure 30-60-1].
Figure 30-60-2

1
P-66812
Remove the belt shield (Item 1) [Figure 30-60-2].

DRIVE BELT (CONT’D) Figure 30-60-4
Adjusting
Stop the engine.
Open the rear door and disconnect the negative (-) cable
from the battery.
Remove three belt shield fasteners and remove the belt

1
shield.
Figure 30-60-3
1 P-48479A
2 Push the idler pulley against the belt, using a pry bar
[Figure 30-60-4]. The pointer will be at the 3 o'clock
position (Item 1) [Figure 30-60-4] when the idler pulley is
against the stop (maximum movement)
Raise the idler assembly slightly so that the pulley is

operating on spring tension and not against the stop.

NOTE: Do not set the idler against the travel stop in
P-48478A the 3 o'clock position.
Tighten the mounting bolt (Item 1) [Figure 30-60-3] to 34

Loosen the bolt (Item 1) [Figure 30-60-3] on the spring - 38 N•m (25 - 28 ft-lb) torque.
loaded drive idler.
Run the engine for a few minutes. Stop the engine and
NOTE: The pointer will be at the 1 o'clock position recheck the pointer position.
(Item 2) [Figure 30-60-3] when the belt
tensioner is not under spring tension. Readjust if necessary.
After the idler has been in service, readjust when the

pointer reaches the 1 o'clock position.
Install the belt shield and fasteners.
Connect the negative (-) battery cable.

Belt Removal And Installation
Figure 30-60-5
P-48481
Remove the drive belt from the pump pulley and flywheel.
P-48000 Remove the drive belt from the loader [Figure 30-60-7].
Install the new drive belt. Install the belt tensioner

Stop the engine. Open the rear door. assembly.

Raise the operator cab. (See Raising on Page 10-30-1.) Adjust the drive belt. (See Adjusting on Page 30-60-2.)
Remove the negative (-) cable from the battery. The Reinstall belt shield and connect the negative (-) cable to
battery may be removed for additional working clearance. the battery.
(See Removal And Installation on Page 60-20-1.)
Remove the belt shield [Figure 30-60-5]. (See Shield

Figure 30-60-6
P-66813
Remove the air conditioner belt if so equipped.
The belt tensioner is located between the flywheel and

pump pulley. Loosen and remove the bolt (Item 1)
[Figure 30-60-6] from the belt tensioner.
Remove the belt tensioner assembly.

DRIVE BELT (CONT’D)
Tensioner Pulley Removal And Installation
Figure 30-60-8
P-48000
Stop the engine. Open rear door.

Remove the negative (-) cable from the battery. the
battery may be removed for additional working clearance.
Remove the belt shield [Figure 30-60-8]. (See Shield

Figure 30-60-9
P-66813
Loosen and remove the belt tensioner mounting bolt

(Item 1) [Figure 30-60-9].
Installation: Apply Loctite® 242 to the mounting bolt and

Remove the belt tensioner from the flywheel housing.
Reverse the removal procedure to install the belt

tensioner.

DRIVE BELT (CONT’D)
Tensioner Pulley Parts Identification
1. Cover
2. Bolt with preapplied threadlocker 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring

19. Shaft 6 13
20. Bracket
5
14
NOTE: Tensioner pulley parts are not all
available individually. Consult
parts catalog for available 15
sub-assemblies.
7
16
8
9 17
18
10
19
20
E-2296

Tensioner Pulley Disassembly
Figure 30-60-10
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly

P-8858 (Item 2) [Figure 30-60-12] only if they have been
damaged.
Remove the grease cover (Item 1) [Figure 30-60-10]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-60-12] with a plastic hammer.

Figure 30-60-11
Figure 30-60-13
2
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-60-13].
assembly (Item 5) [Figure 30-60-11].

Tensioner Pulley Assembly
Figure 30-60-14
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-60-16] into the hub.
Figure 30-60-17
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-60-14] as shown.

Figure 30-60-15
2
3
P-8874
Install a punch as shown and turn clockwise while

P-8872 applying down pressure on the pulley.
Turn until the pulley snaps down into place; this

Install the shaft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of the
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-60-17].
[Figure 30-60-15] over the alignment pin on the bracket.

Tensioner Pulley Assembly (Cont'd)
Figure 30-60-18
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly

P-8875 (Item 2) [Figure 30-60-20]. Press on the outer formed
edge of the grease cap.
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-60-18] over the roll pins. assembly, do not press down on the arrow

indicator plate. Support the hub assembly so
Figure 30-60-19 that it contacts only the hub and not the arrow
indicator plate.
2
1
P-8876
Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-60-19].
Tighten the bolt to 38 - 45 N•m (28 - 32 ft-lb) torque.
Fill the grease cap 1/4 full (approximately 0.5 - 0.75 oz) of
grease.
Installation: Clean and dry bolt threads. Apply Loctite®

242 to the bolt (Item 3) and tighten to 38 - 45 N•m (28 -
32 ft-lb) torque.

TWO-SPEED VALVE
Description
Figure 30-70-1
P-76175
The two-speed valve (Item 1) [Figure 30-70-1] is located

on top of the chaincase in front of the hydrostatic pump.

The high range is selected by a switch located on the
right handle for manual loaders and on the left joystick for
SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.
The two-speed valve also contains a two-speed pre-

warming solenoid, which provides warm hydraulic oil to
preheat the drive motors preventing damage in cold
conditions. When the hydraulic oil reaches a pre-
determined temperature, the pre-warming solenoid is
turned off and the two-speed is engaged.
The case drain filter for the drive motors is mounted to

the top of the two-speed valve.

TWO-SPEED VALVE (CONT'D) Mark all hydraulic hoses and tubelines for proper
installation.
Valve Removal And Installation
Figure 30-70-2
DANGER
2 2
1 1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-76174

can cause lift arms to drop. Scribe a mark across the top of the steering linkage bars
• Keep out of this area when lift arms are raised (Item 1) [Figure 30-70-2] which are connected to the
unless supported by an approved lift arm steering shaft on the control panel.

D-1009-0409
[Figure 30-70-2].

WARNING bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque. Verify linkage neutral
adjustment. (See Linkage Neutral (Adjusting) on Page
50-100-13.)
Figure 30-70-3
W-2059-0598
2
WARNING 1

W-2017-0286
P-76161
1.)
Raise the lift arms and install an approved lift arm 30-70-3] from the two-speed pre-warming solenoid.
Raise the operator cab. (See Raising on Page 10-30-1.) 30-70-3] from the two-speed solenoid.

TWO-SPEED VALVE (CONT'D) Figure 30-70-6
Valve Removal And Installation (Cont'd)
Figure 30-70-4
1
1
2
1
P-76148
Remove the two mounting bolts (Item 1) [Figure 30-70-6]

1 P-76160 from the valve bracket.
Remove the two-speed valve assembly from the loader.

Disconnect the three hydraulic tubelines (Item 1) [Figure
30-70-4] from the two-speed valve.

Disconnect the hydraulic hose (Item 2) [Figure 30-70-4]
from the two-speed valve.
Figure 30-70-5
2
2
P-76155
Disconnect the hydraulic hose (Item 1) and the three

tubelines (Item 2) [Figure 30-70-5] from the two-speed
valve.

TWO-SPEED VALVE (CONT'D) Figure 30-70-8
Valve Disassembly And Assembly
Figure 30-70-7
1 6 1
3
4
2
7
5
P-76185
Check the O-rings (Item 1) [Figure 30-70-8] on the two-

P-76134 speed solenoid stem for wear and replace as needed.
Figure 30-70-9
Mark all hydraulic tubelines and fittings for proper
installation.

Remove the two-speed solenoid nut (Item 1), two-speed
solenoid (Item 2), and two-speed solenoid stem (Item 3)
[Figure 30-70-7] from the valve block.
Assembly: Tighten the two-speed solenoid nut to 6,8 1

N•m (5 ft-lb) torque.
Assembly: Tighten the two-speed solenoid stem to 27,1

Remove the pre-warming solenoid nut (Item 4), pre-

warming solenoid (Item 5), and pre-warming solenoid 2 P-76188
stem (Item 6) [Figure 30-70-7] from the valve block.
Assembly: Tighten the pre-warming solenoid nut to 6,8 Check the O-rings (Item 1) and back-up washers (Item 2)
N•m (5 ft-lb) torque. [Figure 30-70-9] on the pre-warming solenoid stem for
wear and replace as needed.
Assembly: Tighten the pre-warming solenoid stem to
27,1 N•m (20 ft-lb) torque.

valve fittings.

TWO-SPEED VALVE (CONT'D)
Valve Disassembly And Assembly (Cont’d)
Figure 30-70-10
P-76136A
Remove the two bolts and nuts (Item 1) [Figure 30-70-

10] fastening the two-speed valve and case drain filter

clamp to the valve mounting bracket.
Remove the two-speed valve (Item 1) and case drain

filter clamp (Item 2) [Figure 30-70-10] from the valve
mounting bracket.
Assembly: Tighten the two mounting bolts to 9 - 10 N•m



CASE DRAIN FILTER Figure 30-80-3
Description
The case drain filter is an external filter assembly in the

case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and / or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See

Removing And Replacing Hydraulic Case Drain Filters
(Single Speed Loaders) on Page 10-120-3.) or (See P-76218
Removing And Replacing Hydraulic Case Drain Filters
(Two-Speed Loaders) on Page 10-120-4.)
Remove the filter element and spring assembly (Item 1)
Figure 30-80-1
[Figure 30-80-3]
NOTE: Remember the orientation of the filter element

and spring assembly for correct assembly.

Figure 30-80-4
3
1
1
P-76212
Remove the filter housing nut (Item 1) from the filter 2

housing (Item 2) [Figure 30-80-1].
Figure 30-80-2
P-76216
The larger taper spring (Item 1) slides over the end of the
filter element (Item 2) and the smaller tapered spring
2 (Item 3) [Figure 30-80-4] slides into the filter element.
P-76214
Remove the packing (Item 1) and O-ring (Item 2) [Figure

30-80-2] from the filter housing nut.


DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Disc Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-2
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2

Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3


BRAKE (SINGLE SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-1.)
Description
Disconnect and remove the engine speed control. (See
The brake is used to hold the machine in place. The Removal And Installation on Page 70-20-1.)
brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the front accessory panel. Remove the control panel from the loader. (See Removal
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the center chaincase cover. (See Center Cover
shafts. An electric solenoid is sent power from a relay to Removal And Installation on Page 40-30-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Remove the traction lock assembly. (See Removal And
discs. Installation on Page 60-120-2.)
The hold signal will be interrupted and the wedge will Figure 40-10-2
drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake. (See TRACTION 1

LOCK on Page 60-120-1.)
Figure 40-10-1

1
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.
1 Figure 40-10-3
P-76419
Disc Removal And Installation
WARNING
1
N-19105
support device can allow the lift arms or attachment Inspect the traction lock guides (Item 1) [Figure 40-10-3]
to fall and cause injury or death. and the brake disc for damage or wear and replace as
W-2059-0598
necessary. (See Inspecting on Page 60-120-6.)

BRAKE (SINGLE SPEED) (CONT’D)
Disc Removal And Installation (Cont’d)
Figure 40-10-4
N-19082A
Figure 40-10-5

1
N-19083A
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-10-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

BRAKE (TWO-SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-1.)
Description
Disconnect and remove the engine speed control. (See
The brake discs on two-speed loaders have a rubber Removal And Installation on Page 70-20-1.)
isolator riveted to the side of the brake discs.
Remove the control panel from the loader. (See Removal
The brake is used to hold the machine in place. The And Installation on Page 50-100-2.)
brake is operated by a switch (Item 1) [Figure 40-11-1]
located on the front accessory panel. Remove the center chaincase cover. (See Center Cover
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the traction lock assembly. (See Removal And
shafts. An electric solenoid is sent power from a relay to Installation on Page 60-120-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Figure 40-11-2
discs.
The hold signal will be interrupted and the wedge will

drop if the engine drops below 700 RPM, the seat bar
sensor fails or if there is a break in the wires for the brake 1
solenoid.
For more information on the brake. (See TRACTION

LOCK on Page 60-120-1.)
Figure 40-11-1
N-19081A
The parking brake discs (Item 1) [Figure 40-11-2] are

located beneath the center chaincase cover.
Figure 40-11-3
P-76419
Disc Removal And Installation
WARNING 1
N-19105

Inspect the traction lock guides (Item 1) [Figure 40-11-3]
and the brake disc for damage or wear and replace as
necessary. (See Inspecting on Page 60-120-6.)
W-2059-0598

BRAKE (TWO-SPEED) (CONT’D) NOTE: When installing the two-speed brake discs,
make sure the discs isolators are facing each
Disc Removal And Installation (Cont’d) other towards the center of the loader. The
rivets fastening the isolator to the disc are
Figure 40-11-4 orientated so the disc can be slid between the
two sprockets without interfering with the
rivets.
Disc Disassembly And Assembly

2 1
Figure 40-11-6
P-73918
Figure 40-11-5 2

P-76405
1
Remove the four rivets (Item 1) from the isolator (Item 2)
[Figure 40-11-6] fastened to the disc.
Remove the isolator (Item 2) [Figure 40-11-6] from the

disc.
NOTE: Make sure rubber isolator is seated tight

against disc after rivets are installed.
P-73917
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-11-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-11-4] off the sprocket

(Item 1) [Figure 40-11-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

DRIVE COMPONENTS
Description

P-66933
The drive components consist of the chaincase, drive

chains, sprockets, axleshafts, hubs and a brake.
The chaincase is partially filled with hydraulic fluid to

lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for

access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT’D) Installation: Support the flange of the axle hub and
install the two studs with a hammer. A hydraulic press
Axle Seal Removal And Installation can also be used to install the studs.
2
2
2 1
P-4157 P-4159
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.

Axle Hub Puller Tool
1399 - Seal Driver Tool A driver tool (Item 2) [Figure 40-20-2] can be used for
1242 - Power Ram (may be used if desired) centering the threaded rod of the puller.
To loosen the axle hub mounting bolt (Item 1) [Figure 40-

20-1], use the following procedure:
Before lifting and blocking the loader, loosen the hub

WARNING
mounting bolt (Item 1) [Figure 40-20-1].
NEVER STAND IN-LINE OF THE HUB WHEN
NOTE: If the axle and bearings are being replaced, REMOVING A HUB FROM AN AXLE. The hub has a
also loosen the sprocket mounting bolt inside tapered fit on the axle end and can come off the axle
the chaincase before lifting and blocking the with great force and cause serious injury.
loader. (See Axle, Sprocket And Bearings W-2186-0395
Use a wrench with the puller and remove the axle hub
Lift and block the loader. (See Procedure on Page 10-10- from the axle tube. A spacer and a power ram can be
1.) used between the axle and the tool if available, instead of
the wrench, threaded rod and driver tool.
Remove the front tire / wheel assembly.
Remove the hub mounting bolt (Item 1) [Figure 40-20-1]

and washer from the axle.
Installation: Tighten the hub mounting bolt to 983 - 1085

Remove two of the wheel mounting studs (Item 2)

[Figure 40-20-1].
Use a wheel mounting nut on each stud and remove the

two studs with a hammer.

DRIVE COMPONENTS (CONT’D) Figure 40-20-5
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-3
P-4160
1
Installation: 1399 seal driver tool is necessary for the
P-4161 following procedure:
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair

Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
1 Reverse removal procedure to install the axle hub and

wheel assembly.
P-4181
Drill a small hole in the axle seal.
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end in the axle seal.
Remove the axle seal.

Axle, Sprocket And Bearings Removal And

Installation
The tools listed are needed for the following procedure:
1242 - Power Ram

1202B - Axle Bearing Service Set
NOTE: The procedure shown is for removing the
front axle, bearings and sprocket. This
procedure can also be used for the rear axle,
bearings and sprocket. (See Rear Cover
Removal And Installation on Page 40-30-3.) 1
Use jackstands to support the rear of the loader. (The
P-4147A
loader wheels should remain on the ground.)
Loosen the axle sprocket mounting bolt (Item 1) [Figure

WARNING 40-20-7].
Never work on a machine with the lift arms up unless Lift and block the loader. (See Procedure on Page 10-10-
the lift arms are secured by an approved lift arm 1.)

support device can allow the lift arms or attachment Remove the fluid from the chaincase. (See Removing
to fall and cause injury or death. And Replacing Oil on Page 10-130-1.)
W-2059-0598
Remove the axle hub. (See Axle Seal Removal And
support device. (See Installing on Page 10-20-1.) Remove the sprocket mounting bolt (Item 1) [Figure 40-
20-7].
Installation: Tighten the sprocket mounting bolt to 407 -
Remove the control panel. (See Removal And Installation 447 N•m (300 - 330 ft-lb) torque.
on Page 50-100-2.)
Figure 40-20-6
P-34255
Remove the eight front cover mounting bolts (Item 1) and

the front cover (Item 2) from the chaincase [Figure 40-
20-6]. (See Front Cover Removal And Installation on
Page 40-30-1.)

Axle Sprocket And Bearings Removal And

Installation (Cont’d)
Figure 40-20-8 1
P-4170
A bearing puller (Item 1) [Figure 40-20-10] is needed for

1 the following procedure:
P-4158A
Put the axle / outer bearing assembly in the bearing
puller as shown and put in the hydraulic press [Figure
Install the 1242 power ram (Item 1) [Figure 40-20-8] 40-20-10].

between the two sprockets.
Put a spacer between the power ram and axle. Push the
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure
until the axle is free from the sprocket and inner bearing.
Figure 40-20-9
2
1
P-4162A
Remove the drive chain from the sprocket (Item 1)

[Figure 40-20-9] and remove the sprocket from the
chaincase.
Remove the inner bearing (Item 2) [Figure 40-20-9] and

remove the axle from the axle tube. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-20-
4.)
Installation: Pack both axle bearings with grease before

installing them.


4
3
Figure 40-20-11
P-4169
Installation: A piece of round tubing (Item 1) [Figure 40-

20-12] is needed to install the bearing on the axle shaft.
P-4171 The tubing needs to measure approximately 12,7 mm
(0.500 in) to 25,4 mm (1.0 in) in length. The inside
diameter of the tubing should not be under 53,3 mm
Be sure the bearing puller makes good contact with the (2.100 in) and the outside diameter should not be over 60

inner race of the bearing and press the bearing off the mm (2.400 in),
mounting surface of the axle.
A bearing puller (Item 2) [Figure 40-20-12] is also
Be sure to hold onto the axle during removal as it will needed to install the bearing on the axle.
slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts Put the tubing (Item 1) on the bearing puller (Item 2)
the spline on the shaft. [Figure 40-20-12].
Press the splined end of the axle free from the bearing Put the bearing (Item 3) [Figure 40-20-12] on the tube as
[Figure 40-20-11]. shown.
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
Be sure to hold onto the axle during installation, as it will

slide freely along the axle shaft after the spline end has
passed through the bearing and until it reaches the
bearing mounting surface on the axle.


Figure 40-20-13
2
1
P-4179
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-15] on the slide hammer.
P-4175
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated After the bearing cup tool is inside the axle tube, pull the
[Figure 40-20-13]. tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-15] on the tool.
Figure 40-20-14
Figure 40-20-16
P-4172
P-4180
Use the tools provided in the 1202 Axle Bearing Service

Set for bearing cup removal and installation. A slide Use the slide hammer and remove the bearing cup from
hammer is also necessary for this procedure. the axle tube [Figure 40-20-16].
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-14].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].

DRIVE COMPONENTS (CONT’D) Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
Axle Sprocket And Bearings Removal And tool.
Secure the tool to the threaded rod with a nut [Figure 40-
Figure 40-20-17 20-18].
Hold the inside nut (Item 3) [Figure 40-20-17] with a

1 wrench and tighten the outside nut as shown in photo
2 [Figure 40-20-18].
Tighten the nut until the bearing cup is seated.
Figure 40-20-19
P-4174A
Figure 40-20-18

1
P-4173
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
Put the bearing cup tool on the short rod.

2
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [Figure 40-20-19].
P-4164
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.
Use the bearing cup installation tools (Item 1) [Figure
40-20-17] and (Item 1) [Figure 40-20-18] and the long
threaded rod (Item 2) [Figure 40-20-18] from the service
set to install the inner and outer bearing cups.
Put the inner bearing cup in the axle tube (Item 2)

[Figure 40-20-17].
Put the installation tool (Item 1) [Figure 40-20-17] in the

axle tube.
Install the long threaded rod (Item 2) [Figure 40-20-18]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-17].
Secure the tool to the threaded rod with a nut (Item 3)

[Figure 40-20-17].

Chain Removal And Installation 2
WARNING
1
W-2059-0598
P-54227
Remove the parking brake disc (Item 1) [Figure 40-20-
Lift and block the loader. (See Procedure on Page 10-10- 20]. (See Disc Removal And Installation on Page 40-10-
1.) 1.) or (See Disc Removal And Installation on Page 40-11-
1.)
Raise the loader operator cab. (See Raising on Page 10-
30-1.) Remove the six carrier mounting bolts (Item 2) [Figure

40-20-20] from inside the chaincase.
Drain the fluid from the chaincase. (See Removing And
Replacing Oil on Page 10-130-1.) Installation: Tighten the motor carrier mounting bolts to
170 - 190 N•m (125 - 140 ft-lb) torque.
Installation on Page 70-20-1.) Figure 40-20-21

on Page 50-100-2.)

Installation on Page 60-120-2.) 1
Remove the front (or rear) chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the front (or rear) axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on P-54226
Page 40-20-4.)
Tip the end of the sprocket on the motor carrier toward

the rear of the loader and remove the rear drive chain
from the sprocket.
NOTE: It may be necessary to tie the front drive chain

up as shown in photo [Figure 40-20-21], so the
carrier / motor assembly can be moved
enough to free the rear drive chain (Item 1)
[Figure 40-20-21] from the sprocket.
Remove the front drive chain from the chaincase.

DRIVE COMPONENTS (CONT’D)
Chain Removal And Installation (Cont’d)
Figure 40-20-22
B-13504A
The tool listed is needed for the following procedure:

1037 - Chain Link Tool
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use 1037 Chain Link Tool and #80 chain adapter.
Secure the tool and place the connector link in the tool as
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22]. Tighten the
threaded rod of the chain link tool to 176 N•m (130 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Description on Page 40-20-1.) 2
Raise the loader operator cab. (See Raising on Page 10-

30-1.) 3
3
P-34255
DANGER
Remove the front chaincase cover mounting screws
(Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are machined recesses (Item 3) [Figure
40-30-1] on the bottom side of the cover to
P-90328 help pry the covers off.
AVOID DEATH Installation: Apply polyurethane sealer to mating
• Disconnecting or loosening any hydraulic surfaces. Polyurethane sealant should be applied to the
tubeline, hose, fitting, component or a part failure screw threads to stop oil leakage. Tighten the mounting
can cause lift arms to drop. screws to 27 - 34 N•m (20 - 25 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-1.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH

Figure 40-30-3
unless supported by an approved lift arm 1
2
D-1009-0409
3 3
on Page 50-100-2.)
1
Figure 40-30-2 3 3
4 P-66980
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
1 Remove the center chaincase cover (Item 2) [Figure 40-

2 30-3] from the loader.
3
40-30-3] on the bottom side of the cover to
help pry the covers off.
P-66969
Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
If loader is equipped with SJC, skip to [Figure 40-30-3]. screw threads to stop oil leakage. Tighten the mounting
screws to 27 - 34 N•m (20 - 25 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
support device. (See Installing on Page 10-20-1.) 3 3
1
Raise the loader operator cab. (See Raising on Page 10- 2
30-1.)
DANGER 3 3
P-66959
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
Remove the rear chaincase cover (Item 2) [Figure 40-30-

P-90328 4].
AVOID DEATH

• Disconnecting or loosening any hydraulic 40-30-4] on the bottom side of the cover to
tubeline, hose, fitting, component or a part failure help pry the covers off.
• Keep out of this area when lift arms are raised Installation: Apply polyurethane sealer to mating
unless supported by an approved lift arm surfaces. Polyurethane sealant should be applied to the
support. Replace if damaged. screw threads to stop oil leakage. Tighten the mounting
D-1009-0409
screws to 27 - 34 N•m (20 - 25 ft-lb) torque.
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Removal And Installation on
Page 30-70-2.)
If loader is equipped with high flow, remove the high flow

valve. (See Removal And Installation on Page 20-150-4.)
Disconnect the front steering linkage bars from the rear

linkage bars. (See Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.


MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2

Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-5
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Foot Pedal Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-13
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-17
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-3
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-2

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Installation (Split Molding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Installation (Continuous Molding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

WINDOW (CAB DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1

Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1
Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-2
Removal And Installation (Special Applications Window) . . . . . . . . . . . . . . . . . . . . 50-133-4
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3


SEAT BAR Figure 50-10-3
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
1
The seat bar is located in the operator cab.
Figure 50-10-1
N-18572
1 1
Remove the seat bar mounting nuts (Item 1) [Figure 50-
10-3] (both sides).
Installation: Tighten the nuts to 33,9 - 38 N•m (25 - 28 ft-

lb) torque.

2.)
P-85239 Figure 50-10-4
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2 1
P-85238
1
Remove the seat bar (Item 1) [Figure 50-10-4] from the

operator cab.
P-85237
Reverse the above procedure to install the seat bar into
the operator cab.
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]
from the cab harness.
Lower the seat bar.

SEAT BAR (CONT'D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] and [Figure 50-10-6] to 33,9 - 38 N•m (25 - 28
Disassembly And Assembly ft-lb) torque.
5 5
4 6 4 6
7
3
2
7
3
8
9
10 1 2
P-85232 P-85231
Figure 50-10-6
Figure 50-10-8

4 5 9 8
3 6
4 5
3
6
10 2
7 2
1
7
P-85233
P-85234
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-5] and [Figure 50-10-
Assemble the parts as shown for the right side of the seat
6].
bar pivot assembly [Figure 50-10-7] and [Figure 50-10-
8].
Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Seat Bar Mount (Item 1)
Keyed Plastic Bushing (Item 3)
Mounting Nut (Item 2)
Seat Bar (Item 4)
Pivot Bushing (Item 3)
Magnetic Bushing Assembly (Item 5)
Spacer Bushing (Item 4)
Pivot Bushing (Item 6)
Seat Bar (Item 5)
Sensor Bracket (Item 7)
Keyed Plastic Bushing (Item 6)
Sensor Mounting Nut (Item 8)
Mounting Bolt (Item 7)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Installation: Tighten the mounting bolt (Item 7) [Figure
Installation: Tighten the mounting bolt (Item 9) [Figure 50-10-7] and [Figure 50-10-8] to 33,9 - 38 N•m (25 - 28
50-10-5] and [Figure 50-10-6] to 5,6 - 7,9 N•m (50 - 70 ft-lb) torque.
in-lb) torque.

SEAT BAR (CONT'D) Figure 50-10-10
Compression Spring Disassembly And Assembly 5 6
Figure 50-10-9
4 7
2
3
2
1 P-85236
Disassemble and assemble the seat bar compression

P-85235 spring and parts as shown in [Figure 50-10-10].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-9] and [Figure 50- Bushings (Items 2)
10-10] out of the clevis. Spring (Item 3)

Clevis (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Retaining Pin (Item 5)
threads. Adjust the compression spring by turning the Bushing (Item 6)
bolt in past the end of the clevis three turns. Cotter Pin (Item 7)
NOTE: For procedures requiring the use of Loctite®

#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.


OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-66826 P-66827
1
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-2] (both sides).
Installation: Tighten the nut to 54 - 68 N•m (40 - 50 ft-lb)

torque.

Figure 50-20-3
P-66825
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].
WARNING
P-66828
support device can allow the lift arms or attachment Raise the operator cab (See Raising on Page 10-30-1.)
to fall and cause injury or death. to release the tension on the gas cylinder.
W-2059-0598
Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Raise the lift arms.
Install an approved lift arm support device. (See Installing

on Page 10-20-1.)

Gas Cylinder Removal And Installation (Cont’d) SINGLE GAS CYLINDER
Figure 50-20-4
1
2
P-48262A
Figure 50-20-6
DUAL GAS CYLINDER

P-31966
Install a strap (Item 1) [Figure 50-20-4] from the operator

cab to the loader mainframe to prevent the cab from
tipping forward when the gas cylinder(s) are removed.
1 2
P-43354A
Loosen the front screw (Item 1) and remove the rear

screw (Item 2) [Figure 50-20-5] and [Figure 50-20-6]
from the gas cylinder mounting bracket.

Gas Cylinder Removal And Installation (Cont'd) SINGLE GAS CYLINDER

Figure 50-20-7
1
P-66830
Figure 50-20-9
N-19184 DUAL GAS CYLINDER
Rotate the mounting bracket forward to relieve any

remaining tension on the gas cylinder(s) [Figure 50-20- 1
7].
Remove the front screw (Item 1) [Figure 50-20-7] from

the gas cylinder mounting bracket.
2
Installation: Tighten the screws to 11,3 - 14,7 N•m (100
- 130 in-lb) torque.
P-66829
Remove the retaining pin(s) (Item 1) [Figure 50-20-8]

and [Figure 50-20-9] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-8]

and [Figure 50-20-9] from the operator cab.
Reverse the above procedure to install the gas cylinders

onto the operator cab.

OPERATOR CAB (CONT’D) Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Figure 50-20-10
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
2 cylinders. If the operator cab is tilted forward without
1 the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796
Remove the operator cab gas cylinder(s). (See Gas

Cylinder Removal And Installation on Page 50-20-1.)
Figure 50-20-12
P1008
Remove the clevis (Item 1) and washer (Item 2) [Figure

50-20-10] from the end of the gas cylinder.

Remove the gas cylinder from the outer housing.
Assembly: Install a replacement cylinder inside the

cylinder housing.
Figure 50-20-11
P-66828
P1006
Use the hoist connected to the operator cab grab handles

Apply a small amount of thread-locker on the threads of to lower or (raise) the operator cab when the gas
the cylinder rod [Figure 50-20-11]. cylinders are disconnected [Figure 50-20-12].
Reinstall the washer and clevis on the cylinder rod.

Figure 50-20-13
1
N-19231
Install lift eye (Item 1) [Figure 50-20-15] (both sides) to

P-66831 the cab.
Figure 50-20-16
Remove screw (Item 1) [Figure 50-20-13] from the cab
ground.

1
torque.
Remove any tie-straps connected to the harness [Figure

50-20-13].
Figure 50-20-14
P-31966
1
Remove the strap (Item 1) [Figure 50-20-16] preventing
P-66829
the cab from tipping forward.
Lower the cab.

Remove the bolt (Item 1) [Figure 50-20-14] from the cab
ground. Start the engine.
Remove the lift arm support device. (See Removing on

Page 10-20-2.)
Stop the engine.

Figure 50-20-17
2
1 1
N-19202
P-66832
Remove the rear mounting bolt (Item 1) [Figure 50-20-

18] (both sides) and nut from the operator cab.
Installation: Tighten the bolt and nut to 34 - 47 N•m (25 -

35 ft-lb) torque.

Figure 50-20-19
P-31967
Connect the slings (Items 1 and 2) [Figure 50-20-17] to a

chain hoist. P-66831
Lift the operator cab up and forward.
Disconnect the cab harness connector (Item 1) [Figure

50-20-19].
Installation: Tighten connector screw to 3,39 - 3,96 N•m

Remove the operator cab from the loader.
Reverse the above procedure to install the operator cab.

OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1 1
1 2
N-20729
N-20729
Raise the operator cab. (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Item
1 and 2) [Figure 50-30-3] and peel back or cut insulation

Remove the four seat mounting nuts (Item 1) [Figure 50- to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 27 N•m (20 ft-

lb) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Item 1 and 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 73

N•m (54 ft-lb) torque. Tighten nut (Item 2) [Figure 50-30-
P10564 P10563 4] to 46 N•m (34 ft-lb) torque.
Repeat for other half of seat belt and guide

Lower the cab and install one of the mounting washers
and a nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.


OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
1 2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seat belt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising on Page 10-30-1.) Figure 50-31-4

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 27 N•m (20 ft-

lb) torque.
Figure 50-31-2
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P10564 P10563
Lower the cab and install one of the mounting washers

and a nut [Figure 50-31-2].
NOTE: With the seat removed, the cab will raise.

seat.

OPERATOR SEAT (SUSPENSION) (CONT’D) Seat Belt Removal And Installation
Slide Rail Removal And Installation Figure 50-31-6
Figure 50-31-5
1 1
2 1
2
1
1
N-20974
N-18587
Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Remove the seat belt.

Remove the operator seat. (See Removal And
Installation on Page 50-31-1.) Installation: Tighten the mounting nuts to 78,6 - 84 N•m
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.

seat slide rail.

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-9
Lower Cushion Removal And Installation
Figure 50-31-7
1
N-18581
Remove the cushion (Item 2) [Figure 50-31-8] from the

N-18579 seat frame (Item 1) [Figure 50-31-9].
Figure 50-31-10
Press the two buttons (Item 1) [Figure 50-31-7] and
[Figure 50-31-8] and lift the seat cushion.

Figure 50-31-8
1 1
N-18580
Inspect the seat ride adjustment [Figure 50-31-10].

N-18582
seat back.

OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
Back Cushion Removal And Installation Figure 50-31-13
Figure 50-31-11
2
1
P-43118
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50- Remove the operator seat. (See Removal And
31-11] and tilt the seat back all the way forward. Installation on Page 50-31-1.)

Figure 50-31-12 Remove the seat shock mounting bolts (Item 1) [Figure
50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-13].

seat shock.
1 1
N-18578

31-12] from the seat back and remove the back.

seat back.

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-16
3-Point Seat Belt Removal And Installation
Remove the operator seat. (See Removal And

Figure 50-31-14 1
2
OUTSIDE OF CAB
P16131
Remove the mounting bolt (Item 1) [Figure 50-31-16]
1 Figure 50-31-17

P16285 1 2
Remove the mounting nut (Item 1) [Figure 50-31-14]

P16126
Remove the end release buckle (Item 2) [Figure 50-31-
14]
Installation: Be sure tether strap (Item 3) [Figure 50-31-

14] is on the seat belt stud behind the end release
buckle.
Figure 50-31-15 INSIDE OF CAB

P16128
Remove the shoulder harness retractor (Item 1) [Figure

50-31-17]
Installation: Line up the bolt (Item 1) [Figure 50-31-16]

2
with the mounting bracket (Item 2) [Figure 50-31-17] on
the inside of the cab.
1
P16284

Remove the seat belt retractor (Item 2) [Figure 50-31-15]
Installation: Be sure tether strap (Item 3) [Figure 50-31-
15] is on the seat belt stud behind the seat belt retractor.


BOB-TACH (HAND LEVER) Figure 50-40-2
Description
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach uses two
manually operated, spring assisted, locking wedge and
lever assemblies to secure the attachment the Bob-Tach. 1
2
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.
Figure 50-40-1
N-18545
Remove the pivot pin (Item 1) [Figure 50-40-2] from the

tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
1

Loosen the bolt (Item 2) [Figure 50-40-2] at the Bob-
Tach pivot pin.
Installation: Tighten the bolt to 240 - 260 N•m (175 - 190

ft-lb) torque.
N-18544
Figure 50-40-3
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

nut from the tilt cylinder rod end pin (both sides). 1
Installation: Tighten the retainer bolt and nut to 34 - 38

P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-40-3] out of the Bob-Tach frame. This allows
grease to escape when driving the pivot pins into the
Bob-Tach frame.

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

N-18547 [Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-40-4] to Figure 50-40-7
push the pivot pin into the Bob-Tach frame.

Remove the bolt.
Use a long punch to push the pivot pin all the way into the
1
Bob-Tach.
Remove the Bob-Tach from the lift arms.
Remove the Bob-Tach pivot pin (both sides).
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
N-18560
Remove the Wedge (Item 1) [Figure 50-40-7].
Always replace bent or broken wedges.
N-18558
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-10

(Cont’d)
Figure 50-40-8
3 N-18563
2 Use a punch and hammer to drive the roll pin (Item 1)

1 [Figure 50-40-10] flush with the face of the Bob-Tach.
N-18561
Reverse the removal procedure to install the Bob-Tach
lever and wedge [Figure 50-40-10].
Remove the lever mounting nut (Item 1), washer (Item 2),

spring (Item 3) and lever (Item 4) [Figure 50-40-8].

torque.
Figure 50-40-9
4 2
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.
Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-40-9] torque to 88,0 - 95,0 N•m
(65 - 70 ft-lb).

BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-11
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Use a seal pick to remove seal (Item 1) [Figure 50-40-
11] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-11]

with a driver tool and hammer.
Figure 50-40-12
3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-40-12].

BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
2 3
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
lever assemblies by pressing a switch on the front
accessory panel. The switch activates the Power Bob-
Tach block to allow flow into or out of the hydraulic
cylinder connected to the levers on the Bob-Tach. 1
The Power Bob-Tach block is located on the rear of the

P-48131
gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-41-1].

Lower the Bob-Tach onto the blocks.
Remove the hoses to the cylinder fittings [Figure 50-41-

1].
NOTE: The hose with the 45 degree end (Item 1)

[Figure 50-41-1] is connected to the base end
fitting on the cylinder.
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.

nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 34 - 38


BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
N-18547
2
Strike the head of the bolt (Item 1) [Figure 50-41-4] to

P-48185 push the pivot pin into the Bob-Tach frame.
Remove the bolt.

Remove the pivot pin (Item 1) [Figure 50-41-2] from the
tilt cylinder rod end (both sides). Use a long punch to push the pivot pins all the way into

the Bob-Tach frame.
Remove the tilt cylinder rod end from the Bob-Tach (both
sides). Remove the Bob-Tach from the lift arms.
Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob- Remove the Bob-Tach pivot pin (both sides).
Tach pivot pin.
Installation: Tighten the bolt to 240 - 260 N•m (175 - 190

ft-lb) torque.
Figure 50-41-3
P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-41-3] out of the Bob-Tach frame. This allows
the grease to escape when driving the pivot pins in to the
Bob-Tach frame.

BOB-TACH (POWER) (CONT’D) Figure 50-41-7
Figure 50-41-5
N-18560
1
Remove the Wedge (Item 1) [Figure 50-41-7].

P-48135
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-41-8
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and

wedge.
Figure 50-41-6
1
2
1
3
5
4
P-48135
Remove the washers and bolts (Item 1) [Figure 50-41-8].

N-18559
lb) torque.
Use a punch and hammer, remove the roll pin (Item 1)
[Figure 50-41-6] from the Bob-Tach Wedge and spring Remove the cylinder off the lever pivots. Position the rod
clevis. end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].

torque.

BOB-TACH (POWER) (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-11

(Cont’d)
Figure 50-41-9
2 1
4
N-18557
3 2
N-20625 Remove the Power Bob-Tach. (See Removal And

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), Use a seal pick to remove seal (Item 1) [Figure 50-41-

or clevis (Item 4) [Figure 50-41-9] are damaged, put the 11] on the Bob-Tach.
assembly in a vise.
Remove and replace bushing (Item 2) [Figure 50-41-11]
Remove the bolt and replace the damaged parts as with a driver tool and hammer.
needed.
Figure 50-41-12
Figure 50-41-10
3
2
1
NA5472
N-18563
Installation: The seal (Item 1) needs to be seated in the

Use a punch and hammer to drive the roll pin (Item 1) Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
[Figure 50-41-10] flush with the face of the Bob-Tach. 3) [Figure 50-41-12].
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge [Figure 50-41-10].
Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-41-9] torque to 88,0 - 95,0 N•m
(65 - 70 ft-lb).

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation
Figure 50-50-1 1
P-31969A

N-18851 the stabilizer link pivot pin.
Figure 50-50-4
Lower the lift arms.

Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-1]. 2
NOTE: The Bob-Tach and front wheel are removed in

photo [Figure 50-50-1] for clarity purpose 1
only. The Bob-Tach and front wheel do not
need to be removed to remove the stabilizer 3
link.
Figure 50-50-2
P-31968A
Use a slide hammer (Item 1), remove the stabilizer link

pivot pin (Item 2) [Figure 50-50-4].
1
Remove the stabilizer link (Item 3) [Figure 50-50-4] from
the lift arm.
2 Reverse the above procedure to install the stabilizer link.
N-18813

the stabilizer link pivot pin.
Remove the stabilizer link pivot pin (Item 2) [Figure 50-

50-2].

LIFT ARMS (CONT’D) Figure 50-50-6
Link Removal And Installation
Figure 50-50-5
1
2
P-31974
Connect a chain and chain hoist on the lift arm link

N-18806 [Figure 50-50-6].

Lower the lift arms. Stop the engine. nut from the lift arm link pivot pin.

Remove the retainer bolt (Item 1) [Figure 50-50-5] and Figure 50-50-7
nut from the lift arm pivot pin.
WARNING
Wear safety glasses to prevent eye injury when any 1
P-31975
W-2019-0907
Open the rear door.
Raise the radiator cover part way to gain access to the

pivot pin.
Lower the rear grille. Close the rear door.
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
Reverse the removal procedure to install the lift arm link

on the loader.

Figure 50-50-8
N-18850
Mark the tubelines for correct installation (both sides).

P-31849 Pull the tubelines down, disconnect the hoses (Item 1)
[Figure 50-50-10] (both sides).
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.

Remove the Bob-Tach frame from the lift arms. (See Figure 50-50-11
Install jackstands under the rear of the loader [Figure 50-

50-8].
Figure 50-50-9
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-11].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Remove the tubeline clamps (Item 1) [Figure 50-50-9]

under the lift arms (both sides).

Figure 50-50-12
1
P-34136
Remove the tilt cylinder mounting bolt base end (Item 1)

N-18792 [Figure 50-50-14].

Remove the three front step mounting bolts (Item 1)
[Figure 50-50-12]. Remove the tilt cylinders and tilt tubelines from the

loader.
Figure 50-50-13
Figure 50-50-15
N-18793
N-18851
Remove the tilt port block mounting bolt (Item 1) [Figure

50-50-13] under the step. Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-15].

Figure 50-50-16
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
N-18806 pin (Item 1) [Figure 50-50-18] (both sides).
Strap the lift cylinders to rear of the uprights.

nut from the lift arm pin (both sides).

Use a drift pin and hammer remove the lift arm pivot pin
Figure 50-50-17
P-31972

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

Figure 50-50-19
1
1

3 P-31970A
Connect a nylon lift strap, chain and chain hoist to the lift
P-31971A arms (Item 1) [Figure 50-50-19] and [Figure 50-50-20].

the stabilizer pivot pin.
Use a slide hammer, remove the stabilizer pivot pin (Item

3) [Figure 50-50-19] (both sides).
Remove the chain from the front axle.
Remove the lift arms from the loader.
Reverse the removal procedure to install the lift arm.

REAR GRILLE Figure 50-60-3
Figure 50-60-1
2
P-48130
Installation: Line up the tab (Item 1) on the grille with the

P-48251 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grille.

Figure 50-60-2
P-48252
Lift up on the rear grille (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grille away from the loader.


REAR DOOR (TAILGATE) Figure 50-70-3

1
Figure 50-70-1
2
3
2
P-34606
1
Remove the top and bottom door hinge mounting bolts
P-68264 (Item 1) [Figure 50-70-3] and nuts.
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) in the top hinge as shown
50-70-1] from the engine harness. [Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the mounting bolts and nuts to 34 -
the door. (See Rear Removal And Installation on Page 38 N•m (25 - 28 ft-lb) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2 flat on the floor.
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker Disassembly And Assembly
Striker Removal And Installation Earlier Models
Earlier Models Figure 50-70-6
Figure 50-70-4
2 2
3
4
1
1
P-31320
P-31126
Remove the lock nut (Item 1) [Figure 50-70-6].

Later Models Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-6].
Figure 50-70-5
Check the parts for wear and replace as needed.

1 28 ft-lb) torque.
Later Models
Figure 50-70-7
2
3
P-76970A
4
Remove the two striker mount bolts (Item 1) [Figure 50- 1
70-4] and [Figure 50-70-5].
Remove the striker assembly from the loader.

P-31320A
Remove the lock nut (Item 1) [Figure 50-70-7].
Remove the roller (Item 2) and the spacer (Item 3) from

the bolt (Item 4) [Figure 50-70-7].
Check the parts for wear and replace as needed.

28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
Striker (Adjusting) the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
WARNING
Open the door.
Installation: Tighten the mounting bolts (Item 1) [Figure
Never service or adjust the machine when the engine
50-70-8] and [Figure 50-70-9] to 125 - 135 N•m (90 -
is running unless instructed to do so in the manual.
W-2012-0497
100 ft-lb) torque.

Earlier Models
Tighten both striker mount bolts (Item 1) [Figure 50-70-
Figure 50-70-8 8] to 125 - 135 N•m (90 - 100 ft-lb) torque.

1
P-31126
Later Models
Figure 50-70-9
P-76970A
Loosen the striker assembly mount bolts (Item 1) [Figure

50-70-8] and [Figure 50-70-9].
Align the striker assembly in the center of the mounting

holes.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-12
Latch Removal And Installation
Figure 50-70-10
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-12]

P-31125 from the rear door.
Disconnect the spring (Item 1) [Figure 50-70-10] from

the rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-10] from
the latch.
Figure 50-70-11
1
P-31127
Remove the spring (Item 1) [Figure 50-70-11] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-11] from

the door handle.

FUEL TANK Figure 50-80-3

2
Figure 50-80-1
P-28143

P1616
Remove the cover (Item 1) [Figure 50-80-1] which is Page 70-10-8.)
installed over the fuel drain near the rear of the

chaincase. Remove the two mounting bolts (Item 1) [Figure 50-80-3]
from the battery holder.
Installation: Tighten the cover mounting bolts to 21,5 -
27 N•m (190 - 240 in-lb) torque. Installation: Tighten the battery holder mounting bolts to
21,5 - 27 N•m (190 - 240 in-lb) torque.
Figure 50-80-2
Remove the battery holder (Item 2) [Figure 50-80-3]
from the loader.
Figure 50-80-4
1 1
P1619
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
P-28144
Remove the mounting bolts (Item 1) [Figure 50-80-4]

from the fuel tank retainer bracket.
Installation: Tighten the mounting bolts to 21,5 - 27 N•m


FUEL TANK (CONT’D) Fuel Level Sender Removal And Installation
Figure 50-80-5
P13870
P13876
Loosen the fuel level sender (Item 1) [Figure 50-80-6]
with a wrench.
Disconnect fuel sender.
Turn the fuel level sender out and remove it from the fuel

Disconnect fuel vent hose. tank. Check the fuel level sender for damage and replace
if necessary.
Disconnect fuel fill hose.
Installation: tighten the fuel level sender to 5,7 - 6,8 N•m
Lift the fuel tank up and remove the tank from the loader (50 - 60 in-lb) torque.
[Figure 50-80-5].

FUEL TANK (CONT’D)
Fuel Fill Screen Removal And Installation
Figure 50-80-7
2
1
P13874
Remove the clamp (Item 1) [Figure 50-80-7] and remove

the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.

Figure 50-80-8
P13875
Remove the fuel fill screen (Item 1) [Figure 50-80-8]

from the tank. Check the screen for damage and replace
if necessary.
Remove the fuel supply screen (Item 1) [Figure 50-80-8]

from the hose. Check the screen for damage and replace
if necessary.


CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
WARNING P-26008
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Check the rubber bushing in the pedal for wear and
to fall and cause injury or death. replace as needed.
W-2059-0598

Figure 50-90-2
support device. (See Removing on Page 10-20-2.)
Raise the operator cab. (See Raising on Page 10-30-1.) 1
DANGER
P-34375
P-90328 Remove the two mounting bolts (Item 1) [Figure 50-90-2]

from the pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
2
1
P-34376
Remove the crossbar from the pivot [Figure 50-90-5].

P-66969A
Installation: Check the nylon bushing (Item 1) [Figure
50-90-5] for wear and replace as needed.
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.

Remove the crossbar pivot bolt (Item 2) [Figure 50-90-
3].
Figure 50-90-4
P-34260
Remove the hairpin clip and cross-pin (Item 1) [Figure

50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

Linkage Removal And Installation (Cont’d)
Figure 50-90-6
P-34258
Remove the hairpin clip and cross-pin (Item 1) [Figure

P-66969 50-90-8] from the control valve tilt spool.
Figure 50-90-9
disconnect the lift foot pedal linkage from the crossbar

linkage.
Figure 50-90-7
1
P-26008

disconnect the lift foot pedal.
P-24759

disconnect the lift foot pedal.

Pedal (Adjusting)
After installing the pedal, adjust the pedal angle so that 2

there is clearance under the rear of the pedal. The valve 1
spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-90-10
P-26008
1
Loosen the bolt (Item 2) [Figure 50-90-11] and nut on
the pedal linkage.
Check the rubber bushing in the pedal for wear and

replace as needed.

Tilt the pedal back and forth until an acceptable “neutral”
angle is achieved on the pedal.
Tighten the two mounting bolts (Item 1) and pivot bolt

P-34375 (Item 2) [Figure 50-90-11] on the pedal assembly to
standard torque.
Loosen the two mounting bolts (Item 1) [Figure 50-90-

10] from the pedal mounting bracket.

CONTROL PEDALS (ACS) Figure 50-91-3
Description
The control pedals send an electronic pulse to the

actuators on the control valve. The electronic pulse tells
the actuators to move the lift or tilt spools on the control
valve.
1
The control pedals are located on the lower mainframe at
the operators feet.
Foot Sensor Removal And Installation
Figure 50-91-1
P-21927
2 Remove the two bolts (Item 1) [Figure 50-91-3] from the

foot sensor shield.
P-21936
Installation: Tighten the bolts to 9,0 - 10,2 N•m (80 - 90
in-lb) torque.

1
P-21938
Pull the pin (Item 1) [Figure 50-91-1] holding the foot

pedal linkage to the sensor.
Disconnect the two connectors (Item 2) [Figure 50-91-1]

from the sensor and lock solenoid.
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Remove the foot pedal and sensor assembly from the
loader.

CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-5
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6

Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly.
P-21935A

lb) torque.
Remove the sensor assembly.
P-21934
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.

CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Linkage Disassembly And Assembly
Figure 50-91-7
P-21931
Remove the bolt (Item 1) holding the linkage (Item 2) to

the side of the foot pedal [Figure 50-91-7].

Figure 50-91-8
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].


CONTROL PANEL
Description
Figure 50-100-1

P-54658
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. The returning force of the torsion bushings.
bellcranks have grease fittings.
NOTE: Torsion bushings need to be replaced if torn
The forward travel is adjusted by drift adjustment bolts. or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
The bellcranks are attached to steering linkage bars with made. Do not fully tighten torsion bushing
rubber torsion bushings pressed into the bellcranks. bolts again until all steering adjustments have
Bellcranks mount to the control panel. been made first.
Steering linkage bars are a two-piece design. Steering Sequence of steering adjustments:
linkage bars are adjustable in length for “full travel
adjustment”. 1. Set neutral of pintle arms, “creep”
2. Set full travel at steering linkage bars
Steering linkage bars attach to the pintle arms where a 3. Set drift at drift adjustment bolts
rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-100-2
2 1
DANGER 3
P-48462
P-90328
AVOID DEATH Raise the lift arms and install an approved lift arm
• Disconnecting or loosening any hydraulic support device. (See Installing on Page 10-20-1.)
can cause lift arms to drop. Raise the operator cab. (See Raising on Page 10-30-1.)
unless supported by an approved lift arm Remove the engine speed control. (See Removal And

D-1009-0409
Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-100-2].
WARNING Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
Figure 50-100-3
W-2059-0598
WARNING
fall or move and cause injury or death. P-48277
W-2017-0286
Disconnect the control harness connectors (Item 4)

control levers.

CONTROL PANEL (CONT'D) Remove the fuse / relay shield mounting screws (Item 3)
[Figure 50-100-5].
Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
Figure 50-100-4 torque.
Remove the fuse / relay shield (Item 4) [Figure 50-100-5]
Figure 50-100-6
2 2
1 1
P-54609

P-26325

Remove the four steering linkage mounting bolts (Item 2) Remove the fuse / relay block [Figure 50-100-6].
[Figure 50-100-4].

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
1 1
P-26323
Remove the fuse cover mount screws (Item 1) [Figure

50-100-5].

torque.
Remove the fuse / relay cover (Item 2) [Figure 50-100-5].


1
Figure 50-100-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)

P-26326 [Figure 50-100-7], [Figure 50-100-8] and [Figure 50-
100-9] from both sides of the control panel.
Figure 50-100-8 Installation: Tighten the control panel mounting bolts to

20 - 27 N•m (15 - 20 ft-lb) torque.

Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
1
1
P-26327

CONTROL PANEL (CONT’D) Shaft Removal And Installation
Shock Removal And Installation NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Figure 50-100-10 Photo [Figure 50-100-11] shows the control
panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-100-10].
1
Remove the steering shock mounting nuts (Item 2)
3 [Figure 50-100-10].
Figure 50-100-11
P-48275

from the end of the shock connected to the steering

linkage. 3

from the other end of the shock connected to the bracket 1 2
on the control panel.
P-48278

(25 - 28 ft-lb) torque. Remove Control Handle Lever (Item 1) [Figure 50-100-
11]. (See Lever Removal And Installation on Page 50-
110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

100-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 34 - 38 N•m (25 -

28 ft-lb) torque.
Remove the steering shaft from the control panel.

CONTROL PANEL (CONT’D) Figure 50-100-13
Shaft Disassembly And Assembly

1
Figure 50-100-12
2
2
1 1
P-26331
2
To remove the steering shaft mounting bracket (Item 3)

P-4154 [Figure 50-100-11], remove the three mounting bolts
(Item 1) [Figure 50-100-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks
(Item 1) from the cross shaft assembly [Figure 50-100- Remove the steering shaft mounting bracket.

12].
Assembly: Install new nylon bushings (Item 2) [Figure (15 - 20 ft-lb) torque.
50-100-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left bellcranks.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.

Linkage Removal And Installation
WARNING 2 2
support device can allow the lift arms or attachment 1 1
W-2059-0598
P-54609
WARNING Scribe a mark across the top of the steering linkage bars
[Figure 50-100-14].

W-2017-0286
bars. Tighten the steering linkage mounting bolts to 47,5
Raise the lift arms and install an approved lift arm - 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,
Lift and block the loader. (See Procedure on Page 10-10- the linkage neutral adjustment procedure
1.) must be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-13.)


7
Figure 50-100-15 6 8
3 1 4
1
2
5
2
P-48630
The centering plate / centering spring assembly consists

2 of the following parts:
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-15]. 1 Bolt

2 Bushings
Remove the bolt / spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a 4 Bushing Spacer
NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque. 5 Spring
Figure 50-100-16 6 Lock Nut

7 Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-100-16] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.

Linkage Removal And Installation (Cont’d) SOLID CAMS
Figure 50-100-18
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
If the surface of any of the four solid pintle cams (Item 1)

P-48629 are worn, loosen the bolt (Item 2) and rotate the cams 1/4
turn [Figure 50-100-19].
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-18]. 19] from the pintle.

If the centering blocks need replacement, remove the Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
bolts (Item 2) [Figure 50-100-18]. Remove the centering ft-lb) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 47,5 - 100-19].
54,2 N•m (35 - 40 ft-lb) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-19].
centering plate.
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled.

Figure 50-100-20
ROLLER CAMS 2
2
1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
P-54617 2) [Figure 50-100-22].
Remove the bolts and washers (Item 1) [Figure 50-100-

20] from the pintle.

ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-20].
Figure 50-100-21
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-100-21].
NOTE: The washers (Item 2) [Figure 50-100-21] are

hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (CONT’D) Pintle Arm Disassembly And Assembly
Linkage Removal And Installation (Cont’d) Figure 50-100-24
Figure 50-100-23 2
1
3
1
P-54625
P-48659
Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-24] and inspect the pintle solid cams
NOTE: When installing the pintle base (Item 1) onto for damage or excessive wear.
the pump shaft, the cutouts on the pump shaft

will not line up with the bolt (Item 3) [Figure Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
50-100-23]. ft-lb) torque.
Installation: Install the pintle base (Item 1) onto the Figure 50-100-25
pump shaft (Item 2) [Figure 50-100-23]. The top of the
pintle base should be level with the top of the pump shaft. 2
Tighten the bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque. 3
NOTE: After installing the linkage onto the
hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
(See Linkage Neutral (Adjusting) on Page 50-
100-13.) 2
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-100-

25] are used on ACS loaders only.
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-25].
Inspect the torsion bushing (Item 3) [Figure 50-100-25]

for damage and replace as needed.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.

Pintle Arm Disassembly And Assembly (Cont’d)
Figure 50-100-26
4 1 3
2 2
3 P-48619
Using a bushing driver (Item 1) remove the torsion

P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-27].
Remove the base pintle (Item 1) [Figure 50-100-26] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure

50-100-27] into the pintle arm using the same procedure
Remove the retaining bolt (Item 2), adjusting screw (Item as the removal.
3) and neoprene dampener (Item 4) [Figure 50-100-26]
from the base pintle. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Inspect parts for wear and damage, replace as needed arm should be the same.
[Figure 50-100-26].
NOTE: Anti-seize should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following 1

procedure:
MEL1563 or 6689779 - Remote Start Tool Kit
Connect the remote start tool to the engine harness.

(See REMOTE START TOOL KIT-1563 on Page 10-60-
1.)

1.)
P-48448
Figure 50-100-28
Loosen the bolt / nut (Item 1) [Figure 50-100-29] only

3
until the tension is released from the torsion bushing.
Figure 50-100-30

1
P-48450
2
Tool that may assist in the neutral adjustment [Figure 50-

100-28].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-28] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-30].
A steering centering block (Item 3) [Figure 50-100-28] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-100-30] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-31
2
P16121
2 Using the remote start tool, turn the key (Item 1) [Figure
P-54614 50-100-33] to the run position.
Move the traction lock override switch (Item 2) [Figure

Loosen the two bolts (Item 1) holding the right centering 50-100-33] so the traction function is unlocked. (The
block. Move the right hand centering block (Item 2) traction lock override switch light will be ON.) On a

[Figure 50-100-31] until both pintle cams contact the standard loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels /
NOTE: The left centering block is not adjustable. By tracks may begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
3 release the hydraulic brake.
Using the remote start tool, turn the key (Item 1) [Figure
50-100-33] and start the engine and run at low idle.
1
Tighten bolts (Item 3) [Figure 50-100-32] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
2
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-31] and [Figure
50-100-32].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-28] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
32] around both centering blocks.
Lock the C-Clamp in place.

Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-34
2 1
1
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
P-48632 NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
Loosen the left pump pintle adjustment lock bolts neutral adjustment.
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-34].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-100-35]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
NOTE: If the bolts are too loose or too tight, the counterclockwise to a point between forward and reverse
neutral adjustment may be affected. where there is zero creep.
Stroke the left steering lever to forward and allow the

lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.

CONTROL PANEL (CONT’D)
Figure 50-100-36
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-36] to 47,5 - 54,2 N•m (35 - 40 ft-lb).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-36] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-36] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre applied
Loctite®.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-17.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjustment procedure 2

is being done as part of the loader neutral
adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448
support device. Failure to use an approved lift arm Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
support device can allow the lift arms or attachment (Item 2). The bolt (Item 2) [Figure 50-100-37] must be
to fall and cause injury or death. loosened enough to allow the torsion bushing to turn
W-2059-0598
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm Figure 50-100-38

1
WARNING
Put jackstands under the front axles and rear corners 2
W-2017-0286

1.) P-54613

Loosen the nut (Item 1) only until the tension is released
Pre-load tension in the torsion bushings must be from the torsion bushing (Item 2) [Figure 50-100-38].
removed before adjusting the steering linkage.
The bolt must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)

2
Figure 50-100-39
1 3 4
P-51174
Move the right side steering lever forward and install a 24

P-37574 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-41].
Remove access plug from the top of the control panel.
This will allow the pintle arms to move freely while

Turn the control lever drift adjustment bolts (Item 1) adjusting the steering linkage for full forward travel
[Figure 50-100-39] (one on each control lever) out until it speed.
is flush with the bottom of the nut.
Remove the 10 mm (3/8 in) thick spacer (Item 4) [Figure
Figure 50-100-40 50-100-41].
Figure 50-100-42
3 2
4
1
P-51173
1
P-51133
Move the right side steering lever to the rear and install a
10 mm (3/8 in) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) Before adjusting the linkage, check that the base pintle
[Figure 50-100-40]. arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] and tighten to 48
- 54 N•m (35 - 40 ft-lb) torque. There should be no play
between the pintle arm and the square pump shaft.
Also check that the cam mounting nuts or bolts (Item 4)

[Figure 50-100-40] are tight, 48 - 54 N•m (35 - 40 ft-lb)
torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-43
1 1 1
P-51175
Remove the spacer (Item 1) [Figure 50-100-45].

P-54609
Disconnect the remote start tool. (See REMOTE START
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
43] on each steering linkage bar.
Figure 50-100-46

Figure 50-100-44
2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-46].
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-100-
44]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-47 1
1
P-37574
Push the control lever to full stroke and turn drift

P-48448 adjustment bolt (Item 1) [Figure 50-100-48] in until it
touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Items 1 and 2) [Figure Repeat steps on the other control lever.
50-100-47] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the

steering bell cranks. Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,048 m

(10 ft) of “drift” in 30,48 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-48] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The SJC control panel has two electronic handles that
control the steering, lift, and tilt functions. There is no Remove the engine speed control. (See Removal And
mechanical linkages connecting to the hydrostatic pumps Installation on Page 70-20-1.)
or the control valve.
Figure 50-101-1
The control panel is connected to the lower mainframe
and wraps around and underneath the operator seat.
WARNING 1

W-2017-0286
P-73451

Remove the lift arm bypass control knob and rubber
DANGER washer (Item 1) [Figure 50-101-1].
Figure 50-101-2
2
1
1
P-90328
AVOID DEATH 4
can cause lift arms to drop. 3 3
unless supported by an approved lift arm P-64319
D-1009-0409 Remove the fuse cover mount screws (Item 1) [Figure
50-101-2].
torque.
WARNING Remove the fuse / relay cover (Item 2) [Figure 50-101-2].

Remove the fuse / relay shield mounting screws (Item 3)
Never work on a machine with the lift arms up unless [Figure 50-101-2].
the lift arms are secured by an approved lift arm Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
support device. Failure to use an approved lift arm torque.
to fall and cause injury or death. Remove the fuse / relay shield (Item 4) [Figure 50-101-2]
W-2059-0598

CONTROL PANEL (SJC) (CONT’D)
Figure 50-101-3
1 1
P-64309
Remove the control panel mount screws (Item 1) [Figure

50-101-3] from the both sides of the control panel.

Installation: Tighten the control panel mounting screws
to 20 - 27 N•m (15 - 20 ft-lb) torque.
Figure 50-101-4
P-73293
Disconnect the right and left joystick wire harness

connectors (Item 1) [Figure 50-101-4].
Remove the control panel from the loader.

CONTROL HANDLE / LEVER Lever Removal And Installation
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel.
1
P-48462
Disconnect the electrical connectors from the control

lever [Figure 50-110-1].
Figure 50-110-2

1 1
2
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure

50-110-2] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-2] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-3] on the front of the control panel.
Installation: Tighten the U-bolts so the lever can not be

moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Figure 50-110-3
N-18884
To replace the rubber boot (Item 1) [Figure 50-110-3] on

the control panel, remove the control lever (See above

procedure).
Drill out the four rivets (Item 2) [Figure 50-110-3] located

on the flange of the rubber boot and remove the old boot.
Install the new boot and reinstall the control lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation

forward and reverse travel and the lift and tilt
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are
located in the base of the control handle / levers.

panel.
1
Figure 50-111-1
P-21864
1 Loosen the nuts (Item 1) [Figure 50-111-2].
Installation: Tighten the u-bolts so the lever can not be


seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-111-3
P-21879
Handle Sensor (Item 1) [Figure 50-111-1]. 2
P-21837
Tilt the control handle (Item 1) [Figure 50-111-3] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-3].

CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-111-6
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-4
1
P-21860
2
Remove the handle lock solenoid connector (Item1)
P-21836 [Figure 50-111-6] from the clip.
NOTE: Pry out with a small screw driver and push the
Disconnect the harness connector (Item 1) [Figure 50- connector down.
111-4] from the handle sensor connector.

Figure 50-111-7
Disconnect the harness connector (Item 2) [Figure 50-
111-4] from the handle lock solenoid connector. 1
Figure 50-111-5
5
2
1 4
1
P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-7] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-5] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screw driver and push the handle sensor, remove the one plastic spacer (Item 3),
connector down. the spring (Item 4) and washer (Item 5) [Figure 50-111-
7].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-8 2
P-21878
1
Figure 50-111-11
P-21880
3
2
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor.

Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-9
4 1
3 8
P-21799
1
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-10] and [Figure
3 7 50-111-11] to assure proper return of the control handle
to neutral and minimize harness movement.
5 6
NOTE: Route wires (Item 2) [Figure 50-111-10] and
2
P-21882 [Figure 50-111-11] as shown away from stop
strap (Item 3) [Figure 50-111-10] and [Figure
50-111-11] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-9]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-9]

can only be replaced as a complete assembly.
Check the spacer (Item 2) and screws (Item 3), mounting

pin (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), stop strap (Item 8) and replace as needed
[Figure 50-111-9].

Handle Removal And Installation
Figure 50-111-12
1
1 N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-14] from the handle.
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-13 1
1 2 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
P16534 111-15] from the handle assembly.
Installation: Tighten the allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-13]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT'D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-18
Figure 50-111-16
1
1
1
2
1 N-22667
N-17394
Disconnect the electrical connectors (Item 1) [Figure 50-
111-18] from the control lever switch handle.
Remove the handle sleeve (Item 1) and bushings (Item 2)
from the handle [Figure 50-111-16]. Remove the electrical connectors from the control lever

switch handle. (See Handle Sensor Connector
Check all parts for wear and replace as needed. Disassembly And Assembly on Page 60-130-3.)
Figure 50-111-17
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-17] that

connects the handle to the handle sensor for wear,
replace as needed.

Lever Removal And Installation (Cont'd)
Figure 50-111-19
2
1
P13734
2
The control lever (Item 1) [Figure 50-111-21] must be
N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-111-21] can be

Figure 50-111-20 replaced separately from the control lever.

463,6 mm
18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-19]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-19]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
463,6 mm (18.25 in) [Figure 50-111-20].
Remove the control lever from the cross shaft and control
panel.

CONTROL HANDLE / LEVER (ACS) (CONT'D)
Boot Removal And Installation
Figure 50-111-22
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-22]

on the control panel, remove the control lever. (See Boot

Drill out the four rivets (Item 2) [Figure 50-111-22]

located on the flange of the rubber boot and remove the
old boot.
Install the new boot and reinstall the control lever. (See
Boot Removal And Installation on Page 50-110-2.)


CONTROL HANDLE / LEVER (SJC) Figure 50-112-2
Description

forward and reverse travel and the lift and tilt functions.

panel.
1
Joystick Testing
Figure 50-112-1
P-64298
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-112-2].
Figure 50-112-3

1
P-28301

procedure:
2
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563 or 6689779-Remote Start Tool
Multi meter
P-28312
Disconnect the joystick harness connector (Item 1) from
Raise the operator cab. (See Raising on Page 10-30-1.) the loader wiring harness (Item 2) [Figure 50-112-3].
Connect the remote start tool to the loader. (See Install the test harness (Item 3) [Figure 50-112-3]
REMOTE START TOOL KIT-1563 on Page 10-60-1.) between the two connectors.
Turn the remote start key to ON position without starting

the loader.
Check the voltage between pin 3 and pin 5 on the joystick

test harness (Item 3) [Figure 50-112-3].
The voltage should be between 2.45 and 2.55 volts.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Removal And Installation
Joystick Testing (Cont’d) When replacing joystick assemblies, they are available as
a complete assembly with the boot and lever already
Figure 50-112-4 attached. This procedure is shown so the electrical
connections can be checked at the bottom of the joystick,
if suspected to be loose or disconnected.


1
Figure 50-112-5
P-64328
Repeat the procedure at the right joystick wiring harness

connector (Item 1) [Figure 50-112-4]. (If needed.)

1
P-73247
Lift the rubber boot (Item 1) [Figure 50-112-5].
Figure 50-112-6
1
1
P-73248
Remove the four screws (Item 1) [Figure 50-112-6] to lift

the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Mount Removal And Installation
Joystick Removal And Installation (Cont’d) Figure 50-112-8
Figure 50-112-7
P-64328
P-73240
Disconnect the joystick wiring harness connectors (Item
1) on both the right and left hand joysticks [Figure 50-
Disconnect the joystick connector (Item 1) [Figure 50- 112-8].
112-7] from the harness connector.

Figure 50-112-9
P-64303
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-9].
The mounting bolts are secured with lock-nuts on the

back of the control panel. Once removed, they need to be
replaced with new.

CONTROL HANDLE / LEVER (SJC) (CONT'D)
Joystick Mount Removal And Installation (Cont’d)
Figure 50-112-10
P-76992
Remove the control lever from the loader [Figure 50-112-

10].

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
2 1
1
2
P-66819
P-66818
Remove the top mounting screw (Item 1), and loosen the
two bottom mounting screws (Item 2) [Figure 50-120-3]
Remove the top mounting screw (Item 1), and loosen the from the front access panel.
two bottom mounting screws (Item 2) [Figure 50-120-1]

from the front access panel. Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
torque.
torque. Remove the front access panel from the loader.
Remove the front access panel from the loader. Figure 50-120-4
Figure 50-120-2
2
1 1
1
1
1 P-66821
1
P-66820
Remove the seven mount screws (Item 1) [Figure 50-
120-4] from the rear access panel.
120-2] from the rear access panel. Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
torque.
torque. Remove the throttle lever assembly (Item 2) [Figure 50-
120-4]from the access panel.
Remove the rear access panel from behind the steering
panel, remove the panel from the loader. Remove the rear access panel from behind the steering
panel, remove the panel from the loader.


ACCESS PANEL (INSIDE) (SJC) Figure 50-121-2
Removal And Installation (Left)

support device. (See Installing on Page 10-20-1.) 1 1
Figure 50-121-1
1 P-64310
2

121-2]
Installation: Tighten the screws to 20 - 27 N•m (15 - 20

ft-lb) torque.

P-64299 Move the lever assembly a slight amount toward the
center of the loader, to allow clearance for the panel to be
removed.
Remove the top mounting screw (Item 1) and loosen the
two bottom screws (Item 2) [Figure 50-121-1]. Remove the inside rear access panel from the loader.

ft-lb) torque.
Remove the inside front access panel from the loader.

ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-5
Removal And Installation (Right)


2
1
Figure 50-121-3
P-64327
Loosen the two bottom mount screws (Item 1) [Figure

50-121-5] from the front inside access panel.
Remove the top mount screw (Item 2) [Figure 50-121-5]

from the front inside access panel.

P-64300 Installation: Tighten the screws to 20 - 27 N•m (15 - 20
ft-lb) torque.
Remove the two mounting screws (Item 1) [Figure 50- Remove the inside front access panel from the loader.
121-3], from the foot throttle assembly.

ft-lb) torque.
Figure 50-121-4
P-64313
Disconnect the foot operated speed control linkage (Item

1) [Figure 50-121-4] from the hand operated speed
control lever arm.
Remove the foot operated speed control assembly from

the loader.

ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-8
Removal And Installation (Right) (Cont’d)
Figure 50-121-6
1 2
P-34553A
Lift the speed control pin (Item 1) from the notch (Item 2)
P-34548 in the speed control rod [Figure 50-121-8].
Figure 50-121-9
Remove the two mount screws (Item 1) [Figure 50-121-
6] from the hand operated speed control lever.

ft-lb) torque.
Figure 50-121-7
P-34549
At the bottom right side of the control panel, remove the

keeper and pin (Item 1) [Figure 50-121-9] that connects
the speed control linkage arm to the speed control rod.
P-34551
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-121-7].

ACCESS PANEL (INSIDE) (SJC) (CONT’D)
Removal And Installation (Right) (Cont’d)
Figure 50-121-10
P-34550
Remove the mount bolt and nut (Item 1) [Figure 50-121-

10] from the speed control linkage arm.

Remove the speed control linkage arm (Item 2) [Figure
50-121-10] from the access panel.
Figure 50-121-11
P-64309
Remove the five mount screws (Item 1) [Figure 50-121-

11] from the access panel.

ft-lb) torque.
Move the lever assembly a slight amount toward the

center of the loader, to allow clearance for the panel to be
removed.
Remove the inside rear panel from the loader.

WINDOW (REAR) Installation (Split Molding)
Removal Clean the area before installing the rubber molding.
Figure 50-130-2
WARNING
W-2019-0907 1
Figure 50-130-1
P16014
Install the rubber molding (Item 1) [Figure 50-130-2]

1 around the edge of the rear opening in the operator cab.

If replacing the rubber molding (Item 1) [Figure 50-130-
2] cut off the excess molding.
Figure 50-130-3
P-64994
Pull on the tag (Item 1) [Figure 50-130-1] on the rear

window to remove the rubber cord.
Using gloves, push the rear window out the rear of the 1
operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
P16015A
installing a new window.
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-3]
into the molding on the inside of the operator cab.
Install the safety tag in the top center of the cord.

WINDOW (REAR) (CONT’D) Figure 50-130-6
Installation (Split Molding) (Cont’d)
Figure 50-130-4
1 1
P16013
Use the plastic stick (Item 1) [Figure 50-130-6] to

P-64997 position the locking tab into the groove to secure the
window in the molding.
Apply liquid soap in the rubber molding (Item 1) [Figure Tapping the window corners will help seat the window in
50-130-4] to make installation easier. the molding.

Install the window from the outside of the operator cab.
Install a lower corner of the rear window into the corner of

the molding. [Figure 50-130-4].
Align the other lower corner of the window in the molding.
Work the window downward until the window is fully

seated in the lower portion of the molding.
Figure 50-130-5
P-64998
Use a plastic stick (Item 1) [Figure 50-130-5] under the

molding lip to guide the window into the molding groove.

WINDOW (REAR) (CONT’D) Figure 50-130-9
Installation (Continuous Molding)
Clean the area before installing the rear window

assembly.
Figure 50-130-7
1
1
P-64997
Install the rear window assembly from the outside of the

operator cab into the window frame.
Install a lower corner of the rear window assembly into

P-85229 the corner of the window frame (Item 1) [Figure 50-130-
9].

Install the rubber molding (Item 1) [Figure 50-130-7] Work the window assembly downward until the window is
around the edge of the rear window. fully seated in the lower portion of the window frame.
Figure 50-130-8
WARNING
2
1 of the following conditions exist:
W-2019-0907
P-85228
Apply liquid soap to the rubber molding (Item 1) [Figure

50-130-8] to make installation easier.
NOTE: Install the window assembly with the narrow

edge (Item 2) [Figure 50-130-8] toward the
inside of the loader.

WINDOW (REAR) (CONT’D)
Installation (Continuous Molding) (Cont’d)
Figure 50-130-10
P-85230
Apply light pressure to the outside of the window

assembly holding it tight up against the window frame.

Use a multipurpose tool (Item 1) [Figure 50-130-10]
under the molding lip to guide the window assembly into
the window frame.
NOTE: Tapping the window with a rubber hammer

will help seat the window assembly in the
window frame.
Figure 50-130-11
P16015A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-
11] with the safety tag into the molding on the inside of
the operator cab.
NOTE: Verify the safety tag is located in the top

center of the window.

WINDOW (TOP)
Figure 50-131-1
1 1
P-24378
Position the window in the recess area.

Install the bolts (Item 1) [Figure 50-131-1] through the
window grommets, the nylon bushings and through the
cab holes.
Figure 50-131-2
1
1
1
1
N-20950
From inside the operator cab, install and tighten the

knobs (Item 1) [Figure 50-131-2] on the window bolts.


WINDOW (SIDE) Figure 50-132-3
Figure 50-132-1
2
N-20814
NOTE: [Figure 50-132-3] is shown with the washer

P-66024 and knob removed to illustrate the direction of
movement.
Release the latch (Item 1) [Figure 50-132-1] and slide Move the window slide rail using the two thumb pads
the front window back towards the rear of the operator (Item 2) [Figure 50-132-2] and [Figure 50-132-3]

cab. towards the rear of the operator cab and then down
towards the bottom of the operator cab.
Figure 50-132-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
window is secure and does not fall. Make sure
the slide rails are in alignment and the window
is positioned in the top track during
1 1 installation.
Remove the front side window from the operator cab.
2 2
P-66019
From inside the operator cab, loosen the knobs (Item 1)

[Figure 50-132-2] and [Figure 50-132-3] on the window
slide rail bolts.

WINDOW (SIDE) (CONT’D)
Figure 50-132-4
2
1
P-66021
Installation: When installing the window make sure the

slide rail (Item 1) adjoins the front stationary slide rail

(Item 2) [Figure 50-132-4].
Figure 50-132-5
P-66020
The rear side window sets in a recessed groove.
NOTE: The window should be secured to prevent

damage when the bolt (Item 1) [Figure 50-132-
5] is loosened.
Loosen the bolt (Item 1) [Figure 50-132-5] on the rear

side window.
Remove the rear side window.

WINDOW (CAB DOOR) Figure 50-133-3
Removal (Standard Window)
Figure 50-133-1
3
2
1
1 1
1 S0363
Push the window out at any corner of the window (Item 1)

P-66051 [Figure 50-133-3].
NOTE: The window may fall when pushing on the

Remove the wiper arm assembly (Item 1) [Figure 50- corners. Have a second technician assist you
133-1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)
[Figure 50-133-1].
Secure the wiper motor inside the cab.
Figure 50-133-2
N-20171
Pull the plastic loop (Item 1) [Figure 50-133-2] at the top

of the window to remove the rubber cord.

WINDOW (CAB DOOR) (CONT’D) Figure 50-133-6
Installation (Standard Window)
Clean the area before installing the rubber molding.
Figure 50-133-4
1
P-66059
Apply liquid soap in the rubber molding to make

installation easier.
P-66058 Install the window from the outside of the door frame.
Install a lower corner of the rear window (Item 1) [Figure

Install the rubber molding (Item 1) [Figure 50-133-4] 50-133-6] into the corner of the molding.
around the edge of the front door frame starting at the
bottom of the door frame. Align the other lower corner of the window in the molding.
If replacing the rubber molding (Item 1) [Figure 50-133- Work the window downward until the window is fully
4] cut off the excess molding. seated in the lower portion of the molding.
Figure 50-133-5 Figure 50-133-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-133-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-133-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.

WINDOW (CAB DOOR) (CONT’D)
Installation (Standard Window) (Cont’d)
Figure 50-133-8
P-66049A
Use the plastic stick (Item 1) [Figure 50-133-8] to

position the locking tab into the groove to secure the

window in the molding.
Tapping the window corners will help seat the window in

the molding.
Figure 50-133-9
P-66051
Install the wiper motor (Item 1) and wiper arm assembly

(Item 2) [Figure 50-133-9].

WINDOW (CAB DOOR) (CONT’D)
Removal And Installation (Special Applications

Window)
Replace the Lexan glazing under the following

conditions:
• When the glazing is four years old;
• When the glazing becomes yellow or hazed;
• Is scratched on either side with scratches that can be

felt with the fingernail;
• Has cracks coming from the edges or mounting holes.

or fine cracks on the surface area;
• Has contacted any fluids that have caused

cloudiness.
Figure 50-133-10

1
P-66101
Remove window from loader.
NOTE: The Special Applications window is held on by

the brackets only, it does not sit in the rubber
molding. During Removal the window may fall
as the mounting bolts are loosened.
Remove the five mounting brackets and bolts (Item 1)

[Figure 50-133-10].

CAB DOOR Figure 50-140-2
Description
The standard cab door is available as an option or dealer

installed kit. The Special Application Kit Door or Forestry
Door kit are available for use with certain attachments.
Figure 50-140-1
3
2
1
4

P-76520
P-76526
Open the cab door.
Remove the gas spring (Item 1) [Figure 50-140-1] from Lift the door (Item 1) [Figure 50-140-2] off the hinges.
the threshold.
Disconnect the electrical harnesses (Items 2 and 3)

[Figure 50-140-1].
Disconnect the washer bottle hose (Item 4) [Figure 50-

140-1].

CAB DOOR (CONT’D) Aligning
Figure 50-140-3 WRONG WRONG
2 1
P-76523A P-76524A
Figure 50-140-5
CORRECT CORRECT

1
2
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-140-
3] from the cab.
P-76522A P-76525A
Remove the hinges (Item 1) [Figure 50-140-3] from the

cab.
When the striker or latch is NOT adjusted properly there
Installation: Install the hinges (Item 1) on the cab and will be a gap (Item 1) [Figure 50-140-4] between the
use the bolts and nuts (Item 2) [Figure 50-140-3] to door and the cab or the striker and the latch.
secure the hinges. Tighten to 9,6 - 10,7 N•m (7 - 7.9 ft-lb)
torque. If adjustment is needed. (See Adjusting on Page 50-140-
3.)
When the striker or latch is adjusted properly there will be

no gap (Item 1) [Figure 50-140-5] between the door and
the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Checking Operation on Page 50-140-3.)

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-8
Figure 50-140-6
1 P-76683
P-76521
Sit in operator’s seat. Turn key ON. (Standard Key Panel),
press RUN / ENTER button (Deluxe Instrumentation
Loosen the two bolts (Item 1) [Figure 50-140-6] and Panel), lower seat bar and close the door. Press the
adjust the latch as needed. PRESS TO OPERATE LOADER button (Item 1) [Figure

50-140-8].
NOTE: For the initial adjustment, position the latch
towards the bottom of the door. Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will flash, an audible tone will sound,
Figure 50-140-7 and the message [door] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will go out and the display will return to
machine hours.
P-76516
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-7].
NOTE: For the initial adjustment, position the striker

towards the front of the machine.
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-140-2.)


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2

Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Standard Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Keyless Start Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Deluxe Instrumentation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Removal And Installation (Left And Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2

BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6

CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Attachment Control Information (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . 60-180-2
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5

3520 3520
3500 3500
Printable Version Click Here 3800 3800 3510
3610
3600 3600
1800 1800
8250 8250
1015
8200
2360
1020
2370
1800
2380
2410
2350
2910
2015
3210
3410
3110
3200
3100
3420
3400
7023
2510
2500
8800
4350
4200
4370
4010
4410
4360
4380
7025 7020
7024
2350 3910
2360
2910 2900
7021
2410
2750 2751
2380 2780
2370
8250
3600 7000
3520 7010
2775 2730
3010
2790
1800
3920 3920
3300 3930 3900 3900
3310
9350 9350
9210 9230 9200 9200
3700 9110 9130 9100 9100
3710
1130
9120
9220
1450 1450
1110
2745
9500
3440 2765
9600
6100
9800
1120
1180
1150
9620
7022
9520
7030
3430 3430
2740 2741
9370
9360
9380
6210
6320
8020
8000
6230
6330
8210
8150
8110
4110
9370
8510
4150
8550
9380
9360
2200 2200 1500

4200 4200 1410
4100 1370
1780 1700 1700
1710 1710
1770
4235
4275
1720
2720
4550
6010
4550
6515 6500
Dealer Copy -- Not for Resale 4275
9520
6415 6400
9620
8100 8100 8120 4220
8150 8800
2800 2800 2810 1740
2090
2600
4230
4240
7100
8200 8200
6100
6330
8500 8500
6410
1120 6510
6200
6310 6310
8200
8000
6200
6210
6230
4150
4110
1500
4100
8110
8020
8550
8210
8510
8120
8150
1370
8500
1410
1120
9120
6100
9220
6320
6340
1730
9600
1160
9800
9500
2710
1050
2010
1150
2010
2040 4440
1180
2040
2070 2440
2540
2550
8000 4430
2430
1350
1740
1360
1330
1070
1060
1030
1320
2000
1140
2050 2060 1790 2020
2030 2030
4450
2450
4460
2460
4480
1730
1780 4330 4920 2480
1300
1570
1310
1770
2330 4310
1410
4320
2110 4300
2130 1420 1160 4340 1560
2340
1340
7210
1430 1175 1170
4830
4810
4820
4840
4910
4930
4940
2430
2440
2340
6520
7200
4640
2460
6420
2330
1235
2785
2235
1040 2240
1060
1070
1310
1570 1560
1010 1030
2390 1580 1590
1050
1340
1300
2300 1430
2120
2520
4240
1580
4810
4830
4840
2530
4820
4640
4300
4320
4910
4940
4310
4920
4930
1590
4230
+
-
623 of 994
Printable Version Click Here
624 of 994
625 of 994
626 of 994
627 of 994
WIRING SCHEMATIC 7100
TO MAINFRAME
C TO OPTIONS
POWER BOB-TACH
SOLENOID NC NO
OPTIONS 2650 TO MAINFRAM ADDITIONAL
C606
F A 7000 A A 9.8 ohms
HARNESS POWER / GROUND
C103
6600 G D 2760 B B
C601
BACK-UP (ACCESSORY POWER) C B A SOURCE FOR KITS
6410 E
S185 (S/N A3L911001 AND ABOVE) ALARM
C
C489A C220A C489B
C607
6310 A B 7010 B B POWER BOB-TACH
A B
(S/N A3LH11001 AND ABOVE) 6510 D E 2770 A A
SOLENOID C B A A B
87A 87
H
30
6200
A B C
C220B
2230
1520
6700
TO BRAKE LIGHT
1500
2200
9.8 ohms
1510
2210
2600 B 1730 6600
HARNESS 7151691
C407
TO TO
C474
6320 A A 6320
TO SJC HARNESS 4210 2730 MAINFRAM TAILGATE
A
(PRINTED AUGUST 2009) POWER BOB-TACH HARNESS -
85
86
2620
TO HARNESS HARNESS
2610
6610
6320
6620
6410
6330
2640
6510
V-1201 TAILGATE
7112290
6700
BRAKE LIGHT C103A C103B
2670
6340
BRAKE LIGHT HARNESS 7151696 HARNESS HARNESS 7151691
HARNESS (For
2630 6210 A B C D E F G H A B C D E F G H
Printable Version Click Here E F C A B D
C602
F E D C B A
C603 LEFT WORK RIGHT WORK
(FOR SJC MODELS ONLY) C407A
A
All Models
Except SJC)
A
B A
OPEN
OPEN
6000
2000
7100
6210
6110
OPEN
6010
6000
2010
7100
6230
6130
6530
6320
E F C A B D F E D C B A A C230A
C800
A
B A
(TO "D" PIN)
(TO "B" PIN)
6430
C410
C431
DELUXE TAILGATE
6500
4640 RIGHT HEAD LIGHT HARNESS 7152108
HARNESS - 7139785 SSL 7-PIN LIGHT

2
6
2
6
6810
2130
6800
2130
A
B
A
B
6420
2110
STOP TURN TAIL STOP TAIL REGISTRATION CAN CONNECTOR
C170
TURN
LEFT TAILLIGHT RIGHT TAILLIGHT LAMP SIDE MARKER 5 5 6830 6830 C C 6220
KEY "RUN" D 9800 D BLINKER 4 4 6820 6820 D D 6440
ADVANCED HAND CONTROL UNSW POWER 2 1160 F 3 3 OPEN OPEN E E 6510 6530
CAN SHIELD C 9700 C 1 1 OPEN OPEN F F OPEN
FLOAT HARNESS - 6727328 TO MAINFRAME SW POWER 1 1710 E To Mainframe To Ground
Harness
CAN LOW B 9600 A A 2 6810 6800 A A 6330
7100 C
2650
CAN HIGH A 9500 B LIGHT B 6 2130 2130 B B 2120
F
C180
GROUND 3 2700 G SIDE MARKER C 5 6830 6830 C C 6120
C103
G 7-PIN
Connector BLINKER D 4 6820 6820 D D 6340 6320
BACK-UP E on Loader C666
ATTACHMENT
CONNECTOR C426 E 3 OPEN OPEN E E 6520
STROBE OR ALARM 6310 A Boom
BEACON F 1 OPEN OPEN F F OPEN
D
CONTROL HARNESS - 6718426 HARNESS 7152108
6310
2030
6410
2020
6200 H LEFT HEAD LIGHT
2600 B
2 1
C609 87A 87 86 87A 87 86
2620
FRONT WIPER A B
2610
6320
6330
2640
HARNESS 7153090
2 1 TO M BOTTLE AND TANK
STROBE/BEACON
6340
2670
TO OPTIONS FRONT WIPER 30 85 30 85
2630 6210 MOTOR
6700 E C668 OR C670 1 2 2 1
2775
A C604 C605 V GROUNDS
6300
6400
TO OPTIONS LEFT WORK RIGHT WORK
M 2010
(4 WAY FLASHER) C 1 2 2 1
1010
1400
1020
1410
2 2785 2780 D 2000 2020
C669
C622
7200 or YEL
REGISTRATION
7150 or DGN
2030
2765 or BRN
1 6440 F
L X
3 6540 B
STANDARD TAILGATE A B A B
EXTERIOR CAB HARNESS - HARNESS - 7109403 ROAD LIGHTS To Starter "B" Terminal
RIGHT TAILLIGHT TO OPTIONS
LEFT TAILLIGHT
(EUROPE ONLY)
2745
6718872 (DELUXE ACCESSORY)
1010
Left Marker Fuse 10A Right Marker Fuse 10A
3 7310
HARNESS 7141369
PARK
HIGH
2 2735 2755 B B
C610
C667
5 7160 C C
SSL 7-PIN
C426 To Mainframe 1 7210 A A
DOOR SENSOR
Harness
CAN CONNECTOR D F C E A B G 6 7180 7180
2 2 2 2
4 4710 1 1 4720 1 1
C412
B 87A 87 86
9800
1160
9700
1710
9500
9600
2710
2785
WIPER HARNESS DOOR HARNESS A 1420
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN 7117322 7104465

30 85
UNSW POWER 2 1160 RED/WHT 2720 H GROUND
C402 C490
B 2740
2700
1420
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
ACD A 1720
SW POWER 1 1730 RNG 1720 B SW POWER
Machine
CAN LOW B 9620 PUR 9610 E CAN LOW A 1720
Connector
CAN HIGH A 9520 PUR 9510 D CAN HIGH B 2720
GROUND
C666
3
7-PIN
2730
ATTACHMENT
BLK C
A
OPEN
OPEN Dealer Copy -- Not for Resale
CONNECTOR G OPEN
C 7200
C427
J
BOOM-MOUNTED B 6415
N ACD CONNECTORS A 6515
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK B 6000
E OUTPUT E 5100 5100 C E OUTPUT TO C OPEN
C401
F OUTPUT F 5350 5350 H F OUTPUT MAINFRAME
D 6410
C404
B
G OUTPUT G 5400 5400 J G OUTPUT E OPEN
ACD 7100 A
H OUTPUT H 5050 5050 B H OUTPUT A 6510
Output
C OUTPUT C 5300 5300 G C OUTPUT
6510
Connector BACK-UP ALARM
6510
D OUTPUT D 5150 5150 D D OUTPUT SWITCHES
A OUTPUT A 5250 5250 F A OUTPUT 7110 TO
MAINFRAME 87A 87 86
M OUTPUT M 5200 5200 E B OUTPUT
87A 87 86
C402
1720 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
2720 B
ID (K TO P) P 5510 5450 K K OUTPUT 30 85
BACK-UP ALARM 30 85
C506 14-PIN
C704 ADDITIONAL POWER
ATTACHMENT J3 - 10-PIN GRAY
SWITCHES HARNESS -
2780
6020
CONNECTOR CONNECTOR
2790
6010
5900 J ID #1
C491
B
5500 A ID #2 7107544 1740 A
B ID #3
ACD
C ID #4 Input
D ID #0 Connector
E OPEN SJC HORN / BLINKER
C433
C433
F
G
OPEN
OPEN
A
C
RNG
LGN
A
C
HARNESS - 7151940
H OPEN B BLK B
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN - +
ADVANCED HAND CONTROL

SSL 7-PIN
C426 To Mainframe
JUMPER HARNESS - 6728742
CAN CONNECTOR Harness
D F C E A B G TO ATTACHMENT
TO ATTACHMENT
B
B
J
9800
1160
1710
9500
9600
2710
9700
J
N
N
P
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN M TO OLDER
P LEFT RIGHT
MODEL ATTACHMENTS M TO OLDER FLASHER FLASHER
UNSW POWER F 1160 RED/WHT 2720 H GROUND A LIGHT LIGHT
C506
MODEL ATTACHMENTS
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD C
C506
D WHT S
SW POWER E 1730 RNG 9 1720 B SW POWER ACD D S
C BRN LT
C623
9 Machine A BRN LT
C623
CAN LOW B 9620 PUR 9610 E CAN LOW E BLK TM
14 Connector to
CAN HIGH A 9520 PUR 9510 D CAN HIGH E BLK TM TO OPTIONS
Engine F DBL CENTER
2790
2795
(EXTERIOR CAB)
GROUND G 2730 BLK 13 C OPEN Compartment F DBL CENTER
G RED GD
Connector 7-PIN A OPEN G RED GD 6440 1
C669
on Loader C666 ATTACHMENT
CONNECTOR G OPEN
H
L
YEL
RNG
RT
H YEL RT 2785 2
Boom L 6540 3
J K RNG
BOOM-MOUNTED K
SW POWER
N
K 1740
ACD CONNECTORS
GRADER HARNESS - 4 WAY FLASHER
GROUND B 2740 C703 J2 - 10-PIN BLACK
GRADER HARNESS - HARNESS - 6718873
E OUTPUT E 5100 5100 C E OUTPUT
6707303 6706391
F OUTPUT F 5350 5350 H F OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
Output
C OUTPUT C 5300 5300 G C OUTPUT TO HORN
Connector to
D OUTPUT D 5150 5150 D D OUTPUT CONNECTOR
Engine
C412
A OUTPUT A 5250 5250 F A OUTPUT Compartment 2750 B

M OUTPUT M 5200 5200 E B OUTPUT HORN RELAY 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
12 2770
85 86
7200
ID (K TO P) P 5510 5450 K K OUTPUT
87
11 2750 30
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A 2760 ADDITIONAL POWER
CONNECTOR
Connector CONNECTOR
C490
5900 J ID #1 E 85 86 2740 B
on Loader 2780 6415
87
Boom 5500 A ID #2 D 6410 6410 30 1740 A
C411
87A 6020 RED = RED BATTERY FEED 1000-1999 RED, RED/WHT, RNG
B ID #3 C WIRES CONNECT BY
ACD RNG = ORANGE GROUND 2000-2999 BLK
C LETTER ACROSS MONITORING 3000-3999 LBL
ID #4 Input B 6000 BLK = BLACK
TO AWS TO MAINFRAME LBL = LIGHT BLUE CONNECTORS HYDRAULIC 4000-4999 LGN
Connector to
C401or
D ID #0 A 6510 B C A A B ATTACHMENT CONTROLS 5000-5999 YEL

C402
CONTROLS DBL = DARK BLUE

Engine RIGHT BLINKER
C489
DELUXE ATTACHMENT E OPEN

Compartment RELAY C497
2720
1720
B
A TO OPTIONS
DOME LIGHT
LGN = LIGHT GREEN
DGN = DARK GREEN
B A
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
F OPEN SWITCH ENGINE 8000-8999 TAN
CONTROL HARNESS - 2790
85 86
6515
YEL = YELLOW
SOME CONNECTOR COMMUNICATION 9000-9999 PUR
C608
G OPEN 87 A RED PNK = PINK

6510 30 WHT = WHITE BODIES NOT SHOWN
628 of 994 6732730 H
K
OPEN
OPEN
87A 6010 B BLK
BRN = BROWN
TAN = TAN
FOR DRAWING CLARITY
Rev. none
AWS HORN/BLINKER HARNESS - 6726662 DOME LIGHT PUR = PURPLE
GRY = GRAY
V-1201 (7-23-09)
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710 SPLICE (•) - Used to show when

3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A
SPEED SENSOR - magnetic pickup -
detects rpm.
B

Standard Cab Harness Connectors
C 212
C 434
C 482
408 C 499

C 479
C 129 C 480
C 209 S1
S2
T3
SW1
C 435
C 500
C 408
MS2660

Deluxe Cab Harness Connectors
C 212
SW9
C670 SW8
SW7 C 483
S3
S4
C 611
C 630
C 635
T5 C 434
T6 *C 129 C 482
408 C 479

S1
C 40
T2 S2
C 209 C 40
T1
T3
SW1
SW2
C 480 SW3
C 435 SW4
C 408 SW5
SW6
MS2441

Mainframe Harness Connectors
CC426
408
C 405
T1
T6
T8
C 486 T4
T5
C 112 C4
T3
C 108 C 350
408
C 408
C 113
C 135

C 107 C 446
C 407-1
C 407-2
C 103 C 478
C 105 C 489
C 406 C 423
C 606 C 415
J1
C 101 J2
C 413
C 414 C 126
C 416 C 419 C 404
C 417 C 420 C 409 C 410
C 418
C 421 C 411
C 422 C 412
C 425
C 492
MS2179

Description
Figure 60-10-1
P-13849
P-76895
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by

fuses located in the cab on the steering control panel,
and a 100 ampere master fuse [Figure 60-10-1] in the
engine compartment on the left side of the engine, under
the air cleaner. The fuses will protect the electrical
system when there is an electrical overload. The reason
for the overload must be found before starting the engine
again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuse And Relay Location / Identification 11

1 9 13 15 17
5
Figure 60-10-2
2 6 18
1
3 7 19
8 16 20
4 10 12 14
7159779
P-76302
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure

60-10-2]. A decal is inside the cover to show location and
amp ratings. N-19660
Remove the cover to check or replace the fuses.

The location and sizes are shown below and [Figure 60-
10-3].
RE RE
DESCRIPTION AMP DESCRIPTION AMP
F F
1 Unswitched 25 11 Front & Marker R
Horn Lights
2 ACS/AWS/SJC 5 12 Fuel Shutoff R
Switched
3 Alternator & 25 13 Rear Lights R
Accessories
Back-up Alarm
4 Attachments 25 14 Traction R
5 Heater & Air 25 15 Glow Plugs R
Conditioning
6 Front & Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Traction 30
8 Bobcat 25 18 Fuel Shutoff 30
Controller
9 Heater & Air R 19 Power Plug 15
Conditioning
10 Switch Power R 20 ACS/AWS/SJC 25
Unswitched
R - Relay

Solenoid Testing
Figure 60-10-4
P9175

10-4]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807
metal parts with the battery terminals.

Open the rear door. Connect the negative (-) cable last to prevent sparks.
Figure 60-20-1 Connect and tighten the battery cables.
Install and tighten the battery hold down.
2 Close the rear door before operating the loader.
1 WARNING
3 BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
P-76973 make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

Disconnect the negative (-) battery cable (Item 1) [Figure battery. Warm battery to 16°C (60°F) before
60-20-1]. connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Remove the battery hold down clamp (Item 2) [Figure lean over battery while boosting, testing or charging.
60-20-1]. W-2066-0910
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.

BATTERY (CONT’D)
Servicing
Figure 60-20-3
P-09589 P-09590
The battery cables must be clean and tight. Check the

electrolyte level in the battery. Add distilled water as

needed. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water
solution.[Figure 60-20-3]
Put Battery Saver (6664458) or grease on the battery

terminals and cable ends to prevent corrosion.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONT’D) Figure 60-20-4
Using A Booster Battery (Jump Starting)
If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and 4 2
disconnect the battery cables.
The key switch must be OFF or the STOP button must be

pressed. The booster battery must be 12 volt.
WARNING 3 1
P-76896
BATTERY GAS CAN EXPLODE AND CAUSE

make final connection (negative) at machine frame.

P-31292
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never Connect the end of the first cable (Item 1) [Figure 60-20-
lean over battery while boosting, testing or charging. 4] to the positive (+) terminal of the booster battery.
W-2066-0910 Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Connect the end of the second cable (Item 3) [Figure 60-

20-4] to the negative terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285


ALTERNATOR Belt Replacement
Belt Adjustment Remove the air conditioning belt, if equipped. (See

REGULAR MAINTENANCE on Page 80-20-1.)
Loosen the alternator shield mounting bolts (Item 1) and
Figure 60-30-1 remove the alternator shield (Item 2) [Figure 60-30-1].
Loosen the alternator mounting and adjustment bolts

(Item 1) and remove the alternator belt shield (Item 3)
2 [Figure 60-30-2].
Move the alternator forward as far as it will go.
Remove the belt from the pulleys and inspect the pulleys
for wear. Replace as needed.
Install new alternator belt.
1 Adjust the belt.
P-76903 Install the alternator shield and tighten mounting bolts.
Install the air conditioning belt. (See REGULAR

Loosen the alternator shield mounting bolts (Item 1) and

MAINTENANCE on Page 80-20-1.)
remove the alternator shield (Item 2) [Figure 60-30-1].
Figure 60-30-2
P-76904
Loosen the alternator mounting and adjustment bolts

(Item 1) [Figure 60-30-2].
Move the alternator to tighten the belt. The tension is

correct when there is 8,0 mm (5/16 in) movement at the
middle of the belt span (Item 2) [Figure 60-30-2] with 66
N (15 lb) of force.
Tighten the adjustment and mounting bolts (Item 1)

[Figure 60-30-1].
Install the alternator shield and tighten mounting bolts.

ALTERNATOR (CONT’D) If the charging system malfunctions check the following:
Charging System Inspection Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) Replace belt if
worn or deteriorated.
WARNING Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
Batteries contain acid which burns eyes and skin on Check the fuse for the alternator in the fuse panel. If fuse
contact. Wear goggles, protective clothing and is burned, find the cause and repair / replace. If fuse is in
rubber gloves to keep acid off body. doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled

water as needed. (Does not apply to maintenance free
batteries.)
minutes. Verify the charge of the battery. Make sure battery is fully
charged.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get Disconnect the battery cables (negative first, then
prompt medical attention. positive). Inspect the cable clamps and battery posts for
W-2065-0807 corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to

prevent corrosion. Reconnect the cable to the positive
terminal.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
make final connection (negative) at machine frame.

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-4
Figure 60-30-3
P-66815
P-34676
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-4] off the alternator.
Open the rear door.
Turn the remote start tool key to the ON position.

Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-1563 on Page 10-60-1.) Figure 60-30-5
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-3].
1
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test. 2
P-66816
Check the voltage across the “L” terminal (Item 1) and a

good ground source (Item 2) [Figure 60-30-5]. The
voltage should be what the battery voltage is. If not,
check wire harness, relay and fuses. If the wire harness,
relay and fuses are ok then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-3.) for further component testing.

ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-6
P-34679 P-66817
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-4] off the alternator.

Check the continuity between the “S” terminal (Item 1)
[Figure 60-30-6] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-6].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-3.) for further component testing.

ALTERNATOR (CONT’D) Raise the operator cab. (See Raising on Page 10-30-1.)
Removal And Installation Disconnect the negative (-) cable from the battery.
Place jackstands under the rear corners of the loader. Figure 60-30-7
DANGER
2
1
P-90328
AVOID DEATH P-66815

tubeline, hose, fitting, component or a part failure Disconnect the red wire (Item 1) [Figure 60-30-7] from
can cause lift arms to drop. the alternator which comes from the battery.

unless supported by an approved lift arm Disconnect the wiring harness connector (Item 2)
support. Replace if damaged. [Figure 60-30-7] from the alternator.
D-1009-0409
Figure 60-30-8
WARNING 1

W-2059-0598 2
IMPORTANT P-24543
Damage to the alternator can occur if: Remove the adjustment bolt (Item 1) [Figure 60-30-8]
• Engine is operated with battery cables from the mounting bracket.
disconnected.
• Battery cables are connected when using a fast Remove the alternator belt (Item 2) [Figure 60-30-8]
charger or when welding on the loader. (Remove from the alternator pulley.
• Extra battery cables (booster cables) are Remove the mounting bolt (Item 3) [Figure 60-30-8].
connected wrong.
I-2023-1285


ALTERNATOR (CONT'D)
Figure 60-30-9
1. Alternator 11. Bearing
2. Nut 12. Stator
3. Pulley 13. Housing 7
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Housing 16. Rectifier 1
7. Bolt 17. Cover
8. Bearing 18. Spacer 6
9. Retainer 19. Nut
10. Rotor
14
13
4 7
3
12 5
2
11
10

9
8
19
18
17
15 16 C-3529B

STARTER Figure 60-40-2
Testing
Figure 60-40-1 Bat

S
M
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

A-1992 between the M terminal and the BAT terminal [Figure 60-
40-2].
The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.

The battery must be at full charge. If the starter does not turn, the starter is defective.
The cable connections on the battery must be clean and

tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.

STARTER (CONT’D)
Figure 60-40-3
4
2
1
P-34385

Remove the negative (-) and positive (+) cables from the
battery.
Disconnect the ground wire (Item 1) [Figure 60-40-3]

from the starter.
Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-3].

12.3 ft-lb) torque.
Disconnect the tan wire (Item 3) [Figure 60-40-3] from

the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-40-3] from

the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-40-3]

from the starter.
Remove the starter from the engine.
Installation: Tighten the three mounting bolts to 34 - 38

Reverse the removal procedure to install the starter.

STARTER (CONT'D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32 7*
15
37
14

16 20
17
19 18
5 8
12
14
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
24 36. Bracket
37. Bearing
* Not serviceable parts B-16488


INSTRUMENT PANELS
Left Panel
Figure 60-50-1
3 12
2
7 16
1
4 13
8 10 11 15
6 9
14
5

17 20
18 19
21 22
23
P-76459C
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information.
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right turn signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.

14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and
right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to engage the auxiliary hydraulics. (Left green LED will
light.) Press a second time to disengage.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine rpm
• Battery voltage
• Maintenance clock
• Service codes*
Press and hold for seven seconds to reset the maintenance clock.
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
or joystick(s) to move the loader forward or backward when using the
backhoe attachment or for service. Press a second time to lock the
brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ System when the seat bar is down and
operator is seated in operating position. Button will light.
Press and hold three seconds to engage Steering Drift Compensation.
(See STEERING DRIFT COMPENSATION on Page 60-161-1.)
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* For further description on Service Codes (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

INSTRUMENT PANELS (CONT’D) Keyless Start Panel
Standard Key Panel Figure 60-50-3
Figure 60-50-2
2 3
4
5
6
P-90816A
S4498
This machine may be equipped with a Keyless Start
Panel [Figure 60-50-3].
This machine may be equipped with a Standard Key
Panel [Figure 60-50-2]. 1. Keypad (keys 1 through 0): Used to enter a number

code (password) to allow starting the engine. An
The Standard Key Panel is used to turn the loader’s asterisk will show in the left panel display screen for
electrical system on and off, and to start and stop the each key press.
engine.
2. LOCK Key: Used to lock keypad. The lock key will
display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. START Button: Used to start the engine.
5. STOP Button: Used to stop the engine and shut

down the loader electrical system.
6. RUN Button: Used to turn on the loader electrical

system.

INSTRUMENT PANELS (CONT'D) 8. Keypad: The numeric keypad has two functions:
Deluxe Instrumentation Panel - To enter a number code (password) to allow starting

the engine.
Figure 60-50-4
- To enter a number as directed for further use of the
Display Screen.
9. Start Button: Used to start the engine.
10. Run / Enter Button: Used to turn on the loader’s

1 7 electrical system.
4 Figure 60-50-5
5
2 3 6
ENTER PASSWORD
9
8
LANGUAGES

B-16165
10 11 B-15553N
The first screen you will see on your new loader will be as
shown in [Figure 60-50-5].
This machine may be equipped with a Deluxe When this screen is on the display you can enter the
Instrumentation Panel [Figure 60-50-4]. password and start the engine or change the Display
Screen setup features.
1. Display Screen: The Display Screen is where all
NOTE: Your new loader (with Deluxe Instrumentation
system setup, monitoring, troubleshooting and error
Panel) will have an Owner Password. Your
conditions are displayed.
dealer will provide you with this password.
2. Bobcat Main Controller Error: Indicates Change the password to one that you will
communication error between Bobcat Main Controller easily remember to prevent unauthorized use
and Deluxe Instrumentation Panel. (See of your loader. (See Changing The User
DIAGNOSTIC SERVICE CODES on Page 60-90-1.) Password on Page 60-190-2.) Keep your
password in a safe place for future needs.
3. Display Error: Indicates communication error
between instrument panel and Bobcat controller. Change Language: Press the Selection Button at the end
(See DIAGNOSTIC SERVICE CODES on Page 60- of the arrow [Figure 60-50-5] to go to the next screen.
90-1.) Use the Keypad to select the number of the language.
4. Engine Air Filter Icon: Indicates engine air filter Press EXIT. The screen will return to [Figure 60-50-5].
requires service. You can then enter the password and start the engine.
5. Hydraulic Filter Icon: Indicates hydraulic filter See CONTROL PANEL SETUP for further description of
requires service. screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
6. Selection Buttons: The four Selection Buttons allow
you to select items from the Display Screen and scroll NOTE: Pressing the EXIT key will go to the previous
through screens. screen and you can continue pressing until
you get to the initial (home) screen.
7. Stop Button: Used to stop the engine and shut down SHORTCUT: Press the “0” (zero) key to get to
the loader’s electrical system. the home screen immediately.

INSTRUMENT PANELS (CONT'D) Front Panel
Side Panel Figure 60-50-7
Figure 60-50-6 1 2 3 4 5 6 7 8
B-15993Q
OR
9
7 8 9
1 2 3 4 5 6
B-15993R
P-76602 NOTE: Parking Brake (Item 4) [Figure 60-50-7] is

standard on all loaders.
REF
. DESCRIPTION FUNCTION / OPERATION

REF
NO.
. DESCRIPTION FUNCTION / OPERATION
NO. 1 ADVANCED Press the top to select Hand
CONTROL Controls; bottom to select Foot
1 POWER PORT Provides a 12 volt receptacle
SYSTEM (ACS) Controls.
for accessories.
(Option)
2 NOT USED ---
2 NOT USED ---
3 FRONT WIPER Press the bottom of the switch
3 POWER Press and hold the up arrow to
(Option) to start the front wiper (press
BOB-TACH disengage the Bob-Tach
and hold for washer fluid).
(Option) wedges. Press and hold the
Press the top of the switch to
down arrow to engage the
stop the wiper.
wedges into the mounting
4 REAR WIPER Press the bottom of the switch frame holes.
(Option) to start the rear wiper (press
4 PARKING BRAKE Press the top to engage the
and hold for washer fluid).
(Standard on all PARKING BRAKE; bottom to
Press the top of the switch to
loaders) disengage.
stop the wiper.
5 HYDRAULIC Press the top to engage
5 NOT USED ---
BUCKET Hydraulic Bucket Positioning;
6 NOT USED --- POSITIONING bottom to disengage.
7 FAN MOTOR Turn clockwise to increase fan (Option)
(Option) speed; counterclockwise to 6 HAZARD LIGHTS Press the top to turn the
decrease. There are four (Option) HAZARD LIGHTS ON; bottom
positions; OFF-1-2-3. to turn OFF.
8 AIR Press bottom of switch to start; 7 ROTATING Press the top to turn the
CONDITIONING top to stop. Fan Motor (Item 7) BEACON (Option) ROTATING BEACON ON;
SWITCH (Option) must be ON for A/C to operate. bottom to turn OFF.
9 TEMPERATURE Turn clockwise to increase the 8 NOT USED ---
CONTROL temperature; counterclockwise
9 SELECTABLE Press the top to select ‘ISO’
(Option) to decrease.
JOYSTICK Control Pattern; bottom to
CONTROLS select ‘H’ Control Pattern.
(SJC) (Option)

INSTRUMENT PANELS (CONT’D)
Front Panel Removal And Installation
Figure 60-50-8
1
1
P-26255

8].

Installation: Be careful to not overtighten the front
accessory panel mounting bolts to prevent damage to the
plastic panel.
Figure 60-50-9
2
1
P-26251
Pull the front accessory panel down and disconnect the

wire harness connector(s) (Items 1 and 2) [Figure 60-50-
9] from the switches.
Remove the panel.
Reverse the procedure to install the front accessory

panel.

INSTRUMENT PANELS (CONT’D) Figure 60-50-12
Removal And Installation (Left And Right)
Figure 60-50-10
1
P-76985A

P-76985 12].
Installation: Be careful to not overtighten the instrument

Remove the three mounting bolts (Item 1) [Figure 60-50- panel mounting bolts to prevent stripping of the threaded
10]. holes in the panels.

Installation: Be careful to not overtighten the instrument Figure 60-50-13
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-11
N-20163
Pull the right instrument panel down and disconnect the

P-76987 wire harness connector (Item 1) [Figure 60-50-13] from
the panel.
Pull the right instrument panel down and disconnect the Remove the panel from the loader cab.
wire harness connector (Item 1) [Figure 60-50-11] from
the panel.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT’D) Figure 60-50-16
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-14
1
3
1
P-76982
Pull the left instrument panel down and disconnect the

N-20142 wire harness connector (Item 1) [Figure 60-50-16] from
the loader alarm.
NOTE: The instrument panel (Item 1) [Figure 60-50- Disconnect the wire harness connector (Item 2 and 3)
14] must be replaced as a complete unit. [Figure 60-50-16] from the loader instrument panel.

Figure 60-50-15 Remove the instrument panel from the loader.
P-76986

15].
Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded
holes in the panels.

INSTRUMENT PANELS (CONT'D) Alarm Removal And Installation
Key Switch Removal And Installation Figure 60-50-18
Remove the right side instrument panel. (See Removal

And Installation (Left And Right) on Page 60-50-7.)
Figure 60-50-17
2
1
N-20144
1 Remove the left side instrument panel.
P-76989 Remove the retaining nut (Item 1) [Figure 60-50-18] from

the loader alarm.

Remove the ignition key (Item 1) from the switch. Remove the alarm from the loader instrument panel.
Remove the ignition switch retaining nut (Item 2) [Figure
60-50-17] from the switch. Figure 60-50-19
Remove the ignition switch from the control panel.
N-20147
To install the bulbs, place them in the sockets and turn

clockwise [Figure 60-50-19].


LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1 1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the

N-19348 socket.
Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative(-) cable from the battery. (See
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.

LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-6
Figure 60-60-4
1 2 1
1
3
P-66221
P-68264
Remove the screws (Items 1) [Figure 60-60-6] from the
light cover.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb NOTE: The wires for the switch will hold the light

assembly a 1/4 turn. cover. Do not pull the light cover to far away
from the light housing to prevent damage to
Figure 60-60-5 the wires.
Move the light cover to allow access to the bulb.
Figure 60-60-7
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
Reverse this procedure for installation.

Remove and replace the bulb (Item 1) [Figure 60-60-7]
from the light housing.

BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)
Description
The Gateway and Auxiliary controller provide information

to all other controllers. All loaders have a Gateway and
Auxiliary controller.
The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.

(CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

(CONT’D)
Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR

12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO-SPEED GROUND
27 2360 BLACK TWO-SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

(CONT’D)
J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL

12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO-SPEED MAKEUP
26 4350 LGN TWO-SPEED SIGNAL

(CONT’D)
Auxiliary Controller
1 1
34 26
J2A J2B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

(CONT’D)
J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT

12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

(CONT’D)
J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) Figure 60-70-2
(CONT’D)

1
1
WARNING
W-2059-0598
P-76643

support device. (See Installing on Page 10-20-1.) Remove the mount bolts (Item 1) [Figure 60-70-2] and
remove the panel.
Stop the engine. Raise the seat bar.
Figure 60-70-3
Page 10-10-1.)

Figure 60-70-1 2
1 1
1
P-76642
Unplug the two harness connectors (Item 1) [Figure 60-

70-3] from the Gateway controller.
P-76644 Unplug the two harness connectors (Item 2) [Figure 60-

70-3] from the Auxiliary controller.
Remove the mount bolts (Item 1) [Figure 60-70-1]. NOTE: The connectors are keyed and will only plug
in one way.
Remove the panel from the loader.

(CONT’D)
Figure 60-70-4
1 1
2 2
P-66928A
Remove the controller mounting bolts (Item 1) [Figure

60-70-4] from the left fender.
Loosen the controller mounting bolts (Item 2) [Figure 60-

70-4].
Installation: Tighten the controller mounting bolts to 16 -

Lift and remove the Gateway and Auxiliary controllers

from the loader.


BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS

or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.
The ACS controller is located behind the right side

access panel near the operators right foot.

BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
D
J1
C
J3
J1 J2

P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-3
Figure 60-71-1
P-21840

P-21839 from the controller.
Remove the controller from the loader.

Loosen the bottom bolts and remove the top bolt on the
right front panel [Figure 60-71-1]. NOTE: The calibration procedure must be followed

when replacing actuator or ACS Controller.
Remove the right front panel (Item 1) [Figure 60-71-1] (See CALIBRATION on Page 60-160-1.)
from the loader.
Figure 60-71-2
P-21843
Disconnect the wiring harness connectors (Item 1)

[Figure 60-71-2] from the controller.


BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same used on the ACS
drive functions. system.
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operators right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the Gateway controller in an SJC
system. All these controllers are capable of software
upgrades.
HYDRAULIC
RIGHT DRIVE MOTOR
HAND CONTROL
PANEL

ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS
INTERNAL CAN BUS
GEAR ENGINE
SERIAL TT BUS
PUMP
RIGHT
JOYSTICK
ISO
SWITCH FWD / REV
SWASH PLATE
SENSORS
LEFT
JOYSTICK
AUXILIARY DRIVE
LEFT PUMP
CONTROL
HAND SPEED
PANEL SENSOR
EXTERNAL
CAN BUS ACD
GATEWAY CONTROL
CONTROL HYDRAULIC
MOTOR MS2582S

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification
P-64295

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-2
WARNING 1

W-2059-0598
P-64322
Pull the controller out from the fender and loosen the
Raise the operator cab. (See Raising on Page 10-30-1.) connector screw (Item 1) [Figure 60-72-2] to release the
connector.
Installation on Page 70-20-1.) Installation: Tighten the connector screw to torque. DO
NOT OVERTIGHTEN!

Remove the inside access panels (right side). (See
Removal And Installation (Right) on Page 50-121-2.)
Figure 60-72-1
P-66835
Remove the top controller mounting bolt (Item 1). Loosen

the two bottom controller mounting bolts (Item 2) [Figure
60-72-1] from the right side fender.
Lift and remove the controller from the fender.


SPEED SENSORS (SJC) Testing
Figure 60-80-1
1
P-28302
P-64765
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loader’s controllers to sense if the 1609-Wheel Speed Sensor Test Harness

drive motor is rotating. The end of the sensor is magnetic [Figure 60-80-2]
and counts the magnetic pulses as a rotating disc,
attached to the motor carrier shaft, rotates by the sensor 1563 - Remote Start Tool Kit
end. Multimeter
The speed sensor is sealed with an O-ring (Item 1) Raise the lift arms and install an approved lift arm
[Figure 60-80-1] to keep hydraulic oil inside the motor support device. (See Installing on Page 10-20-1.)
carrier and dirt out.

REMOTE START TOOL KIT-1563 on Page 10-60-1.) or
(See REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-4
Testing (Cont’d)
Figure 60-80-3
3
2
1
2
1
P-64976
Connect the speed sensor test harness (Item 1) [Figure

P-64762 60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
Locate the speed sensor (Item 1) [Figure 60-80-3] on the Turn the remote start key to ON position without starting
top of the right or left hydrostatic motor carrier. the loader.

Remove the transmission cover screw (Item 2) [Figure Take a voltage reading, with the multimeter, at the speed
60-80-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-80-4].
torque. The voltage should be approximately 5 volts.
Disconnect the speed sensor wire connector (Item 3) Repeat the procedure for the opposite side speed sensor.
[Figure 60-80-3] from the loader harness wire connector. (If needed.)

Figure 60-80-5 1
1 P-64764
Lift the speed sensor (Item 1) [Figure 60-80-7] out from

P-64762 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Raise the lift arms and install an approved lift arm Figure 60-80-8

Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
2
P-64765
1
Remove the speed sensor [Figure 60-80-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure

60-80-6], to loosen the connector clamp.

torque.
Disconnect the speed sensor electrical harness

connector (Item 2) [Figure 60-80-6].

Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
1
2
P-26295
Installation: The alignment pin (Item 1) at the bottom of

the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue

DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes.
The Service Codes will aid your dealer in diagnosing
conditions which can damage your machine. Figure 60-90-2
Figure 60-90-1
Press TOOL / SETUP
2 B-16163
Press OWNER UTILITIES
B-24288
Enter PASSWORD (owner or master)

on Keypad
1 P-76455G
then press ENTER
to Continue
B-24290
Press the INFORMATION button (Item 1) to cycle the

DATA DISPLAY (Item 2) [Figure 60-90-1] until the
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the Press SERVICE CODES
DATA DISPLAY.
B-24291
NOTE: Corroded or loose grounds can cause
multiple service codes and / or abnormal
symptoms. All instrument panel lights
Press NEXT to view the next 8
flashing, alarm sounding, headlights and Service Codes. (A total of 40 Codes
taillights flashing, could indicate a bad can be stored.)
ground. The same symptoms could apply if B-24298
the voltage is low, such as loose or corroded
battery cables. If you observe these
symptoms, check grounds and positive leads
first. The Display Panel will list the Code Number, (CODE)
hourmeter reading when the error occurred (HOUR), and
the User (USER) who was logged in to operate the
machine when the error occurred [Figure 60-90-2].
A total of 40 Codes can be stored. When more than 40

codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-3 The following word errors may be displayed:
2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.
Service Codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-90-3]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed A8503 ACD output ‘F’ error OFF

A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003 ACD output ‘A’ error OFF A8506 ACD output ‘F’ short to ground
A8005 ACD output ‘A’ short to battery A8507 ACD output ‘F’ open circuit
A8006 ACD output ‘A’ short to ground A8532 ACD output ‘F’ overcurrent
A8007 ACD output ‘A’ open circuit A8602 ACD output ‘G’ error ON
A8032 ACD output ‘A’ overcurrent A8603 ACD output ‘G’ error OFF
A8102 ACD output ‘B’ error ON A8605 ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high

Service Codes List (Cont’d)

D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF

D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541 Right swash plate sensor out of range high D7592 Right swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7593 Right speed sensor unresponsive
D7543 Left forward drive solenoid error ON D7594 Left speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545 Right forward drive solenoid error ON D7596 Right speed sensor reversed
D7546 Right reverse drive solenoid error ON D7597 Controller programmed
D7547 Right front steer extend short to battery D7598 In drive calibration mode
D7548 Left front steer extend short to battery D7599 In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent


H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic / Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic / Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low

H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure


M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807 Lift spool lock open circuit M4803 Front light relay error OFF
M1832 Lift spool lock overcurrent M4807 Front light relay open circuit
M2005 Two-speed primary short to battery M4902 Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit M4907 Rear light relay open circuit

M2032 Two-speed primary overcurrent M5002 Front light output error ON
M2102 Glow plug output error ON M5003 Front light output error OFF
M2103 Glow plug output error OFF M5007 Front light output open circuit
M2107 Glow plug output open circuit M5028 Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202 Starter output error ON M5103 Rear light output error OFF
M2203 Starter output error OFF M5107 Rear light output open circuit
M2207 Starter output open circuit M5128 Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF


M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224 ACS calibration failed W3264 Pedal lock short to battery
W3231 Tilt actuator fault W3265 Sensor supply voltage out of range
W3232 Tilt actuator wiring fault W3266 Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle / pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error

W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236 Lift actuator fault W3271 Right hand drive short to battery
W3237 Lift actuator wiring fault W3274 Left joystick X-axis out of range
W3238 Lift handle wiring fault W3275 Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240 Lift handle / pedal not in neutral W3277 Remote control information error
W3241 No communication W3905 Left joystick X-axis not in neutral
W3249 Lift actuator short to ground W4005 Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Figure 60-100-1
1 2 3
P-76459A
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system
consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-100-1] of the loader cab.
The Press To Operate button (Item 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS™ (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers slowly forward
Figure 60-100-2 and backward. The TRACTION lock must be
engaged. Lower the seat bar. Press the PRESS TO
1 2 3 OPERATE LOADER button.
7. Engage parking brake and move steering levers

slowly forward and backward. The TRACTION lock
must be engaged.
6 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5 brake is disengaged.
4 Inspecting The Lift Arm Bypass Control
8. Raise the lift arms 2 m (6 ft) off the ground. Stop

engine. Turn lift arm bypass control knob clockwise 1/
P-76459A
4 turn. Pull up and hold lift arm bypass control knob
until lift arms slowly lower.

1. Sit in operator’s seat. Turn key to RUN or press RUN
button. Lower seat bar and disengage parking brake. Inspecting Deactivation Of Lift And Tilt Functions
Press the PRESS TO OPERATE LOADER button (ACS And SJC)
(Item 4). Two BICS™ lights (Items 1 and 2) [Figure
60-100-2] [SEAT BAR AND LIFT & TILT VALVE] on 9. Sit in operator’s seat and fasten seat belt. Lower seat
left instrument panel must be OFF. The PRESS TO bar, start engine and press the PRESS TO OPERATE
OPERATE LOADER button will light. LOADER button.
2. Raise seat bar fully. All three BICS™ lights (Items 1, 10. Raise lift arms about 2 m (6 ft) off the ground.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE and PARKING BRAKE] on left instrument 11. Turn key OFF or press STOP button, and wait for the
panel must be ON. The PRESS TO OPERATE engine to come to a complete stop.
LOADER button light will turn OFF.
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
Inspecting Deactivation Of The Auxiliary Hydraulics
(foot pedal, hand control or joystick) to lower the lift
System (Engine STOPPED - Key ON)
arms. Lift arms must not lower.
3. Sit in operator’s seat, lower seat bar and press the
13. Move the control (foot pedal, hand control or joystick)
PRESS TO OPERATE LOADER button (Item 4).
to tilt the bucket (or attachment) forward. The bucket
Press the auxiliary hydraulics button (Item 5). The
(or attachment) must not tilt forward.
auxiliary hydraulics light will be ON (Item 6) [Figure
60-100-2]. Raise the seat bar. The light must be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

WARNING
brake and fasten seat belt.
5. Start engine and operate at low idle. Press the The Bobcat Interlock Control System (BICS™) must
PRESS TO OPERATE LOADER button. While raising deactivate the lift, tilt and traction drive functions. If it
the lift arms, raise the seat bar fully. The lift arms must does not, contact your dealer for service. DO NOT
stop. Repeat using the tilt function. modify the system.
W-2151-1111

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into
place.

3. Check pins in connectors for pins pushed back or bent.
4. Use seat bar sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
5. Possible low or high voltage.


SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.

2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:

Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operators seat.
Figure 60-110-5
1 2
P100745
Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-110-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-110-7].
2
P100742

Remove the sensor mounting bolt and nut (Item 1)
[Figure 60-110-5]. Disconnect the sensor wiring
Figure 60-110-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-110-6].
NOTE: Approximately 4 turns of the clevis bolt
should be adequate to release the spring
tension. When tension is released, the clevis
pin can easily be rotated using the retaining
pin.


3
Figure 60-110-8
2
1
4
P100748
Install the new keyed bushing (Item 1), magnet bushing

P100746
(Item 2) and seat bar sensor (Item 3) [Figure 60-110-10].
Reinstall the metal pivot bushing (Item 4) [Figure 60-
110-10].
Pull the front of the seat bar down slightly from the top of
the cab, while raising the sensor end of the seat bar up, NOTE: The sensor must be centered on the metal
away from the mount [Figure 60-110-8].
pivot bushing. When centered, the assembly

NOTE: The sensor end of the seat bar will raise easily will slide freely into the mount.
ONLY if the front of the seat bar is pulled
slightly down from the top of the cab. Figure 60-110-11
Figure 60-110-9
4
3
1
3
6 1
2
P100749
2
P100747
Position the clevis (Item 1) over the mount (Item 2) and
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9] lower the end of the seat bar until the mounting bolt (Item
on the cab side screen to hold the seat bar above the 3) [Figure 60-110-11] is resting on the top of the mount.
mount.
Remove the nut from the mounting bolt. Remove the
Remove the clevis pin bushing (Item 2) [Figure 60-110- mounting bolt and lower the seat bar until the seat bar
9]. Apply grease to the shoulder of the bushing to help and mount holes align and the clevis is over the clevis pin
retain it during assembly. Reinstall the clevis pin bushing. bushing. Reinstall the seat bar mounting bolt. Apply
Loctite® 243 to the nut threads. Install the nut and tighten
Remove and dispose of the keyed bushing (Item 3),
to 34 ft-lb (46 N•m) torque.
magnet bushing (item 4), and seat bar sensor (Item
5)[Figure 60-110-9].
Remove and save the metal pivot bushing (Item 6)

[Figure 60-110-9].

SEAT BAR SENSOR (CONT'D)
Figure 60-110-12
1
2

P100751
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-110-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5] and tighten to 6,8 N•m (60 in-lb)
torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.

Bobcat Interlock Control System (BICS™) Circuit

Test
Figure 60-110-13
3
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor

adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-14] on the sensor tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-110-13].
NOTE: The sensor test light (Item 3) [Figure 60-110-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)
Figure 60-110-15
P-85413
The BICS™ seat bar indicator light (Item 1) [Figure 60-

110-15] should turn OFF.
Figure 60-110-16
P-4699
Move the toggle switch (Item 1) [Figure 60-110-16] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-15] should

illuminate.
If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.


TRACTION LOCK Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The Traction Lock Control System will lock the traction problems. It is recommended that these procedures be
drive system when the engine stops. The Traction Lock done by authorized Bobcat Service Personnel only.
Control System is incorporated into the BICS™ System.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11

1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp. fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See
Fuse And Relay Location / Identification on Page 60-10-9.)
5. To test the solenoid, the pull coil should be about 0.3 ohm and the hold coil should be about 10.9 ohm.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel rpm sensor and wiring.
12. Check the Display Panel for an error code. (See Electrical System Service Manual)
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.

TRACTION LOCK (CONT'D) Figure 60-120-2
WARNING
1
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat
P-68140
Company parts if repair is necessary.
W-2165-0100
Remove the bracket (Item 1) [Figure 60-120-2] from the

Raise the loader operator cab. (See Raising on Page 10- chaincase cover.
30-1.)
Installation: Apply polyurethane sealer to the bolt
Figure 60-120-1 threads and tighten the mounting bolts to 34 - 38 N•m (25
- 28 ft-lb) torque.

Be sure the solenoid mounting bracket is installed in the
same position. The solenoid mounting surface has a
2
slight angle which tips the top of the solenoid toward the
rear of the loader when installed correctly. See inset
photo [Figure 60-120-1].
P-4712
Figure 60-120-3
1
P-66958
2
NOTE: The loader control panel and linkage crossbar
have been removed for clarity purpose only.
The traction lock can be removed without
removing the control panel.

120-1] from the electric solenoid mounting bracket. P-68141

(80 - 90 in-lb) torque. Remove the traction lock assembly (Item 1) [Figure 60-
120-3] from the chaincase.
Remove the electric solenoid (Item 2) from the chaincase
cover [Figure 60-120-1]. Inspect gasket (Item 2) [Figure 60-120-3], replace if
necessary.

TRACTION LOCK (CONT'D) Installation: Thoroughly clean and dry the shaft
mounting bolt (Item 1), the shaft (Item 5) and wedge
Removal And Installation (Cont'd) (Item 4) [Figure 60-120-5]. Use Loctite® #242 when
assembling these parts to the traction lock assembly.
Figure 60-120-4
Figure 60-120-6
4 1
3 2
1
P-68143
P-68142
Remove and inspect the compression spring (Item 1) and

spring cap washer (Item 2) [Figure 60-120-4] for wear or Inspect the guides (Item 1) [Figure 60-120-6] for wear or

damage. Replace if necessary. The spring may also stay damage. Replace if necessary.
with the shaft when the electric solenoid and bracket are
removed from the chaincase. If replacement is necessary, remove the center
chaincase cover. Remove the screws (Item 2) [Figure
Installation: Install the compression spring (Item 1) 60-120-6] and pry the center cover off.
[Figure 60-120-4] on the collar located on the electric
solenoid. Installation: Apply polyurethane sealant to the screw
threads and center chaincase cover. Tighten screws to
Inspect the shaft (Item 3) and wedge (Item 4) [Figure 60- 20 - 27 N•m (15 - 20 ft-lb) torque.
120-4] for scoring and deep scratches, replace if
damaged. (Item 3) [Figure 60-120-4] from the
chaincase.
Figure 60-120-5
4 5
3
2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-120-5]. Inspect all parts for
damage or wear. Replace if necessary.


1
3
Figure 60-120-7
1
2
2
P11332
Installation: Thoroughly clean the polyurethane from the

P11331 chaincase cover (Item 1), bolts (Item 2) and traction lock
guides (Item 3) [Figure 60-120-9] and dry.
NOTE: Bolt (Item 1) is on the rear of the chaincase Figure 60-120-10

cover, notice the direction of the groove (Item

2) [Figure 60-120-7] in the traction lock
guides.
Figure 60-120-8
P11333
Installation: Apply a bead of polyurethane on the

1
traction lock guides and bolts [Figure 60-120-10].
P11330
To remove the traction lock guides remove the four bolts

(Item 1) [Figure 60-120-8].

Figure 60-120-11
1
INCORRECT CORRECT
2
3
2
P11337
1
Install the traction wedge assembly (Item 1) into the
N-19106 N-19105 solenoid and traction lock guides (Item 2) [Figure 60-
120-12].
Install the traction lock guides (Item 1) to the chaincase After the bolts have been tightened recheck to make sure
cover (Item 2) [Figure 60-120-11] using the four bolts the shaft assembly is moving freely in the guides.

(removed earlier).
Remove the wedge assembly (Item 1) [Figure 60-120-
Do not tighten at this time. 12].
NOTE: The wedge assembly must slide freely in the

grooves of the guides. Tighten the four guide
bolts to 123 - 135 N•m (90 - 100 ft-lb) torque.
Lower operator cab. (See Lowering on Page 10-30-2.)
Perform the BICS™ inspection procedure. (See BOBCAT

INTERLOCK CONTROL SYSTEM (BICS™) on Page 60-
100-1.)

Inspecting
Figure 60-120-13
1
P-68145
1 Check the wire connections at the engine flywheel rpm

P-76674 speed sensor (Item 1) [Figure 60-120-14].
NOTE: When the Traction Lock Override Button is

Fasten the seat belt, disengage the parking brake button, activated, the Traction Lock Override Control
press the PRESS TO OPERATE LOADER Button (Item System will NOT engage the Traction Lock if

1) [Figure 60-120-13] and raise the Seat Bar fully. Move the engine stops.
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-120-13] should be (See Adjusting on Page 60-170-1.) for Flywheel rpm
engaged. Lower the Seat Bar. Press the PRESS TO sensor adjustment.
OPERATE LOADER Button (Item 1) [Figure 60-120-13].
Fasten the seat belt, disengage the parking brake pedal,
Engage the parking brake pedal and move the steering press the green PRESS TO OPERATE Button and raise
levers slowly forward and backward. The TRACTION lock the Seat Bar fully. Move the control levers slowly forward
should be engaged. and backward. The Traction lock should be engaged.
Lower the Seat Bar. Press the green PRESS TO
NOTE: The TRACTION light on the left instrument OPERATE Button.
panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER Engage the parking brake pedal and move the control
Button is pressed and the parking brake is levers slowly forward and backward. The Traction lock
disengaged. should be engaged.

CONTROL SYSTEM (ACS)
Description
The (ACS) Actuator Control System system is an option

that allows the operator to quickly switch between foot
and hand control modes.
The ACS control uses the electric actuators on the main

hydraulic control valve to control the lift and tilt spools in
the hydraulic control valve, foot sensors, handle sensors
and a specially designed control handle.
Hand controls contain a locking solenoid which lock when

the switch on the center control panel is switched to foot
mode.
Foot controls also contain solenoids which lock when the

switch on the center control panel is switched to hand
mode.
Both the hand and foot controls contain sensors that

relay information to the ACS controller as to which
function should be activated and how far the spool should

be moved.

CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
2
3
1
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be

removed from the handle sensor wires, using the 1-Terminal - Red
following procedure.
2-Terminal - Black
Figure 60-130-2
3-Terminal - Green
1
1
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

Switch Handle Removal
Figure 60-130-4
1
3
2
P13735
1
2
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.

130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
P13725 P13732

harness connector (Black) that connects to the handle
1
lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

Switch Handle Removal (Cont'd)
Figure 60-130-8
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
P13735 3 and 4) [Figure 60-130-10] from the loader wiring
harness connectors.
Using a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.

Figure 60-130-9
2 2
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Items 1 Using a small screwdriver, lift the handle tabs (Item 2)
and 2) [Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2 Tape 1/2 of Wires

Tape back 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 152,4 mm (6 in) piece of

heat shrink tubing placed over the end of the wires.
Cut the wires (Item 2) [Figure 60-130-12] below the Remove the heat shrink tube from the end of the wires
switch handle and remove switch handle. before routing the harness through handle and control
lever tube.
NOTE: Only cut the wires if the switch handle is bad
and needs replacement. If the switch handle is NOTE: Leave all the other heat shrink tube on the
good and just needs to be removed for control wires for protection.
handle or lever replacement, then remove the
connectors on the end of the harness and pull Tape half of the wires back and half forward [Figure 60-
switch handle and harness up through the top 130-14] to keep the harness small enough to route
of the lever tube. through the control lever tube.
Figure 60-130-13
P-24234
If the harness has been cut: pull the harness (Item 1)

[Figure 60-130-13] out through the bottom of the control
lever tube.

CONTROL SYSTEM (ACS) (CONT'D) Right Switch Handle
Switch Handle Installation (Cont'd) Ten-Pin Connector

A-Terminal - Orange
Figure 60-130-15 B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
1 E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
P-21700A Left Switch Handle
Install the new switch handle and wires from the top of Ten-Pin Connector
the control lever. A-Terminal - Orange
B-Terminal - Dk. Blue

Route wire (Item 1) [Figure 60-130-15] through the C-Terminal - White
casting, along side the handle sensor and into the control D-Terminal - Purple
lever tube. E-Terminal - Yellow/Red
F-Terminal - Tan
NOTE: Do not pull the wire harness tight. Allow a G-Terminal - Pink
small amount of slack or slight bend at the H-Terminal - Orange/Black
handle pivot area. Verify the control handle J-Terminal - Blank
returns to neutral position. K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
2 C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
A-Terminal - Dk. Green
1 B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695
E-Terminal - Blank
Remove tape from wires for installation and install the

152,4 mm (6 in) of heat shrink tube (Item 1) [Figure 60-
130-16] approximately 76,2 mm (3 in) into the control
lever. Apply heat to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.
Install the wires into the connectors as listed below:

Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
P13735
1 Install the wires into the connectors as listed below:

N-17779
Left And Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18
1-Terminal - Red/White

2-Terminal - Black/White
3-Terminal - Purple/White
1
Figure 60-130-20
3 1
N-17772
2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
connectors.
P13735
Left And Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

CONTROL SYSTEM (ACS) (CONT'D) Actuator Connector Disassembly And Assembly
Switch Handle Installation (Cont'd) NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-21
Figure 60-130-22
P-21804
P-66842
Connect the handle harness connectors to the sensor

and lock solenoid connectors [Figure 60-130-21]. Check the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.
Figure 60-130-23
N-17741
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Lift And Tilt Actuator
1. Terminal-Black/Green-Larger diameter wire (16
gauge)
2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
gauge)
4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)

CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
P-21878A
1
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads

and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
130-24] from the handle lock solenoid connector.
Figure 60-130-27
Figure 60-130-25
1 P-21789
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for

Remove the two screws (Item 1) [Figure 60-130-25] damage. Replace as necessary.
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38

in-lb) torque.
Remove handle lock solenoid assembly from handle.

CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-130-28
1
P-24269
Remove the two bolts (Item 1) [Figure 60-130-28] from

the end of the foot sensor.

Installation: Tighten the bolts to 10,2 N•m (90 in-lb)
torque. Apply Loctite® 242 to the threads.
Figure 60-130-29
3
2
1
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-130-29].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-29]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

Foot Lock Solenoid Removal And Installation
Figure 60-130-30
P-21790
Check the O-ring (Item 1) [Figure 60-130-32] for

1
P-21938 damage. Replace as necessary.
Remove the two bolts (Item 1) [Figure 60-130-30] from

the foot sensor shield.

in-lb) torque.
Figure 60-130-31
P-21939
Disconnect the foot lock solenoid connector (Item 1)

[Figure 60-130-31] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-130-31].
Installation: Apply a drop of oil on the solenoid threads

and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
lubed torque.

ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 5 10 11 12
6 7
13
9
4
B-15781F / B-22178D / B-15781E
REF. NO. DESCRIPTION

1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)

Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 STEERING LEVERS
6 LIFT ARM PEDAL
7 TILT PEDAL
8 ENGINE SPEED CONTROL
9 LIFT ARM BYPASS CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 TWO-SPEED CONTROL (Option)
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for

more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
12, 13,

B-16447 14 B-16448
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect

the Service PC (See SERVICE PC (LAPTOP 6 5 4 2
1
COMPUTER) on Page 60-150-1.) 7
The ACD (Attachment Control Device)

automatically recognizes the use of the seven
or fourteen pin connector when connected.
3
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to NA1891
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,

B-16447 14 B-16448

1

3
Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
12, 13,

B-16447 14 B-16448

1

3
Number Number
block.
pump.


1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
12, 13,

B-16447 14 B-16448

1

3
Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 6 11 12 13
7 8
9
4
14
5 10
B-15781D / B-22178E / B-15781E


4 FLOAT CONTROL
5 FRONT HORN
6 STEERING LEVERS AND LIFT / TILT HANDLES
7 LIFT ARM PEDAL
8 TILT PEDAL
9 ENGINE SPEED CONTROL

ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899

P-90900 14 P-90900A

1

3
Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899

P-90900 14 P-90900A

1

3
Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899

P-90900 14 P-90900A

1

3
Number Number
block.
pump.


13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front 11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899

P-90900 14 P-90900A

1

3
Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
10 11
18
6 7 19
12
B-19873A / B-15546K / B-19874A


Also: SPEED MANAGEMENT
*2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
*4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 JOYSTICKS
9 FOOTRESTS
10 ENGINE SPEED CONTROL (FOOT)
11 ENGINE SPEED CONTROL (HAND)
* 14 NOT USED
* 16 NOT USED
18 FLOAT CONTROL
* Also used as Attachment Function Control: See your attachment Operation & Maintenance Manual.

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

1

3
Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

1

3
Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

1

3
Number Number
block.
pump.


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

1

3
Number Number
block.
pump.

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-150-1
1 2
2
1 3
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start

Tool (Service Tool) Kit
1565 - Service Tool Harness Control Kit Includes:
1566 - Service Tool Harness Communicator (Computer
Interface) 7003030 - Remote Start Tool (Service Tool)
NOTE: Make all connections with the key in the OFF 6689747 - Loader Service Tool Harness
position. 6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item NOTE: Make all connections with the key in the OFF
2) [Figure 60-150-1]. When connected to the loader, the position.
Service PC is used to monitor, conduct diagnostics, and
upgrade software. The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-150-2]. When
Connect the Service Tool Harness Communicator (1566) connected to the loader, the Service PC is used to
(Item 3) [Figure 60-150-1] to the designated serial port monitor, conduct diagnostics, and upgrade software.
on the Service PC.
Connect the Remote Start Tool (Service Tool) Computer
NOTE: The recommended serial cable length should Service Tool Harness (Item 3) [Figure 60-150-2] to the
not exceed 4,6 m (15 ft). A serial cable longer designated serial port on the Service PC.
than 4,6 m (15 ft) will create a degraded signal
causing communication errors. NOTE: The recommended serial cable length should
not exceed 4,6 m (15 ft). A serial cable longer
Connect the other end to the connector on the Remote than 4,6 m (15 ft) will create a degraded signal
Start Tool. causing communication errors.
Connect the Remote Start Tool to the loader. (See Connect the other end to the connector on the Remote
REMOTE START TOOL KIT-1563 on Page 10-60-1.) Start Tool (Service Tool).
NOTE: Refer to BobcatNET for PC requirements and Connect the Remote Start Tool (Service Tool) to the
the latest Service Analyzer software. loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and

the latest Service Analyzer software.


CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive Controller, ACS
Controller, pump controller, hydrostatic pump, or
hydrostatic motor. Failure to calibrate after component
replacement may result in poor performance or reduced
life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting

controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
If a Service PC is not available, (See Lift And Tilt
The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-11.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path can not be attained or replacing the 22°C (72°F), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a

Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
The pin may be too large. Oversized pins exceeding 6,30
• Actuator did not fully extend / retract. During the test, mm (0.248 in) in diameter should be replaced.
the spool was not able to fully stroke in both
directions. If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
• Actuator out of neutral. The spool did not return to the 60-160-2], check the following probable causes in
neutral window during the test. Column 2 [Figure 60-160-2].

NOTE: A time out will occur if the test cannot be • Contamination in the spool.
completed within 8 seconds. If this happens,
retry the test. • The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
Figure 60-160-2 centering spring, replace if necessary.
Run Actuator Test
• The wire harness or connectors may have an
intermittent short. Check the connections and wire
Pass Fail harnesses.
Retest With Warm Hydraulic Oil • The controller may be defective, replace the
controller.
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.
• The spool end cap may be defective or the centering

centering spring, replace if necessary.
• Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.
• The actuator may be defective, replace the actuator.

• The spool end cap may be defective or the centering
centering spring, replace if necessary.
• Contamination in the spool.

CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
B-19874
NOTE: The Actuator Test is the preferred method to
calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-28063
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s). Move the right joystick to the forward-right corner position
[Figure 60-160-4] and hold in position.
Figure 60-160-3

1
P-45240
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
1
1
P-76683
1
P-76601 P-76597A At the left panel, press the PRESS TO OPERATE Button
(Item 1) [Figure 60-160-6] while holding the right joystick
in position.
With the seat bar down, turn the ignition key ON (Deluxe
Instrumentation Panel press RUN / ENTER) [Figure 60- Release the joystick.
160-5].

NOTE: During the calibration cycle, the system will
NOTE: Do not start the engine. beep three times. Once the calibration is
complete code W3224 (Calibration
The loader Control Pattern Switch (Item 1) [Figure 60- Performed) will be generated.
160-3] will start flashing and will continue to flash until the
calibration procedure is completed. The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.

CALIBRATION (CONT'D) Figure 60-160-8
Hydrostatic Pump Calibration (SJC)
WARNING
Failure to use jackstands can allow the machine to 1
fall or move and cause injury or death. 1
W-2017-0286
P-76601 P-76597A
10-10-1.)
With the seat bar down, turn the ignition key ON (Deluxe
Operator must be in the seat and the seat bar down. Instrumentation Panel press RUN / ENTER) [Figure 60-
160-8].
Figure 60-160-7
NOTE: Do not start the engine.
Figure 60-160-9

1
1
2
P-45238
Close the cab door. (If loader is so equipped.) P-45238
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-7] in the ISO position. The Control Pattern ISO Switch (Item 1) [Figure 60-160-
9] will start flashing.
Verify the parking brake (Item 2) [Figure 60-160-7] is
OFF.

Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-10
B-19873
P-26476
B-19873
Move the left joystick to the reverse-right corner position
P-26476 [Figure 60-160-12] and hold in position.
Figure 60-160-13
Move the left joystick to the forward-left corner position
[Figure 60-160-10] and hold in position.

Figure 60-160-11
P-76683
1
Press the PRESS TO OPERATE LOADER Button (Item
P-76683 1) [Figure 60-160-13] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-11] while holding the left joystick in
position.
Three audible beeps will sound.
NOTE: Codes D3905 and D3907 will be displayed if

the info button is pressed four times.

Figure 60-160-14
1
P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-26474 16] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Allow the left joystick to go to the neutral position [Figure Figure 60-160-17
60-160-14].

Figure 60-160-15
P-90128
1
P-76683 Move the throttle (Item 1) [Figure 60-160-17] to high idle.
NOTE: If at any time, during calibration, the operator

Press the PRESS TO OPERATE LOADER Button (Item needs to stop the loader, turn the key OFF, lift
1) [Figure 60-160-15]. the seat bar, or return the joystick to the
neutral position. The calibration procedure
Three audible beeps will sound. will stop.
Start the engine from the RUN, RUN / ENTER position. To return to calibration mode, the operator
DO NOT TURN TO OFF POSITION. This would cancel must start the complete procedure from the
the calibration mode and the procedure would have to be beginning.
repeated.
If code D7572 occurs, drive functions will be
disabled until a successful pump calibration
has been completed.

1 2
WARNING
W-2017-0286
Figure 60-160-18 P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-19] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-19] until it reaches full speed and then
come to a stop.

B-19873 Continue to hold the left joystick in the forward position
until the loader wheels or tracks come to a stop and an
audible beep is heard.
Forward calibration is complete.

P-26482
NOTE: If the wheels or tracks do not stop moving in
Full Speed Forward in 2 minutes or less, there
Move and hold the left joystick to the forward position was an error in the calibration procedure. The
[Figure 60-160-18] until the forward calibration is operator must shut the loader OFF, and start
completed. the calibration procedure from the beginning.

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-20 the calibration procedure from the beginning.
There will be an audible beep, PRESS TO OPERATE

LOADER button light will remain on. The TRACTION light
will illuminate, the SEAT BAR, and LIFT AND TILT lights
will be off. The 75-98 error code will clear. There should
be no other codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
B-19873 neutral.
Press the PRESS TO OPERATE LOADER button. Move

P-26483 the left joystick to forward position [Figure 60-160-18]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-20] until the reverse calibration is 160-20] and check for normal reverse wheel or track

completed. rotation.
Figure 60-160-21 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
1 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift can not be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-1.)
or (See Troubleshooting on Page 60-10-8.)
P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-21] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-21] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See 1
Actuator Testing on Page 60-160-1.) 1
NOTE: This calibration procedure must be followed P-76601 P-76597A

when replacing a hydraulic control valve,
actuator or ACS controller. Failure to calibrate
after component replacement may result in Close the cab door. (If loader is equipped.)
poor performance or reduced life of
actuator(s). With the seat bar down, turn the ignition key ON (Deluxe
Instrumentation Panel press RUN / ENTER) (Item 1)
Figure 60-160-22 [Figure 60-160-23].
NOTE: Do not start the engine.

Figure 60-160-24
P-24826
Update the loader service software to the latest version.

1
Place the rocker switch (Item 1) [Figure 60-160-22] in
the hand control mode. P-76683
Push the PRESS TO OPERATE button (Item 1) [Figure

60-160-24] to unlock the hand controls.

Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-25
Stroke Both Handles Fully In and Hold Them
P-76683
Push the PRESS TO OPERATE button (Item 1) [Figure

B-16628 60-160-26] to begin calibration.
NOTE: The ACS icon will light up and if you listen

Fully stroke both control handles in toward the center of closely the cycling of the actuators can be
the cab and hold the handles [Figure 60-160-25]. heard. The ACS icon will stay lit until the

ignition key is cycled or the loader is started
Lift the seat bar, high enough for the PRESS TO and a function is operated.
OPERATE light (Item 1) [Figure 60-160-24] to go OFF.
NOTE: During the calibration cycle, the system will
Lower the seat bar. beep three times. Once the calibration is
complete code W3224 (Calibration
Performed) will be generated.
Release the control handles.
Calibration is complete.

STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to enable the BICS™.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
• Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
6. Current drive response setting will be displayed briefly
• Driving on uneven terrain such as crowned road in the data display.
surfaces.
NOTE: Raising the seat bar or changing control
Figure 60-161-1 mode (ISO / H) will cause the machine to

disengage from steering drift compensation.
STEERING DRIFT COMPENSATION
The last displayed setting will remain in effect
[S-L10] [S----] [S-R10] until the STOP button is pressed or the key is
turned OFF.
[S-L10] [S----] [S-R10]
B-23580A
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-161-2 to appear in the data display (Item 2) [Figure 60-161-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-161-3
1 2
3 4 5
P-76456F
P-76461L
P-76461N
P-76461M
1 2
Left Joystick Right Joystick

3 4
P-76456F
6 P-76461K
7 P-76461O
P-24820B P-24802B
Saving The Steering Drift Compensation Setting:
Press and hold the PRESS TO OPERATE LOADER
button (Item 1) for three seconds to enter the drive The current steering drift compensation setting can be
response adjustment menu. Press the PRESS TO saved by pressing and holding the PRESS TO OPERATE
OPERATE LOADER button (Item 1) again to adjust the LOADER button (Item 1) for three seconds. [SET] (Item
loader steering drift compensation setting. The current 3) will appear in the data display (Item 2) [Figure 60-161-
steering drift compensation setting will appear in the data 3] and the machine will exit from the steering drift
display (Item 2) [Figure 60-161-2]. compensation adjustment menu.
Press the upper left button (Item 6) on the left joystick to OR

adjust the machine left. [S-L01] (Item 3) through a
maximum of [S-L10] will appear in the data display (Item Press the PRESS TO OPERATE LOADER button to exit
2) [Figure 60-161-2]. The number will increase by one from the steering drift compensation adjustment menu
each time you press the button. The higher the number, without saving the current setting. [DONE] (Item 4) will
the greater the amount of steering drift compensation to appear in the data display (Item 2) [Figure 60-161-3] and
the left. Adjustments to steering drift compensation will the upper left and upper right buttons on the left joystick
be effective immediately. will no longer make changes to steering drift
compensation.
NOTE: The last displayed steering drift

compensation setting will remain in effect
until the STOP button is pressed or the key is
turned OFF. The machine will revert back to
the last saved setting the next time it is
started.

FLYWHEEL RPM SENSOR Figure 60-170-2
Description 2
The flywheel rpm sensor has a magnet located on the 1

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
main Bobcat controller which registers the rpm of the
engine.
The flywheel rpm sensor is located just above the starter

on the left side of the engine.
Code 06-13 will occur if the main Bobcat controller loses

the signal for the flywheel rpm sensor.
P-68137
The inability to unlock the traction lock (brake) is a
symptom of losing the flywheel rpm sensor signal. Not
being to read engine speed on the service tool or deluxe Turn the rpm sensor and the jam nut out from the
display panel is also a symptom of losing the flywheel flywheel. Set a clearance of 1,27 mm (0.050 in) between
rpm sensor signal the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Adjusting
NOTE: New rpm sensors have a plastic tip which is

Figure 60-170-1 used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 16 - 23

N•m (12 - 17 ft-lb) torque, while holding the sensor from
1 turning.
P-68136
When installing the rpm sensor, turn the rpm sensor

(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-170-1] until it

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the rpm sensor when the
sensor is turned back out for adjustment.


CONTROL PANEL SETUP
ICON DESCRIPTION
Right Panel Setup (Deluxe Instrumentation Panel) SET Set accepts current installed password.
Examples
Icon Identification
Figure 60-180-2
Figure 60-180-1
Press
TOOL / SETUP
SELECTION
EXAMPLE
BUTTONS
Press
B-16162
LOADER FEATURES
Make selection by pressing the SELECTION BUTTON

adjacent to the icon [Figure 60-180-1].

ICON DESCRIPTION
LOCK / UNLOCK: Allows machine to be Press
locked / unlocked. You must lock machine to
DISPLAY OPTIONS
activate security system.
When system is unlocked, the user can press
RUN / ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL / SETUP: Access system options.
Use to set clock, check system warnings,
select language, set passwords, etc.
Press
? HELP: Access help on current menu item.
ADJUST CONTRAST
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL / SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one screen.
OUTLINE ARROWS: No screen available Press
UP OR DOWN
(backward / forward). Arrow to
change
contrast
SELECTION ARROW: Use to select menu
item.
Press EXIT to
NEXT Goes to the NEXT screen in series. return to
EXAMPLE: the next Active Warning screen. previous level
menu
INFO Goes to more information about attachments.
B-16163/B-24288/B-16161A/B-16166/B-16167
YES / NO Answer yes / no to current setup question.
CLEAR Removes previously installed password.

CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Deluxe
Instrumentation Panel)
Right Panel Setup (Deluxe Instrumentation Panel)
(Cont’d) The Deluxe Instrumentation Panel allows the user to view
information concerning the operation of Bobcat
More Examples attachments.
Clocks Figure 60-180-3
Press . . .
TOOL / SETUP Press
LOADER FEATURES
TOOL / SETUP
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock. Press
Press EXIT to return to previous level menu.
LOADER FEATURES
RESET JOB CLOCK (Password required)
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK / UNLOCK to unlock.

Enter Password and press RUN / ENTER.
Press
Languages ATTACHMENTS
Press . . .
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES Press
Select the language, press RUN / ENTER. RUN / ENTER BUTTON
Press EXIT to return to previous level menu. on keypad
Vitals (Monitor the engine, hydraulic / hydrostatic,

electrical functions when engine is running.)
Press
UP OR DOWN
Press . . . Arrow to
TOOL / SETUP scroll through
LOADER FEATURES. attachments
VITALS
Press SELECTION ARROW to select METRIC or
ENGLISH (M / E) readouts
Press
the keypad number
You can monitor real-time readouts of: of a switch to view
Engine Oil Pressure a description of the
Engine Coolant Temperature attachment function
Hydraulic Charge Pressure of the switch
Hydraulic Oil Temperature
System Voltage B-16163/B-24288/B-16161A/B-15753A/B-15754A/B-15755A
Engine Speed
The Deluxe Instrumentation Panel is easy to use. Attachments are listed alphabetically [Figure 60-180-3].
Continue to set your own preferences for running / Press the exit button to return one screen or press the “0”
monitoring your Bobcat loader. (zero) key to return to the home screen immediately.

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-190-1
Password Setup is available on machines with a Deluxe
Instrumentation Panel.
Press TOOL / SETUP
Password Description
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start Press OWNER UTILITIES
the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Enter PASSWORD (owner or master)
Master Password: on Keypad
A permanent, randomly selected password set at the then press ENTER
factory which cannot be changed. This password is to Continue
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password. Press PASSWORD UTILITIES

Owner Password:
Allows for full use of the loader and to setup the
Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner Press MODIFY OWNER
or user passwords. Owner should change the
password as soon as possible for security of the
loader.
User Password:
Allows starting and operating the loader; cannot
change password or any of the other setup features. Enter new OWNER
PASSWORD on Keypad
For the procedures to change passwords (See Changing then press ENTER
The Owner Password on this page) (See Changing The to Continue
User Password on Page 60-190-2.)
Re-Enter new OWNER

PASSWORD on Keypad
then press ENTER
to Continue
OWNER PASSWORD procedure

is now complete
B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Password feature so that a password does not need to be used
every time the engine is started.
Figure 60-190-2
Figure 60-190-3
Press TOOL / SETUP
Press
LOCK / UNLOCK
Press OWNER UTILITIES
Enter PASSWORD (owner or master) Enter OWNER

on Keypad PASSWORD
then press ENTER on Keypad
to Continue then press ENTER
to Continue

Press PASSWORD UTILITIES
Press
Press MODIFY USER UNLOCK MACHINE
Enter USER number

on Keypad (There can be up to 8
different Users, each with their
own password)
then press ENTER to Continue
Press
EXIT
Enter USER PASSWORD
on Keypad
then press ENTER to Continue
Machine is now
USER PASSWORD procedure UNLOCKED and
is now complete. Enter can be started
another USER number without using a
password
OR
Press EXIT
B-16163/P-76075/P-76076/P-76076A/P-76077
B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Press the RUN button to turn on the loader electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-191-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
Press the RUN button to turn on the loader electrical

system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.

Figure 60-191-1
1 2
P-90816B
Press the unlock key (Item 2) [Figure 60-191-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2 The loader can now be started without using a password.
P-90816B NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds. Press the RUN button to turn on the loader electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.


MAINTENANCE CLOCK Figure 60-200-2
Description
The Maintenance Clock alerts the operator when the next

service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-200-1
2 1
P-76122
1
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.
3
This message will remain for 10 seconds before reverting
P-76461R back to the previous screen and will appear for 10
seconds every time the machine is started until the
maintenance clock is reset.
During machine operation, a two beep alarm will sound

when there are less than 10 hours until the next planned Figure 60-200-3
maintenance.
The remaining hours before maintenance is required will

appear in the data display (Item 1) for five seconds while
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-200-1] flash.
NOTE: The display will show negative numbers after

counting down to zero.
The display will then revert back to the previous display

and will appear for 5 seconds every time the machine is 1
started until the maintenance clock is reset. B-16163A
The Deluxe Instrumentation Panel, if equipped, will

display a wrench icon (Item 1) [Figure 60-200-3] alerting
the operator to service the machine. This icon will remain
on the display until the maintenance clock is reset.
NOTE: Loaders equipped with a Standard Key Panel

or Keyless Start Panel will not display the
BobCARESM PM message or wrench icon on
the right panel.

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.

Figure 60-200-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored. This will
be displayed on Deluxe Instrumentation Panel equipped
loaders when the maintenance clock is less than 10
hours until next planned maintenance.

Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]

message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
200-11] to reset and set the maintenance clock.

Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it can not be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
P-76455H
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.

Press and hold the information button (Item 2) for seven
seconds until [RESET] appears in the display screen
(Item 1) [Figure 60-200-16].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.


BACK-UP ALARM SYSTEM Figure 60-210-2
Description
The back-up alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the 1
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
Inspecting
Figure 60-210-1 2
P-69346
1
Inspect the back-up alarm electrical connections (Item 1)
[Figure 60-210-2], wire harness (Item 2) [Figure 60-210-
2] and back-up alarm switches (if equipped) (Item 2)
[Figure 60-210-3] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on Page 60-210-2.)

P-76108
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.

BACK-UP ALARM SYSTEM (CONT’D)
Adjusting Switch Position
NOTE: Joystick equipped machines do not have

back-up alarm switches and cannot be
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-210-3
Switch Rollers contacting Bellcranks

2 2
1 1

P-62915
Place the steering levers in the neutral position.
Loosen the screws (Item 1) [Figure 60-210-3] securing

the back-up alarm switches.
Position the back-up alarm switch rollers so that they just

make contact with bellcranks without compressing the
switch springs [Figure 60-210-3]. Torque the screws
(Item 1) [Figure 60-210-3] securing the switches to the
bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Lower the operator cab (See Lowering on Page 10-30-2.)

Inspect back-up alarm system for proper function. (See
Inspecting on Page 60-210-1.)

Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers in the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The alarm or back-up switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) in the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and can not be
Stop the engine and open the tailgate. adjusted.
Figure 60-210-4 Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-210-6
1
2 2
1 1
P-69346
Mark the wires for ease of assembly. Disconnect the

wires (Item 1) [Figure 60-210-5] from the alarm.

Installation: Make sure the wire harness ends do not P-62915
touch the mounting bolts during assembly.

Place the steering levers in the neutral position.
Figure 60-210-5
Loosen the screws (Item 1) securing the back-up alarm
switches. Slide the switch assemblies (Item 2) [Figure
60-210-6] off the mounting bracket.
1
1 Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjusting the switches (See
Adjusting Switch Position on Page 60-210-2.) and
inspecting back-up alarm operation (See Inspecting on
Page 60-210-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.

Switch Removal And Installation (Cont’d)
Figure 60-210-7
1
3
2
3
P-62917
Mark the wires for ease of assembly.

Disconnect the Orange wire from the common terminal
(Item 1) [Figure 60-210-7].
Disconnect the White wire from the normally open

terminal (Item 2) [Figure 60-210-7].
Disconnect the remaining White wires to the other switch

terminals (Item 3) [Figure 60-210-7].
Remove the switches.

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-16
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description
Hydraulic Fan Disassembly And Assembly
Blower Housing Removal And Installation
Fan Removal And Installation
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Description
Hydraulic Fan Disassembly And Assembly
Blower Housing Removal And Installation
Fan Removal And Installation
Hydraulic Fan Motor Removal And Installation
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-13
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-13
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-14
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-15

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Relief Valve - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-70-3
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18

Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-19
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm And Bridge Arm Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2



ENGINE INFORMATION
Description
The S185 has a Kubota direct injected V2607-DI-T turbo

diesel engine with a displacement of 2,6 L (158.7 in3).
The engine is rated at an SAE Net 43,3 kW (58 hp) and
has a closed crankcase ventilation system [Figure 70-
10-1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts. To meet
emission regulations it is also equipped with an Exhaust
Gas Recirculation (EGR) system to reduce Nitrogen
Oxide (NOx).
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic /
hydrostatic fluid temperature sensor.
Figure 70-10-1
P-85028

ENGINE INFORMATION (CONT'D)
Specifications
Fuel Injection Nozzles
Opening Pressure 18637 - 20098 kPa (186,4 - 201bar) (2703 - 2915 psi)
Fuel Tightness Nozzle Seat Dry Nozzle at 16672 kPa (166,7 bar) (2418 psi)
Fuel Injection Pump
Injection Timing 1.00° B.T.D.C. - 0.50° A.T.D.C.

(Engine S/N 8W0001 & Above)
0.50° B.T.D.C. - 1.00° A.T.D.C.
(Engine S/N 8G0001 - 8V9999)
High Idle 2760 - 2900 rpm
Low Idle 1175 - 1325 rpm
Cylinder Head
Cylinder Head Surface Distortion 0,05 mm (0.002 in) Maximum

Top Clearance (Piston to Head) 0,60 - 0,80 mm (0.024 - 0.031 in)

Compression 2199 kPa (32 bar) (464 psi)
Allowable Limit 2199 kPa (22 bar) (319 psi)
Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake And Exhaust) 3,3 - 3,6 mm (0.13 - 0.14 in)
Valve Seat Angle (Intake And Exhaust) 45 degrees
O.D. of Valve Stems (Intake) 5,968 - 5,980 mm (0.2350 - 0.2354 in)
O.D. of Valve Stems (Exhaust) 5,593 - 5,965 mm (0.2344 - 0.2348 in)
I.D. of Valve Guides (Intake And Exhaust) 6,010 - 6,025 mm (0.2367 - 0.2372 in)
Clearance Between Valve Stem And Guide (Intake) 0,030 - 0,0570 mm (0.0012 - 0.0022 in)
Allowable Limit 0,10 mm (0.0039 in)
Clearance Between Valve Stem And Guide (Exhaust) 0,045 - 0,072 mm (0.0018 - 0.0028 in)
Valve Clearance (Cold) 0,13 - 0,17 mm (0.0052 - 0.0068 in)
Valve Recessing (Intake And Exhaust) 0,65 - 0,85 mm (0.026 - 0.033 in)

ENGINE INFORMATION (CONT’D)
Specifications (Cont’d)
Valve Springs
Free Length (Intake and Exhaust) 35,4 - 35,9 mm (1.40 - 1.41 in)
Fitted Length (Intake and Exhaust) 29,7 mm (1.17 in)
Setting Load / Setting Length (Intake and Exhaust) 60,8 N / 29,7 mm (13.7 lb / 1.17 in)
Allowable Limit 45,9 N / 29,7 mm (10.3 lb / 1.17 in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 mm (0.039 in)
Valve Timing
Intake Valve (Open) 12 degrees B.T.D.C.

(Close) 44 degrees A.B.D.C.
Exhaust Valve (Open) 49 degrees B.B.D.C.
(Close) 17 degrees A.T.D.C.
Rocker Arms

O.D. of Rocker Arm Shaft 13,973 - 13,984 mm (0.5501 - 0.5506 in)
I.D. of Rocker Arm Bushings 14,0 - 14,018 mm (0.5512 - 0.5519 in)
Oil Clearance Between Rocker Arm And Bushing 0,016 - 0,045 mm (0.0006 - 0.0018 in)
Camshaft
Journal O.D. 1 34.934 - 34,950 mm (1.3754 - 1.3729 in)

Bearing I.D. 1 35,0 - 35,025 mm (1.3780 - 1.3789 in)
Journal O.D. 2 41,934 - 41,950 mm (1.6510 - 1.6515 in)
Bearing I.D. 2 42,000 - 42,025 mm (1.6536 - 1.6545 in)
Oil Clearance 0,050 - 0,091 mm (0.002 - 0.0035 in)
Alignment Allowable Limit 0,01 mm (0.0004 in)
Cam Lobe Height (Intake) 32,56 mm (1.282 in)
Allowable Limit (Intake) 32,10 mm (1.264 in)
Cam Lobe Height (Exhaust) 33,00 mm (1.299 in)
Allowable Limit (Exhaust) 32,50 mm (1.280 in)
Side Clearance Allowable Limit 0,10 mm (0.0039 in)
Tappet
Oil Clearance Between Tappet And Guide 0,020 - 0,050 mm (0.0079 - 0.0019 in)
Tappet O.D. 9,965 - 9,980 mm (0.3924 - 0.3929 in)
Tappet Guide I.D. 10,000 - 10,015 mm (0.39370 - 0.39429 in)

Cylinder Bore
Cylinder Bore I.D. 87,000 - 87,022 mm (3.4252 - 3.4260 in)

Oversized Cylinder Liner (Bore) I.D. 87,250 - 87,272 mm (3.3450 - 3.4359 in)
Piston Rings
Ring Gap (Top Ring) 0,20 - 0,35 mm (0.0079 - 0.013 in)

Ring Gap (2nd Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (Oil Ring) 0,25 - 0,45 mm (0.0099 - 0.017 in)
Side Clearance of Ring Groove:
Top Ring 0,050 - 0,090 mm (0.002 - 0.0035 in)

Second Ring 0,090 - 0,12 mm (0.0035 - 0.0047 in)
Oil Ring 0,020 - 0,060 mm (0.00079 - 0.0023 in)
Pistons
Piston Pin Bore 26,000 - 26,013 mm (1.0237 - 1.0241 in)

Connecting Rod
Piston Pin O.D. 26,006 - 26,011 mm (1.0239 - 1.0240 in)

Small End Bushing I.D. 26,025 - 26,040 mm (1.0246 - 1.0252 in)
Oil Clearance Between Piston Pin And Small End Bushing 0,014 - 0,034 mm (0.00056 - 0.0013 in)
Connecting Rod Alignment Allowable Limit 0,05 mm (0.002 in)
Oil Pump
Oil Pressure Rated RPM 193,1 - 393 kPa (1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (0,48 bar) (7 psi)
Clearance Between Inner Rotor And Outer Rotor 0,030 - 0,090 mm (0.0012 - 0.0035 in)
Clearance Between Outer Rotor And Pump Body 0,100 - 0,184 mm (0.00394 - 0.00724 in)
End Clearance Between Inner Rotor And Cover 0,025 - 0,075 mm (0.00099 - 0.0029 in)

Crankshaft
Crankshaft Alignment Limit Permitted 0,02 mm (0.00079 in)

Oil Clearance Between Journal And Bearing 0,03 - 0,051 mm (0.0012 - 0.0020 in)
Limit Permitted 0,020 mm (0.0079 in)
Journal O.D. 72,977 - 72,990 mm (2.8732 - 2.8736 in)
Oil Clearance Between Crank Pin And Bearing 0,011 - 0,058 mm (0.00044 - 0.0022 in)
Crank Pin O.D. 46.980 - 46.991 mm (1.8496 - 1.8500 in)
Crank Pin Bearing I.D. 47,0 - 47,046 mm (1.8504 - 1.8522 in)
Crankshaft Side Clearance 0,15 - 0,35 mm (0.0059 - 0.013 in)
Timing Gear
Timing Gear Backlash:

Crank Gear-Cam Gear 0,0400 - 0,137 mm (0.00158 - 0.0539 in)

Idle Gear-Cam Gear 0,0460 - 0,136 mm (0.00182 - 0.00535 in)
Idle Gear-Injection Pump Gear 0,0460 - 0,136 mm (0.00182 - 0.00535 in)
Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing: 0,025 - 0,096 mm (0.00099 - 0.0037 in)
Idle Gear Bushing I.D. 35,000 - 35,055 mm (1.3780 - 1.3801 in)
Idle Gear Shaft O.D. 34,959 - 34,975 mm (1.3764 - 1.3769 in)
Idle Gear Side Clearance 0,050 - 0,20 mm (0.0020 - 0.0078 in)
Thermostat
Valve Opening Temperature 80 - 84°C (176 - 183°F)

Valve Fully Open 95°C (203°F)

Torque Values
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most

common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.

17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

ENGINE INFORMATION (CONT’D) Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Engine Removal And Installation
Figure 70-10-2
DANGER 1
2
4
3
P-90328
AVOID DEATH

can cause lift arms to drop. Remove the nut from the speed control linkage (Item 1)
• Keep out of this area when lift arms are raised and the engine speed control cable adjustment nuts (Item
unless supported by an approved lift arm 2). Unplug the rear door harness connector (Item 3)

[Figure 70-10-2].
D-1009-0409
Remove the fuel fill bracket mounting screws (Item 4)

[Figure 70-10-2].
WARNING Installation: Tighten screws and nut to 20 - 27 N•m (15 -

20 ft-lb) torque.
Figure 70-10-3
W-2059-0598
Put jackstands under the rear corners of the loader.

2

Replacing Hydraulic Fluid on Page 10-120-2.) P-85024
Disconnect the steering linkage.

Remove the mounting screws (Item 1) to remove the oil
Remove the battery from the loader. (See Removal And filter drip shield (Item 2) [Figure 70-10-3].
Drain the engine coolant from the cooling system. (See torque.
Removing And Replacing Coolant on Page 10-90-3.)
Remove the air cleaner. (See Housing Removal And


ENGINE INFORMATION (CONT’D) Figure 70-10-6
Engine Removal And Installation (Cont'd)
Figure 70-10-4
2
1
1
2
P-85033
3
Remove battery cable bracket (Item 1) and disconnect
P-66871 engine ground cable (Item 2) [Figure 70-10-6].
Figure 70-10-7
Disconnect the temperature sender connector (Item 1)
[Figure 70-10-4] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 70-10-4]
for the differential pressure switch on the filter housing. 1

10-4].
Figure 70-10-5
P-85043
1
Disconnect the three main wiring connections (Item 1)
[Figure 70-10-7].
2
P-85048
Disconnect radiator hose (Item 1) and the coolant return

hose (Item 2) [Figure 70-10-5].

Figure 70-10-8
1
P-85040
Disconnect engine oil pressure sender connector (Item 1)

P-85032 [Figure 70-10-10].
Figure 70-10-11
Disconnect fuel line (Item 1) [Figure 70-10-8] for lift
pump.

Figure 70-10-9
1
P-85047
2 Disconnect and plug fuel return line (Item 1) [Figure 70-

P-85041 10-11].
Mark and disconnect fuel shut-off solenoid connector

(Item 1) [Figure 70-10-9].
Cut cable tie (Item 2) [Figure 70-10-9].

Figure 70-10-12
1
1
3
2
P-66882
Disconnect gear pump inlet hose (Item 1) [Figure 70-10-

14].
P-85049
Disconnect supply hose (Item 2) [Figure 70-10-14] from

Disconnect engine coolant hose (Item 1) [Figure 70-10- hydraulic fluid reservoir.
12].

Disconnect gear pump outlet hose (Item 3) [Figure 70-
Cap or plug all hoses and fittings. 10-14].
Figure 70-10-13 Cap or plug all hoses and fittings.
Figure 70-10-15
1
P-66881
P-66884
Disconnect drain hose (Item 1) [Figure 70-10-13] from
the hydraulic cooling fan.
Mark and disconnect the charge pump / fan filter outlet
Cap or plug all hoses and fittings. hose (Item 1) [Figure 70-10-15].
Cap or plug all hoses and fittings.

Figure 70-10-16 1
P-66885
Remove the mounting bolt and nut (Item 1) [Figure 70-

P-66886 10-18] from the right front engine mount.
Mark and disconnect the hydraulic fan motor inlet hose Installation: Tighten the mounting bolt to 95 N•m (70 ft-
(Item 1) [Figure 70-10-16]. lb) torque.
Cap or plug all hoses and fittings.

Figure 70-10-19
Figure 70-10-17
2
2 2
P-28231
1 1
P-28139
P-66883
Mark and disconnect the drive motor hoses (Item 1) Remove the mounting bolt (Item 1) [Figure 70-10-19]
[Figure 70-10-17]. and nut from the left front engine mount.
Cap or plug all hoses and fittings. Installation: Slide the engine mount slot (Item 2) [Figure
70-10-19] in between engine mount washer and nut.
NOTE: Due to the left drive motor hoses orientation,
Tighten the mounting bolt to 95 N•m (70 ft-lb) torque.
hoses may not be completely removed from
fittings until the engine and pump are partially
NOTE: To aid in the removal of the left front engine
removed.
mount bolt, remove the control panel. (See
Installation: Install the left drive motor hoses prior to Removal And Installation on Page 50-100-2.)
alignment with engine mount bolts.
Use 12,7 mm (0.5 in) drive impact wrench, with
NOTE: The hydraulic fittings (Item 2) [Figure 70-10- a 304,8 mm (12 in) extension, on a 19,05 mm
17] on the hydrostatic pump must be (0.75 in) flex socket.
tightened to 156 - 170 N•m (115 - 125 ft-lb)
torque. Removal will be accomplished by reaching under
the hydraulic reservoir to the engine mount bolt.

13”
Figure 70-10-20 2.5”
1-1/2” I.S. Dia.

2-1/2” O.S. Dia.
2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset
1”
16”
4”
2”
P-48583
45° 9”
1”
10-20] from the right rear engine mount.

4”
Installation: Tighten the mounting bolt to 95 N•m (70 ft- 2”
lb) torque.
1”
.5”
Figure 70-10-21
.375”
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine / hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
1
dimensions shown in [Figure 70-10-22] to make the
engine removal tool.
P-66887

10-21] from the left rear engine mount.
Installation: Tighten the mounting bolt to 95 N•m (70 ft-

lb) torque.

Figure 70-10-23
1
1 P-85046
Install the chain hoist on the eyelet [Figure 70-10-25] of

P-48594
the removal tool.
Fasten a chain to other end of the removal tool with two

Fasten securely one end of the chain to the lifting eye bolts as shown in (Item 1) [Figure 70-10-25].
(Item 1) [Figure 70-10-23].

Figure 70-10-24 the loader.
Reverse the removal procedure to install the engine.
P-48592
Fasten securely one end of the chain to the other lifting

eye (Item 1) [Figure 70-10-24].
NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
reach the correct lifting position.

Engine Mount Replacement

Engine
Figure 70-10-26 Mounting
Washer Bracket
1
2
Loader
3 Frame Engine
Mount
4
5 Snubbing Spacer
Washer
MC-1765A
6
7 Install the new engine mount as shown in the cut away

MC-1771A side view [Figure 70-10-27].
Tighten the mounting bolts to 95 N•m (70 ft-lb) torque.

Use the following procedure to install new engine
mounts:

Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts two front and two rear.
Use the parts shown to install the new engine mounts

[Figure 70-10-26]:
Square Nut - (Item 1) - Used on left side engine mounts
Hex Nut - (Item 2) - Used on right side engine mounts
Mount Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Snubbing Washer - (Item 6)
Mounting Bolt - (Item 7)

ENGINE INFORMATION (CONT’D) Disconnect the fuel stop solenoid.
Compression - Checking Crank the engine with the starter cranking rpm.
Figure 70-10-28 If the measurement is below the allowable limit, check the
cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 3199,2 kPa (32 bar)

(464 psi)
1 Allowable Limit (minimum) is 2199,4 kPa (22 bar) (319

psi)
No more than 10% variance among cylinders.
Figure 70-10-30
P-85050

procedure:

10630 - Engine Compression Kit
1655 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plugs - Testing on

Page 70-80-1.)
P-85051
Install the correct compression adapter (Item 1) [Figure

70-10-28] into the cylinder head. Push the button on the compression gauge to release
pressure [Figure 70-10-30].
Figure 70-10-29
Connect the fuel stop solenoid.
P-85052
Connect the compression gauge to the adapter [Figure

70-10-29].
Make sure the engine speed control is fully backward

(engine idle).

ENGINE SPEED CONTROL Raise the operator cab. (See Raising on Page 10-30-1.)
Removal And Installation Remove the two mounting screws (Item 1) [Figure 70-
20-1] from the speed control mounting bracket.

DANGER torque.
Installation: Tighten the mounting bolts (Item 1) [Figure

70-20-1] evenly until the speed control lever moves back
and forth at a comfortable tension.
Figure 70-20-2
P-90328
AVOID DEATH
D-1009-0409 1

P-4072
WARNING Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [Figure 70-20-
Never work on a machine with the lift arms up unless 2] from the control.
support device. Failure to use an approved lift arm Installation: Be sure to install the speed control rod in
support device can allow the lift arms or attachment the bottom hole of the speed control lever.
W-2059-0598 Figure 70-20-3
Figure 70-20-1
1 1
P-34156
Installation: Install the stop bracket (Item 1) [Figure 70-

P-68555A
20-3] in the same location. It is necessary for the front
and rear stop on the bracket to be located correctly.
Raise the lift arms and install an approved lift arm device.
(See Installing on Page 10-20-1.) Reverse the removal procedure to install the engine
speed control.


ENGINE SPEED CONTROL (SJC) Figure 70-21-3

Figure 70-21-1
P-64313
Disconnect the foot speed control linkage (Item 1)

[Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

1

P-64300

from the right side foot rest.
Remove the foot rest, from the loader.
Figure 70-21-2
P-34545
Loosen the two lower access panel mount screws (Item

1) [Figure 70-21-2].
Remove the upper mount screw (Item 2) [Figure 70-21-

2].

torque.

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6

1
Figure 70-21-4 2 4 4
6
1 3 5 3
P-34654
The parts that go into the pivot arm (Item 1) are the bolt
P-34550 (Item 2), washers (Items 3), fiber washers (Items 4),
spacer (Item 5) and nut (Item 6) [Figure 70-21-6].
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.

Figure 70-21-5
1
1
P-34548
P-34549 Remove the two screws (Item 1) [Figure 70-21-7] from

the hand speed control lever assembly.
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
that attaches the pivot arm to the speed control cable. torque.
Remove the speed control pivot arm from the loader.

ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 70-21-10
Figure 70-21-8
P-64305
P-34551
foot speed control assembly.
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader. Figure 70-21-11

Slide the hand speed control lever (Item 1) [Figure 70-
21-8] forward and lift, and disconnect the assembly from
the speed control cable.
Figure 70-21-9
P-64305A
2
Remove the bushing / nut (Item 1) [Figure 70-21-11]
from the pedal lever.
P-34553A
Installation: When installing the hand speed control to

the speed control cable, be sure the speed control lever
(Item 1) fits in the notch (Item 2) [Figure 70-21-9] of the
speed control rod clevis.

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
P-34657 the speed control.
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing / nut.

Remove the foot pedal lever (Item 2) and linkage rod
(Item 3) [Figure 70-21-12].
Figure 70-21-13
P-64307
1
The pivot assembly shown disassembled [Figure 70-21-

15].
NOTE: No lubrication is necessary or recommended

P-34658 on the engine speed control.
Reverse the disassembly procedure to assemble the

Remove the fiber washer (Item 1) and washer (Item 2) (SJC) speed control.
[Figure 70-21-13] from the pivot bolt.

MUFFLER
Figure 70-30-1
3 2
3

P-85053
Open the rear door and raise the rear grille.
Remove the exhaust pipe clamp (Item 1) from the muffler

(Item 2) [Figure 70-30-1].
Disconnect the exhaust pipe from the muffler.
Remove both muffler mounting bolts (Item 3) [Figure 70-

30-1] from the muffler.
Installation: Tighten the muffler mounting bolts to 34 - 38

Remove the muffler from the loader.
Reverse the removal procedure to install the engine

muffler.


AIR CLEANER Figure 70-40-3
Figure 70-40-1
1 1
2
2
P-28915
Remove the lower mounting screw (Item 1) and engine

P-48893 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Installation: Tighten the mounting screw to 20 - 27 N•m
70-40-1] from the air cleaner sensor on the air cleaner. (15 - 20 ft-lb) torque.

Loosen the clamp (Item 2) [Figure 70-40-1] from the Remove the air cleaner from the engine compartment.
hose on the engine manifold.
Reverse the removal procedure to install the air cleaner.
Figure 70-40-2
2
1
P-34450
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.

40-2] from the top mount of the air cleaner.

torque.


ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation

1
Remove the rear grille. (See Removal And Installation on
Page 50-60-1.)
Remove the oil cooler. (See Removal And Installation on

Page 20-100-1.)
WARNING
P-85055
AVOID BURNS
Do not remove radiator cap when the engine is hot. Remove drain plug (Item 1) [Figure 70-50-2] on the
You can be seriously burned. engine block and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1

1
1
P-48242
P-45245
Remove the two sta-straps (Item 1) [Figure 70-50-3]

Loosen the radiator cap (Item 1) [Figure 70-50-1] from holding the pressurized expansion tank fill hose (Item 3)
the pressurized expansion tank. [Figure 70-50-4].

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4
1
1
3
2
2
P-48570
P-48554

P-45245 the inlet hose.
Remove the radiator mounting bolt and block off plate

Remove the two pressurized expansion tank mounting (Item 2) [Figure 70-50-6].

Installation: Tighten the radiator mounting bolt to 15 - 17
Disconnect the pressurized expansion tank fill hose (Item N•m (11 - 13 ft-lb) torque. Use sealant on the block off
3) [Figure 70-50-4] at the radiator end. plate and bolt head (Item 2) [Figure 70-50-6].
Remove the pressurized expansion tank (Item 2) with the

pressurized expansion tank fill hose (Item 3) attached.
[Figure 70-50-4].
Figure 70-50-5
P-48552

the outlet hose.

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-8
Radiator Removal And Installation (Cont'd)
Figure 70-50-7
2 P-48841
1
Remove the hydraulic fill tube (Item 1) [Figure 70-50-8].
P-48553
Lift the radiator up and remove it from the loader.
Remove the clamp (Item 1) [Figure 70-50-7] from the Reverse the above procedure to install the radiator.
hydraulic fill tube.

Remove the radiator mounting bolt (Item 2) [Figure 70-
50-7].
Installation: Tighten the radiator mounting bolt to 15 - 17

Remove the two hydraulic fill tube mounting screws (Item

3) [Figure 70-50-7].

torque.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly (S/N
Hydraulic Fan Description (S/N A3L929999 & Below
And A3LH29999 & Below) Figure 70-50-9
The hydraulic fan is used to cool the engine and hydraulic

/ hydrostatic systems. The hydraulic fan consist of a fan
and hydraulic motor that is controlled by a proportioning 2
valve.
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field. The
adjustment screw is sealed with a tamper 1
evident white material, if this screw has been P-68126
adjusted the proportioning valve must be
replaced.
NOTE: The seals, O-rings and coil nut on the
If the flow from the proportioning valve is proportioning valve (Item 1) are available by
determined inaccurate it must be replaced ordering from Bobcat Service Parts. The fan

with a new one from Bobcat Service Parts. motor (Item 2) [Figure 70-50-9] must be
replaced as an assembly if damaged.
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpm)
can range from 0 - 4000 rpm.
The hydraulic fan speed at cold engine startup will range

from 0 - 500 rpm until the engine coolant and the
hydraulic fluid reach basic operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 - 3500 rpm.

ENGINE COOLING SYSTEM (CONT'D) Remove the fan motor / charge pump filter housing. (See
Charge Filter Housing Removal And Installation on Page
Blower Housing Removal And Installation (S/N 20-80-3.)
Figure 70-50-10
DANGER
1
P-90328
AVOID DEATH

can cause lift arms to drop. Remove cable ties (Item 1) [Figure 70-50-10] attached to
• Keep out of this area when lift arms are raised blower housing.

support. Replace if damaged. Figure 70-50-11
D-1009-0409
1 2
WARNING
4
W-2059-0598 3
P-66610
IMPORTANT Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-50-11].
clean the work area before disassembly and keep all Remove the fan case drain hose (Item 3) [Figure 70-50-
parts clean. Always use caps and plugs on hoses, 11].
damage the system. Disconnect the electrical connector (Item 4) [Figure 70-
I-2003-0888 50-11].

Raise the operator cab.(See Raising on Page 10-30-1.)

ENGINE COOLING SYSTEM (CONT’D)
Blower Housing Removal And Installation (Cont’d) (S/

N A3L929999 & Below And A3LH29999 & Below)
Figure 70-50-12
2
P-66611
Remove the four mounting bolts (Item 1) and (Item 2) and

spacer tubes. The only visible spacers are on the outside
two mounting bolts (Item 2) [Figure 70-50-12].
NOTE: Remove the two rear mounting bolts first.
Figure 70-50-13
P-66649
NOTE: The picture shows the blower housing and fan

assembly removed. Two of the mounting
bolts (Item 2) [Figure 70-50-12] have clips
(Item 1) [Figure 70-50-13] to hold the bolts
from falling out during installation of the
blower housing and fan together.
Remove the blower housing from the loader.
Reverse the removal procedure to install the blower

housing.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Removal And Installation (S/N
Fan Removal And Installation (S/N A3L929999 &
Below And A3LH29999 & Below) Figure 70-50-16
Figure 70-50-14
1 1
P-54421A
P-54418
To remove the blower housing mounting plate, remove
Remove the lock nut and spacer (Item 1) [Figure 70-50- the two bolts (Item 1) [Figure 70-50-16].
14].

torque.
Figure 70-50-15
1
P-54419
Use the following procedure to remove the fan from the

shaft:
Install the nut (Item 1) [Figure 70-50-15] on the tapered

shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-50-15].
As the center bolt (Item 2) [Figure 70-50-15] is tightened,

periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-

15].

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly (S/N
Hydraulic Fan Description (S/N A3L930001 & Above
And A3LH30001 & Above) Figure 70-50-17
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from both the engine 4
and hydraulic temperature sensors.
The hydraulic fan is used to cool the engine and hydraulic 3

/ hydrostatic systems. The hydraulic fan consists of a fan
and hydraulic motor that is controlled by a proportioning
valve.
2
NOTE: The proportioning valve is factory set and can
not be adjusted accurately in the field due to
the adjustment being tamper proof.
1
P-76714A
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpm) NOTE: The mounting gasket (Item 1), proportioning
can range from 0 - 4000 rpm. valve, and proportioning valve O-rings, back
up washer and coil mounting nut (Item 2) are

The hydraulic fan speed at cold engine startup will range available from Bobcat Parts. The fan motor
from 0 - 500 rpm until the engine coolant and the (Item 3) [Figure 70-50-17] must be replaced as
hydraulic fluid reach normal operating temperatures. an assembly if damaged.
During normal operating temperatures the fan speed may Remove the filter cover (Item 4) [Figure 70-50-17].
range from approximately 1900 - 3500 rpm.
Installation: Tighten filter cover (Item 4) [Figure 70-50-
17] to 47,5 - 54 N•m (35 - 40 ft-lb) torque.
Figure 70-50-18
P-76715A

ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-21
Hydraulic Fan Disassembly And Assembly (S/N

(Cont’d)
Figure 70-50-19
1
4
3
P-76717
2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 21].
P-76716A Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-21] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.

Remove coil mounting nut (Item 1), the coil (Item 2), and Figure 70-50-22
the coil valve stem (Item 3) [Figure 70-50-19].
NOTE: Coil mounting nut must be replaced each time

it is removed. Coil mounting nuts are
available from Bobcat Parts.
Installation: Install coil mounting nut with the

counterbored space (Item 4) [Figure 70-50-19] facing
towards the coil and tighten securely by hand.
Installation: Tighten coil valve stem (Item 3) [Figure 70- 1

50-19] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Figure 70-50-20
P-76726
1
Inspect and replace the O-ring (Item 1) [Figure 70-50-
22] if necessary.
P-76637
Inspect and replace O-rings (Item 1) and back up washer

(Item 2) [Figure 70-50-20] if necessary.

ENGINE COOLING SYSTEM (CONT’D) Remove the hydraulic fluid reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Blower Housing Removal And Installation (S/N
A3L930001 & Above And A3LH30001 & Above) Figure 70-50-23
2 4
DANGER
P-67080
1
P-90328
AVOID DEATH 3

can cause lift arms to drop. Remove cable ties (Item 1) [Figure 70-50-23] attached to
• Keep out of this area when lift arms are raised blower housing.

Disconnect and plug the heater hoses (Item 2) [Figure
D-1009-0409
70-50-23].
Disconnect the cab harness connector (Item 3) [Figure

70-50-23].
WARNING Remove the sealant between the blower housing and the
loader frame (Item 4) [Figure 70-50-23].
the lift arms are secured by an approved lift arm Figure 70-50-24
W-2059-0598
IMPORTANT 1

5
damage the system. 2 P-82656
I-2003-0888
Disconnect the two electrical connectors (Item 1) [Figure

Raise the lift arms and install an approved lift arm 70-50-24].
Remove and cap the case drain hose (Item 2) and fan
Raise the operator cab.(See Raising on Page 10-30-1.) inlet hose (Item 3) [Figure 70-50-24].
Remove the fan motor / charge pump filter housing. (See
Remove and cap the fan outlet hose (Item 4) and the pilot
Charge Filter Housing Removal And Installation on Page
pressure hose (Item 5) [Figure 70-50-24].
20-80-3.)

ENGINE COOLING SYSTEM (CONT’D) Reverse the removal procedure to install the blower
housing.
Blower Housing Removal And Installation (Cont’d) (S/
N A3L930001 & Above And A3LH30001 & Above) Figure 70-50-27
Figure 70-50-25
1 2
2 1
1
2
P-76698
P-85630B
After the blower housing is installed, apply a bead of
polyurethane caulk sealant (P/N 6633583) between the
NOTE: Remove the two rear mounting bolts first. front edge (Item 1) of the crossmember and blower

housing (Item 2) [Figure 70-50-27] directly in front of the
Remove the four mounting bolts (Item 1 and Item 2) and inlet opening only.
spacer tubes. The only visible spacer tubes are on the
outside of the blower housing using mounting bolts (Item
2) [Figure 70-50-25].
Figure 70-50-26
P-66649
NOTE: The picture shows the blower housing and fan

assembly removed from the loader. Two of
the mounting bolts (Item 1) [Figure 70-50-25]
have clips (Item 1) [Figure 70-50-26] to hold
the bolts from falling out during factory
installation of the blower housing and fan
together. The clips will fall during the removal
of the fan motor assembly bolts.
Remove the blower housing from the loader.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Removal And Installation (S/N
Fan Removal And Installation (S/N A3L930001 &
Above And A3LH30001 & Above) Figure 70-50-30
Figure 70-50-28
1 1
1
P-82657
P-54418
Remove bolts (Item 1) [Figure 70-50-30] nuts, washers,
cotter pins and rubber gasket and discard.
Remove the lock nut (Item 1) and spacer (Item 2) [Figure
70-50-28].

Reverse removal procedure for installation.
torque. Figure 70-50-31
Figure 70-50-29
1
5 5
2
3
4 4
2
2
P-76699
1
P-54419
Installation: Always install new hydraulic fan rubber
mounting gasket (Item 1), bolts (Item 2), nuts (Item 3),
Use the following procedure to remove the fan from the
thick washers (Item 4) and cotter pins (Item 5). Torque
shaft:
fan motor mounting bolts and nuts to 6,78 - 12,20 N•m (5
Install the nut (Item 1) [Figure 70-50-29] on the tapered - 9 ft-lb). Install cotter pins (Item 5) [Figure 70-50-31] and
shaft to protect the shaft and threads. spread cotter pin ends.
Install the puller on the fan as shown [Figure 70-50-29].
As the center bolt (Item 2) [Figure 70-50-29] is tightened,

periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-

29].

ENGINE COOLING SYSTEM (CONT'D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-33
Drain the cooling system.
Remove the alternator belt.
Remove the water pump bolts. 2

1
Figure 70-50-32
3
4
P-90019
Remove the flange (Item 1) [Figure 70-50-33].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-33] out the impeller side of the water pump.

P-90018 Remove the impeller (Item 3) [Figure 70-50-33] from the
shaft.
Remove the water pump [Figure 70-50-32]. Remove the seal (Item 4) [Figure 70-50-33].
Installation: Always use a new gasket when installing Install a new seal (Item 4) [Figure 70-50-33] when
the water pump. assembling the water pump.

Thermostat Housing Removal And Installation
Figure 70-50-34
7 4

5
6
P-90166
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-34].
Remove bolts (Item 5), housing (Item 6), and gasket

(Item 7) from the cylinder head [Figure 70-50-34].

Thermostat - Checking
Figure 70-50-35
P-37172
Push down the thermostat valve and insert a string

between the valve and the valve seat.

Place the thermostat and a thermometer in a container
with water and gradually heat the water [Figure 70-50-
35].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory spec. 80 - 84°C

opening 176 - 183°F
temperature
Temperature at Factory spec. 95°C
which thermostat 203°F
completely opens


LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Figure 70-60-3
Remove the engine and hydrostatic pump assembly from

Page 70-10-8.)
The engine will have to be on an engine stand or

suspended in the air safely to remove the oil pan.
Figure 70-60-1
1
2
1
P-85061
Remove the bolts from the front cover / oil pump (Item 1)
[Figure 70-60-3].
Installation: Use a liquid gasket adhesive.Tighten the

front cover / oil pump mounting bolts to 24 - 27 N•m (18 -
20 ft-lb) torque.
P-85062
Remove oil pan bolts (Item 1) securing oil pan (Item 2)

[Figure 70-60-2]. Slightly tapping on the oil pan with a
soft mallet will break loose the oil pan from the engine
block.
Installation: Use a liquid gasket adhesive to the oil pan

side of the oil pan gasket. Tighten oil pan bolts to 18 - 20
Figure 70-60-2
2
1
P-85056
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.

LUBRICATION SYSTEM (CONT’D) Remove oil pump cover screws. Measure the clearance
between the lobes of the inner rotor and outer rotor
Relief Valve - Testing [Figure 70-60-5].
Figure 70-60-4 Installation: Tighten cover screws to 7,9 - 9,3 N•m (5.8 -
6.8 ft-lb)
Clearance 0,030 - 0,090 mm

Between Inner & (0.0012 - 0.0035 in)
Outer Rotor
Allowable limit 0,30 mm (0.012 in)
If the clearance exceeds the allowable limit, replace the

oil pump.
Figure 70-60-6
1
2
4
3 P-85057
Remove the relief valve retaining screw (Item 1) from the

front cover / oil pump (Item 2) and remove the relief valve

spring (Item 3) and relief valve (Item 4) [Figure 70-60-4].
Measure free length of relief valve spring (Item 3) [Figure

70-60-4] and check the entire surface of spring for any
scratches. Replace if out of spec or any scratches.
Free Length 60,0 - 60,5 mm

P-85059
(2.37 - 2.38 in)
Measure the clearance between the outer rotor and
Installation: Tighten relief valve retaining screw (Item 1) pump body [Figure 70-60-6].
[Figure 70-60-4] 69 - 78 N•m (51 - 57 ft-lb) torque.
Clearance 0,100 - 0,184 mm
Oil Pump Inspection Between Outer (0.00394 - 0.00724 in)
Rotor & Body
Figure 70-60-5 Allowable limit 0,30 mm (0.012 in)

oil pump.
P-85058

LUBRICATION SYSTEM (CONT’D) Oil Filter Cooler Removal And Installation
Oil Pump Inspection (Cont’d) Figure 70-60-8
Figure 70-60-7
1
3
2
P-85072
P-85060
Remove the cooling hose’s (Item 1) [Figure 70-60-8].
Put a piece of plastic gauge on the rotor face [Figure 70- Remove oil filter cartridge (Item 2) and the oil cooler joint
60-7]. screw (Item 3) [Figure 70-60-8].

Install the cover and tighten the bolts. Remove oil cooler (Item 4) [Figure 70-60-8].
Remove the cover carefully. Measure the width of the Installation: Tighten oil cooler joint screw (Item 3)
press gauge [Figure 70-60-7]. [Figure 70-60-8] 64 - 73 N•m (47 - 54 ft-lb) torque.
If the clearance exceeds the allowable limit replace the oil

pump.
End Clearance 0,25 - 0,75 mm

(0.00099 - 0.0029 in)

LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-9
PI-10010

Install a pressure gauge [Figure 70-60-9].
Start the engine and run until it is at operating

temperature.
If the oil pressure is less than the allowable limit, check

the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable 48,3 kPa (0,48 bar) (7 psi)

Limit
At Rated Speed 193,1 - 393 kPa
(1,9 - 3,9 bar)
(28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)

FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Checking Figure 70-70-3
Figure 70-70-1
1
1
P-85078
P-85078
Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].

Disconnect the connector (Item 1) [Figure 70-70-1] from Figure 70-70-4
the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2 1
P-85077
Remove the mounting screws (Item 1) [Figure 70-70-4]

of the fuel shutoff solenoid.
P-85083
Reverse the above procedure to install the fuel shutoff
solenoid.
The reading between electrical connector terminal C and
terminal A must be between approximately 0.33 ohm
[Figure 70-70-2].
The reading between electrical connector terminal C and

terminal B must be between approximately 24.5 ohm.

Fuel Injection Pump - Checking
The injection pump contains parts which have a very

close tolerance and its operation has a direct effect on
the performance of the engine.
1
WARNING
B-8235
not use your bare hand. Wear safety goggles. If fluid Connect the adapter fuel line (Item 1) to the fitting and
enters skin or eyes, get immediate medical attention connect the pressure gauge (Item 2) [Figure 70-70-5].
W-2072-0807
Move the speed control lever to the high engine idle
position.

procedure: Turn the flywheel to increase the pressure. If the pressure
can not reach the allowable limit, replace the injection
1237 - Adapter Fuel Line pump assembly.
1173-1 Pressure Gauge
Fuel Tightness of Pump 18630 kPa
To check the discharge pressure at the fuel injection Element Allowable Limit (186,3 bar)
pump, use the following procedure: (2702 psi)
Disconnect a high pressure fuel line from the injection With the speed control lever at the low engine idle
pump. Loosen the other end of the same fuel line so it position, turn the flywheel until the pressure is at 18630
can be turned away from the fitting. kPa (186,3 bar) (2702 psi).
Installation: Tighten the injection pipe retaining nut to 23 Turn the flywheel back approximately one-half turn. Keep
- 36 N•m (17 - 26 ft-lb) torque. the flywheel at this position, and measure the time it
takes the pressure to decrease from 17651 kPa (176,5
bar) (2560 psi).
Fuel Tightness of Delivery 5 Seconds

Valve Allowable Limit

Fuel Injection Pump Assembly Removal And

Installation
Remove the alternator. (See Removal And Installation on

Page 60-30-5.)
Figure 70-70-6 2
1
P-85082
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-7] from the injection pump
vent.
Cap the inlets on the injection pump vent where the

P-85085 hoses were removed [Figure 70-70-7].

Figure 70-70-8
Clean the area around the injection pump thoroughly.
Disconnect the high pressure fuel lines (Item 1) [Figure

70-70-6] from the fuel injectors.
Installation: Tighten the injection pipe retaining nut to 23

- 36 N•m (17 - 26 ft-lb) torque. 2
1
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. P-85082
I-2029-0289
Remove the high pressure fuel lines (Item 1) [Figure 70-

70-8] from the injection pump.
Installation: Tighten the injection pipe retaining nut to 23

- 36 N•m (17 - 26 ft-lb) torque.
Remove the engine speed control linkage (Item 2)

[Figure 70-70-8].


Installation (Cont'd)
M8 X 1.25
5,0 mm
Figure 70-70-9 5,0 mm (0.20 in) (0.20 in) dia
0,79 rad (45°)
1
10 mm (0.39 in) 4,0 mm (0.16 in)
45 mm (1.8 in)
P-85091
Construct two fuel camshaft lock screws as shown above

[Figure 70-70-11]
P-85095
Figure 70-70-12
Remove the window cover for the fuel injection pump

assembly (Item 1) [Figure 70-70-9] from the flywheel
housing. 1
Figure 70-70-10
P-85095
Remove the two plugs (Item 1) [Figure 70-70-12].
Installation: Tighten the plugs to 9,81 - 11,2 N•m (7.24 -

P-85094 8.31 ft-lb) torque.
Place the number four piston at top dead center on the

compression stroke and lock the flywheel in place using
the flywheel stopper tool as described below.
Look for the alignment mark on the idler gear and

injection pump gear (Item 1) [Figure 70-70-10] then
using a white marking pen or the like put a alignment
mark to help reassemble these gears in mesh later.
NOTE: When the already existing marks align with

each other, there is no need to put another
alignment mark.

FUEL SYSTEM (CONT’D) Installation: Tighten the injection pump mounting nuts to
18 - 20 N•m (13 - 15 ft-lb) torque.
Installation (Cont'd) Figure 70-70-15
Figure 70-70-13
2
1
P-85095
P-85090
Remove injection pump support (Item 1) [Figure 70-70-
15].
Install one lock tool in the upper plug opening (Item 1)

and tighten until it comes in contact with the fuel Remove injection pump assembly (Item 2) [Figure 70-
camshaft. Make sure the fuel camshaft is not moving. 70-15].
Install second lock tool in lower opening (Item 1) [Figure
70-70-13] and repeat the process. Installation: Reverse procedure to install.
NOTE: Do not over tighten the lock screws after they

have contacted the fuel camshaft. Otherwise
the injection pump may become damaged.
Figure 70-70-14
P-85093
Remove the lubricating oil pipe (Item 1) [Figure 70-70-

14].
Remove the three injection pump mounting nuts (Item 2)

[Figure 70-70-14]
Installation: Tighten the lubricating oil pipe to 16 - 19


FUEL SYSTEM (CONT’D)
Governor Housing Disassembly And Assembly
The governor serves to keep the engine speed constant Jig for Governor Connecting Rod
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the engine load. Application: Use this for connecting the governor
connecting rod to the rack pin of the fuel injection pump
Disassemble and assemble the governor and fuel assembly.
camshaft as shown in figure.
A 0,50 mm (0.020 in)
Check all the parts for wear or damage and replace as B 12,7 - 13,0 mm (0.500 - 0.511 in)
needed. C 8,70 - 9,00 mm (0.343 - 0.354 in)
D 39 mm dia. (1.54 in dia.)
Figure 70-70-16 E 10,0 mm (0.394 in)
F 7,0 mm (0.28 in)
G 6,0 mm (0.24 in)
H 80,0 mm (3.15 in)
I 27,95 - 28,05 mm (1.101 - 1.104 in)
J 5,0 mm (0.20 in)
K 3,000 - 3,010 mm dia, 6,0 mm depth
(0.1182 - 0.1185 in dia, 0.24 in depth)
L 9,0 mm (0.35 in)
M 5,0 mm (0.020 in)

N 14,45 - 14,55 mm (0.5689 - 0.5728 in)
O 5,0 mm (0.020 in)
P 4,0 mm (0.16 in)
Q 2,955 - 2,965 mm dia.
(0.1164 - 0.1167 in dia.)
R 3,020 - 3,030 mm dia.
(0.1189 - 0.1192 in dia.)
S Ra = 1.6a
P-85182
AA Governor housing side
BB Press in side
a 0,60 mm radius (0.024 in radius)
b 1,0 mm radius (0.039 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.4 Chamfer 0,40 mm (0.016 in)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in)
(Item 1) [Figure 70-70-16] Material: S43C-D

(Item 2) [Figure 70-70-16] Permanent Magnet: 8 mm dia.
(0.31 in dia.) Thickness: 3 mm (0.12 in)

FUEL SYSTEM (CONT’D) NOTE: Be careful not to drop the nut inside.
Governor Housing Disassembly And Assembly NOTE: (See Fuel Injection Pump Removal And
(Cont’d) Installation on Page 70-70-12.) for proper
alignment of the governor connection rod
Figure 70-70-17 procedure. The procedure will require a
special tool as shown on page 70-70-6.
3 2 1
Figure 70-70-19
P-85095
Remove the fuel injection pump assembly. (See Fuel

Injection Pump Assembly Removal And Installation on P-85100

Page 70-70-3.).
Slide off the governor connecting rod (Item 1) [Figure 70-
Remove the governor lubricating pipe (Item 1) [Figure 70-19] from the rack pin of injection pump assembly.
70-70-17].
For convenient sake, temporarily hook the start spring on
Remove the stop solenoid (Item 2) [Figure 70-70-17]. the rack pin hole of the governor connecting rod.
Remove the sight cover (Item 3) [Figure 70-70-17] from Remove the governor housing mounting bolts.
the injection pump unit.
Installation: Tighten the governor housing bolts to 9,81 -
11,2 N•m (7.24 - 8.31 ft-lb) torque.
Figure 70-70-18
Figure 70-70-20
2
1
1
3
P-85099
P-85097
Unhook the start spring (Item 1) from the rack pin (Item
2) [Figure 70-70-18] of injection pump assembly. Remove the governor housing assembly (Item 1) [Figure
70-70-20] from the injection pump unit.
Remove the nut (Item 3) [Figure 70-70-18].
NOTE: The injection pump unit is lubricated with
Installation: Reverse procedure to install. Tighten the engine oil. Oil will leak when the governor
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque. housing is removed from the injection pump.

Governor Disassembly And Assembly
Figure 70-70-21
1
1
2
P-85189
Remove the governor fork lever assembly (Item 1) from

P-85101 the housing [Figure 70-70-23].
Figure 70-70-24
Remove the governor fork shaft lever (Item 1) using a bolt
4 mm dia. (0.16 in dia.), pitch 0,7 mm (0.03 in) at least a

inch long (Item 2) [Figure 70-70-21].
NOTE: When assembling the inside parts, lightly put 3

oil on each inside part.
Figure 70-70-22 2
1 2
P-85190
Remove the spring pin (Item 1), then remove speed

control lever (Item 2) and the return spring (Item 3)
[Figure 70-70-24].
P-85188
Unhook the governor spring (Item 1) at the fork lever

(Item 2) [Figure 70-70-22].

FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly (Cont’d)
Figure 70-70-25
P-85192
Remove the start spring (Item 1) [Figure 70-70-25] from

the governor housing.

After reassembling the governor housing assembly,
check the movement of the governor fork lever (Item 2)
[Figure 70-70-22], the speed control lever (Item 2)
[Figure 70-70-24], stop lever (not shown), governor
spring (Item 1) [Figure 70-70-22] and governor fork lever
shaft (Item 1) [Figure 70-70-21].
NOTE: When assembling the inside parts, lightly put

oil on each inside part.
NOTE: Be careful not to deform the start spring.
Installation: Reverse procedure to assemble and install.

Fuel Camshaft Removal And Installation
Remove the fuel injection pump assembly. (See Fuel

Injection Pump Removal And Installation on Page 70-70-
12.)
Remove the fuel injection pump unit. (See Fuel Injection

Pump Removal And Installation on Page 70-70-12.)
WARNING
P-85123
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and
A M35 x P1.5, 6,0 mm depth (0.24 in depth)
clothing. Failure to wear eye and body protection can
result in serious injury. B 35,0 mm dia.,12,0 mm depth
W-2009-1285 (1.38 in dia., 0.472 in depth)
C 30,0 mm dia.,27,5 mm depth
(1.18 in dia., 1.08 in depth)
D 40,00 - 40,20 mm dia. (1.575 - 1.582 in dia.)

E 35,90 - 36,10 mm dia.(1.414 - 1.421 in dia.)
F 2.09 rad (120°)
G M8 x P1.25
H 9,0 mm dia. (0.35 in dia.)
I 19,0 mm dia. (0.748 in dia.)
J 12,0 mm (0.472 in)
K 15,0 mm (0.591 in)
L 27,5 mm (1.08 in)
M 31,0 mm (1.22 in)
N 57,5 mm (2,26 in)
O 100 mm (3,94 in)
P 3,75 - 4,00 mm (0.148 - 0.157 in)
Q 16,17 mm (0.6366 in)
a 5,0 mm radius (0.20 in radius)
b 0,40 mm radius (0.016 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.5 Chamfer 0,50 mm (0.020 in)
To remove and replace the fuel camshaft, make the tool

as shown in figure [Figure 70-70-26].

FUEL SYSTEM (CONT'D) F 16,0 mm dia. (0.630 in dia.)
Fuel Camshaft Removal And Installation (Cont’d) G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
Figure 70-70-27
I 16,0 mm (0.630 in)
Figure 70-70-29
2
1
2
P-85186A
1
Remove the governor sleeve (Item 1) and remove the two P-85183
fuel camshaft lock allen screws (Item 2) [Figure 70-70-

27]. Install injection pump housing to the engine and tighten.
Fix the flywheel with the flywheel stop tool (Item 1)
NOTE: Do not use the fuel camshaft locks screws [Figure 70-70-29].
when removing governor weight, otherwise
damage may occur to the allen screws or the Loosen the injection pump gear mounting nut (Item 2)
governor housing. [Figure 70-70-29].
Figure 70-70-28 Installation: Tighten injection pump gear mounting nut to

93,2 - 102 N•m (68.8 - 75.9 ft-lb).
NOTE: The injection pump gear mounting nut is a left

hand thread to loosen turn towards B and to
tighten turn towards A as seen from the
flywheel side
Figure 70-70-30
P-85215 2
Make flywheel stop tool as shown above in [Figure 70-

70-28].
A 144 mm (5.67 in)

B 104 mm (4.09 in)
P-85121
C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
Remove the fuel injection pump gear (Item 1) using the
E 12,0 mm dia. (0.472 in dia.)
tool (Item 2) [Figure 70-70-30].

FUEL SYSTEM (CONT’D) Fuel Injection Pump Removal And Installation
Fuel Camshaft Removal And Installation (Cont’d) Figure 70-70-33
Figure 70-70-31
2
2
1
3
1
3 P-85199
P-85122
Remove all injection pipes (Item 1) [Figure 70-70-33].
Loosen fuel camshaft stopper mounting bolts (Item 1)
and remove camshaft stopper (Item 2) [Figure 70-70- Remove overflow hose (Item 2) [Figure 70-70-33].
31].

Remove fuel stop solenoid (Item 3) [Figure 70-70-33].
Installation: Tighten fuel camshaft stopper mounting
bolts to 9,81 - 11,2 N•m (7.24 - 8.37 ft-lb). Remove sight cover from housing (Item 4) [Figure 70-70-
33].
NOTE: When reassembling fuel camshaft stopper
make sure the oil path hole (Item 3) [Figure 70- NOTE: The injection pump can be removed and
70-31] is the proper alignment. installed with the crankshaft at any position.
Figure 70-70-32 Figure 70-70-34
3 1
1
2
2
P-85120 P-85099
Remove fuel camshaft (Item 1), then remove fuel Unhook the start spring (Item 1) from the rack pin (Item
camshaft stopper bearing screws (Item 2) [Figure 70-70- 2) [Figure 70-70-34] of injection pump assembly.
32].
Remove the nut (Item 3) [Figure 70-70-34].
If replacing the fuel camshaft bearings tighten the fuel
camshaft stopper bearing plate screws (item 2) [Figure Installation: Reverse procedure to install. Tighten the
70-70-32] to 3,9 - 4,2 N•m (2.9 - 3.1 ft-lb) torque. nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
Installation: Reverse procedure to assemble and install. NOTE: Be careful not to drop the nut inside.

Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-35
1
2
P-85200
Remove the fuel injection pump (Item 1) [Figure 70-70-

37].
Installation: Reverse procedure to install. Tighten the

P-85100
bolts to 24 - 27 N•m (18 - 20 ft-lb) torque.Tighten nuts to
18 - 20 N•m (13 - 15 ft-lb)
Slide off the governor connecting rod (Item 1) [Figure 70-

70-35] from the rack pin of injection pump assembly. Remove top cover (Item 2) [Figure 70-70-37] for
adjusting the governor connecting rod.
For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod. Figure 70-70-38
Figure 70-70-36 4
1 2
3 5
1 P-85203
Hook the governor connecting rod (Item 1) to the rack pin

P-85198 (Item 2) and hand tighten the nut (Item 3) [Figure 70-70-
38].
Remove all of the mounting bolts and nuts (Item 1) Place service jig (Item 4) (Refer to page 70-70-6) in place
[Figure 70-70-36] from the fuel injection pump. of top cover and make sure the magnet is contacting the
governor connecting rod (Item 1) [Figure 70-70-38].
Remove the rear stud closest to the intake manifold. Holding down the service jig tighten the nut to specified
torque.
Hook starter spring (Item 5) to rack pin (Item 2) [Figure
70-70-38].
Installation: Tighten the nut (Item 3) [Figure 70-70-38]
to 2,9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: A = 27,95 - 28,05 mm (1.100 - 1.104 in)

Fuel Injection Pump - Timing
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Remove the drive belt cover.
Remove the engine speed sensor. P-85104
Remove the fuel injection high pressure lines.

Rotate the flywheel counterclockwise (viewed from the
Installation: Tighten the fuel injection high pressure lines flywheel side) [Figure 70-70-40] until fuel fills up to the
to 28 N•m (21 ft-lb) torque. hole of the number one cylinder delivery valve holder
(Item 1) [Figure 70-70-41].
Remove the fuel shutoff solenoid. (See Fuel Shutoff
Solenoid Removal And Installation on Page 70-70-1.) Figure 70-70-41

Figure 70-70-39
2
1
C-85098
2
P-85102
After fuel fills up the hole of the number one cylinder
delivery valve holder (Item 1) [Figure 70-70-41], turn
A timing mark (Item 1) [Figure 70-70-39] is stamped at back the flywheel clockwise approximately 1,6 rad (90°).
the injection pump and flywheel housing parting line
during engine manufacture. Verify the mark is aligned NOTE: A small clear clean plastic tube that fits
before proceeding. If necessary, loosen the three securely in holder port can be inserted and
injection pump mounting bolts (Item 2) [Figure 70-70-39] marked to provide an easier visual indicator
and align the mark. of the fuel level and when it changes.
NOTE: The third injection pump mounting bolt is

located behind the pump.
NOTE: Timing the injection pump is done by rotating

the injection pump assembly upward for
advance, downward for retard.

FUEL SYSTEM (CONT’D) NOTE: If the injection pump timing is not within the
specification, then rotate the injection pump
Injection Pump - Timing (Cont’d) assembly upwards to advance, or downwards
to retard the injection pump timing. Rotating
Figure 70-70-42 the pump 0,64 mm (0.025 in) is equal to
approximately 1 degree.
The table below lists the fuel timing specification, based

on the engine serial number.
1 KUBOTA V2607T RANGE SETTING

ENGINE S/N 1.00° B.T.D.C. 1.00° B.T.D.C.
8W0001 & Above TO
0.50° A.T.D.C
ENGINE S/N 0.50° B.T.D.C. 0.50° B.T.D.C.
8G0001 - 8V9999 TO
1.00° A.T.D.C.
P-90908
NOTE: Set the timing to the advanced end of the

Next turn the flywheel counterclockwise to 0,17 rad (10°) specification range [Figure 70-70-44]. An
before top dead center (Item 1) [Figure 70-70-42]. engine timed after top dead center will exhibit
long cranking times on initial startup in cold

Then slowly turn the flywheel counterclockwise and stop temperatures.
turning when the fuel just begins to come up the holder
(Item 2) [Figure 70-70-41] to get the present injection Figure 70-70-44
timing.
FLYWHEEL MARKS B.T.D.C.
Figure 70-70-43
10
8W0001 & Above
1 TC
1 8G0001 - 8V9999
A.T.D.C.
When timing is correct tighten the three injection pump

P-90909
mounting bolts to 19 N•m (14 ft-lb) torque.
Check the degree marks on the flywheel. The flywheel

has a 1TC mark (Item 1) [Figure 70-70-43] that indicates
top dead center for cylinder number one. Each mark on
the flywheel is 2 degrees.

FUEL SYSTEM (CONT’D) Remove the glow plugs. (See Glow Plugs Removal And
Fuel Injector Removal And Installation
Remove the cylinder head valve cover (See Cylinder
Head Removal And Installation on Page 70-80-4.)

W-2072-0807
IMPORTANT P-85117

Do not bend the high pressure fuel injection tubes Remove the overflow pipe (Item 1) [Figure 70-70-46].
when removing or installing them.
I-2029-0289
Installation: Tighten the overflow pipe assembly
retaining screws to 9,81 - 11,2 N•m (7.24 - 8.31 ft-lb)
Figure 70-70-45 torque.
Figure 70-70-47
P-85085
P-85118
The following are some problems caused by faulty
injectors:
Remove the nozzle holder clamps (Item 1) [Figure 70-
-Engine is hard to start or will not start 70-47].
-Rough engine operation and idle
-Engine will not have full power Installation: Tighten the nozzle holder clamp screws to
-Excessive exhaust smoke 24 - 27 N•m (18 - 20 ft-lb) torque.
Disconnect the high pressure fuel lines (Item 1) [Figure

70-70-45] from the fuel injectors and from the injection
pump.
Remove the high pressure fuel lines from the engine.

FUEL SYSTEM (CONT’D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) The tools listed below will be needed to do the following
procedures:
Figure 70-70-48
4200 - Injector Nozzle Tester
4201 - Injector Nozzle Tester Adapter Set
Figure 70-70-50
1
P-85119
Remove the injector nozzle (Item 1) [Figure 70-70-48]

from the cylinder head.
3EEABAC1P012A

Pull on the injector nozzle to remove the injector nozzle
from the cylinder head. Install the injection nozzle assembly onto the nozzle
tester [Figure 70-70-50] and check the nozzle spraying
Figure 70-70-49 condition.
Slowly move the tester handle to measure the pressure

at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

1 specifications, replace or repair the injection nozzle
2
assembly.
NOTE: Injection nozzle gasket must be replaced

when the injection nozzle is removed for
checking.
Injection Fac- 18637 - 20098 kPa

pressure tory (186,4 - 201 bar)
P-37583 spec. (2703 - 2915 psi)
[Figure 70-70-49] shows the injector nozzle removed

from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) before installing new or
used injectors. [Figure 70-70-49].

FUEL SYSTEM (CONT’D) Valve Seat Tightness
Nozzle Spray Condition The tools listed below will be needed to do the following
procedure:
The tools listed below will be needed to do the following
procedure: 4200 - Injector Nozzle Tester
4201 - Injector Nozzle Tester Adapter Set
4200 - Injector Nozzle Tester
4201 - Injector Nozzle Tester Adapter Set Figure 70-70-52
Figure 70-70-51
Correct Incorrect
3EEABAC1P014A

3EEABAC1P013A
Install the injection nozzle assembly onto a nozzle tester
[Figure 70-70-52].
Install the injection nozzle assembly onto a nozzle tester
[Figure 70-70-51], and check the nozzle spraying Raise the fuel pressure, and keep at 16672 kPa (166,7
condition. bar) (2418 psi) for 10 seconds.
If the spraying condition is defective, replace or repair the If any fuel leak is found, replace or repair the injection
injection nozzle assembly. nozzle assembly.
Valve seat tightness Factory spec No fuel leak at

16672 kPa
(166,7 bar)
(2418 psi)

CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-3
Figure 70-80-1 1 2
1 2
3
P-85178
P-85178
Disconnect the negative (-) cable from the battery.
Disconnect the negative (-) cable from the battery. Remove the nut (Item 1) from the top of each glow plug
[Figure 70-80-3].
Disconnect the glow plug nuts (Item 1), remove glow plug

connecting strap (Item 2) and glow plugs (Item 3) [Figure
Remove the glow plug connecting strap (Item 2) [Figure
70-80-1].
70-80-3].
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque. Loosen and remove the glow plug (Item 3) [Figure 70-
80-3].
Figure 70-80-2
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
2
Figure 70-80-4
3
P-85179
Touch one probe to the end of the glow plug (Item 1) and
the other probe to the body of glow plug (Item 2) [Figure
70-80-2]. P-85179
Use an ohmmeter to check the glow plugs.The resistance

NOTE: Adjust the direction of the ditch (Item 1)
should be approximately one ohm.
[Figure 70-80-4] to the terminal side when the
Repeat the procedure for each glow plug. seal is installed on the glow plug.
NOTE: Adjust the direction of the ditch (Item 3)

[Figure 70-80-2] to the terminal side when the
seal is installed on the glow plug.

CYLINDER HEAD (CONT'D) Valve Clearance Adjustment
Glow Plugs Removal And Installation (Cont’d) Figure 70-80-6
Figure 70-80-5
2
1
3
P-85181
P-48708
Adjust the valve clearance as follows:
Photo [Figure 70-80-5] shows the glow plug removed Loosen the lock nut (Item 1) [Figure 70-80-6].
from the engine. Inspect the glow plugs and replace

when necessary. Turn the adjustment screw (Item 2) [Figure 70-80-6] until
the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and bridge head (Item 3) [Figure
70-80-6].

CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7 3
4
1
4 3 2 1
B 8 7 6 5 4 3 2 1 A
P-85071
B-05569
NOTE: (A) is the front cover side, (B) is the flywheel Remove the engine / hydrostatic pump package from the
housing side. loader. (See Engine Removal And Installation on Page

70-10-8.)
Figure 70-80-8
Remove the flywheel. (See Flywheel Removal And
Cylinder Number 1 2 3 4
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
Valve Number 1 2 3 4 5 6 7 8
Make sure timing marks are in correct alignment [Figure
70-80-9].
Valve Injection Pump Gear (Item 1) [Figure 70-80-9].

I=Intake I E I E I E I E
E=Exhaust Idle Gear (Item 2) [Figure 70-80-9].
Crank Gear (Item 3) [Figure 70-80-9].
Cam Gear (Item 4) [Figure 70-80-9].

Adjust the valve clearance as follows:
0,13 - 0,17 mm (0.0052 - 0.0066 in) Intake And

Exhaust
Use the following sequence to set the valves [Figure 70-

80-7] and [Figure 70-80-8]:
1. With the No. 1 cylinder set at compression top dead

center set valves 1,2,3 and 6.
2. With the No. 1 cylinder at overlap position set valves

4,5,7 and 8.

CYLINDER HEAD (CONT'D) Installation: Tighten overflow pipe to 9,81 - 11,2 N•m (7 -
8 ft-lb) torque.
Cylinder Head Removal And Installation
Figure 70-80-12
Figure 70-80-10
4 2 1
1
3
P-85118
P-85174
Remove the nozzle holder clamps (Item 1) [Figure 70-

Remove the glow plug connecting strap (Item 1), glow 80-12].
plugs (Item 2), and injection pipes (Item 3) [Figure 70-

80-10]. Installation: Tighten the nozzle holder clamp bolts to 24
- 27 N•m (18 - 20 ft-lb) torque.
Remove the valve cover (Item 4) [Figure 70-80-10] and
gasket. Figure 70-80-13
Installation: Gradually tighten the valve cover bolts to

9,81 - 11,2 N•m (7 - 8 ft-lb) torque. Tighten center bolts
first, then work your way to the front and back of the valve
cover.
1
Installation: Tighten injection pipe retaining nuts to 23 -
Installation: Tighten glow plugs to 7,7 - 9,3 N•m (5.7 -

6.8 ft-lb) torque.
Figure 70-80-11
P-85119
1
Remove the nozzle holder assembles and nozzle

gaskets (Item 1) [Figure 70-80-12].
Installation: Tighten the nozzle holder clamp bolts to 24

- 27 N•m (18 - 20 ft-lb) torque.
P-85117
Remove the overflow pipe (Item 1) [Figure 70-80-11].

CYLINDER HEAD (CONT'D) Figure 70-80-16
Cylinder Head Removal And Installation (Cont'd) 1

2
Figure 70-80-14
1 2
P-85170
Remove the thermostat housing bolts and then remove

P-85115 the housing (Item 1), gasket (Item 2) and thermostat
(Item 3) [Figure 70-80-16].
Remove rocker arm assembly (Item 1)[Figure 70-80-14] Figure 70-80-17

as a unit.

Remove push rods (Item 2) and bridge arms (Item 3)
[Figure 70-80-14].
Figure 70-80-15
P-85168
Remove the cylinder head bolts in order of #10 to #1

[Figure 70-80-17].
P-47245 NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Installation: The push rod (Item 1) must be seated in the Installation: Put oil on the bolt threads. Tighten the bolts
tappet (Item 2) [Figure 70-80-15] correctly or the push in the correct sequence in order of #1 - #10 to 147 - 156
rods will be damaged. N•m (109 - 115 ft-lb).
After installing the rocker arm assembly and push rods, NOTE: It is not necessary to retighten the cylinder
the valve lash must be adjusted. (See Valve Clearance head bolts after the engine has been run for 30
Adjustment on Page 70-80-2.) minutes.

Cylinder Head Removal And Installation (Cont'd) 1
Figure 70-80-18
2 P-47252
Find the average measurement of the highest piston

protrusion and the lowest piston protrusion (recorded
earlier) for each piston (Item 1) [Figure 70-80-20].
P-85171
Figure 70-80-21
Remove the cylinder head (Item 1) and gasket (Item 2) 1

[Figure 70-80-18].

Figure 70-80-19
2
1
P-85166
A B
When identifying which head gasket you need the (Item
1) [Figure 70-80-21] shows the correct number of
dimples and how they should look (a) 2 dimples, (b) 1
dimple and (c) no dimples.
P-85169
Figure 70-80-22
Gasket Size
When replacing just the head gasket (Item 1), use a new Piston Protrusion
(Number)
gasket that has the same mark (Item 2) [Figure 70-80-
19] as the original gasket. 2 dimples 0,250 - 0,350 mm
0.00985 - 0.0137 in
When replacing the gasket after an engine rebuild, the 0,350 - 0,450 mm
1 dimple
piston protrusion must be measured. 0.0138 - 0.0177 in
no dimples 0,450 - 0,550 mm
(See Cylinder Head Top Clearance on Page 70-80-8.) 0.0178 - 0.0216 in
NOTE: (A) is the front cover side, (B) is the flywheel

housing side. Select the correct gasket size (thickness) from the chart
[Figure 70-80-22].
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.

CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-23 Figure 70-80-25
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-25] on the
spring [Figure 70-80-23]. cylinder head.

Figure 70-80-24 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-25] between

the straight edge and the surface of the cylinder head.
Figure 70-80-26
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 70-80-23] and [Figure 70-80-24].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-23] and [Figure 70-80-24].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-23] and [Figure 70-80-24]. and two diagonal as shown in figure [Figure 70-80-26].
The maximum distortion of the head surface is ± 0,05

mm (± 0.002 in). If the measurement exceeds the
specification, replace the cylinder head.

CYLINDER HEAD (CONT'D) Remove the solder (Item 1) [Figure 70-80-28] and
measure it.
Cylinder Head Top Clearance
If the measurement exceeds the specifications, check the
Figure 70-80-27 oil clearance of the crank pin journal or the piston pin.
Top Clearance 0,6 - 0,8 mm (0.024 - 0.031 in)

2
Valve Guide - Checking
1 Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
70-80-7.)
Remove the carbon from the valve guide.
Figure 70-80-29
P-85172 1
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-27] being checked at T.D.C.

Put 4 pieces of 1,5 mm (0.06 in) diameter solder (Item 2)
[Figure 70-80-27] on the top of the piston. Use grease to
hold them in position. 2
NOTE: Put the solder in position so they do not touch

the valves.
B-14335
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque Measure the valve stem O.D. (Item 1) [Figure 70-80-29].
in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-80-4.) Measure the valve guide I.D. (Item 2) [Figure 70-80-29].
Turn the crankshaft until the piston exceeds T.D.C. Calculate the clearance. If the clearance exceeds the
Remove the cylinder head. allowable limit, replace the valve and / or valve guide.
Figure 70-80-28
Valve Guide I.D. 6,010 - 6,025 mm
(0.2367 - 0.2372 in)
Valve Stem O.D. 5,968 - 5,980 mm
(0.2350 - 0.2354 in)
Clearance Between 0,030 - 0,057 mm
Valve Stem and Guide (0.0012 - 0.0022 in)
Allowable Limit 0,10 mm
(0.0039 in)
P-85173

CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide Removal And Installation Figure 70-80-32
Figure 70-80-30
220 mm (8.66”)
20 mm 80 mm (3.1”) 40 mm
(0.787”) (1.6”)
9,960-9,980 mm
(0.3922-0.3929”) 5,50-5,70 mm
(0.217-0.224”)
5,0 mm 6,90-7,10 mm 18,0 mm
(0.2”) (0.272-0.279”) (0.71”)
6,0-6,10 mm 25,0 mm PI-9993

10,6-10,7 mm
(0.237-0.240”) (0.98”) (0.418-0.421”)
MC-1364
Grind the valve face to the correct angle using a valve
refacer [Figure 70-80-32].
To remove and replace the valve guide, make the driver
tools as shown in figure [Figure 70-80-30]. Clean the valve seat and combustion chamber.

Figure 70-80-31 Figure 70-80-33
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-31]. recessing with a depth gauge [Figure 70-80-33].
Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-31], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

Reconditioning The Valve And Valve Seat (Cont’d) 1

30° Exhaust
Figure 70-80-34 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-36].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-34].
If the seat surface (b) needs correction, slightly correct

the seat using a 45 degree cutter and then resurface the
Recessing 0,65 - 0,85 mm
seat surface with a 15 degree cutter to get the correct
(0.026 - 0.85 in)
width (Item 2) [Figure 70-80-36].
Allowable Limit (Recessing) 1,20 mm (0.0472 in)
Valve Seat Width
Figure 70-80-35
Intake & Exhaust 3,3 - 3,6 mm
(0.13 - 0.14 in)
Valve Seat And Face Angle
Intake 45°
Exhaust 45°
45° Exhaust
15° Exhaust 45° Intake
15° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-35].

Valve Spring
Figure 70-80-37
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-38].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the

spring [Figure 70-80-37]. Setting Length 29,7 mm (1.17 in)
Setting Load 60,8 N (13.7 lb)
Free Length 35,4 - 35,9 mm (1.40 - 1.41 in)
Allowable Limit 100,0 N (22.5 lb)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-37].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 1,0 mm (0.039 in)

Valve Tappets
Remove the oil pan and oil pump strainer. (See Oil Pan
Remove the idler gear and camshaft. (See Idler Gear
And Camshaft Removal And Installation on Page 70-100-
5.)
1
Figure 70-80-39
1
P-85175
Measure the OD of the tappet (Item 1) [Figure 70-80-41].

tappets.
Tappet OD 9,965 - 9,980mm

(0.3924 - 0.3929 in)
P-85141 Clearance
Between Tappet 0,02 - 0,06 mm
Turn engine with the crankshaft facing up and remove the and Tappet Bore (0.0008 - 0.0024 in)
valve tappets (Item 1) [Figure 70-80-39]. Allowable limit 0,07 mm (0.0028 in)
Figure 70-80-40
P-85142
Measure the ID of the tappet bore (Item 1) [Figure 70-

80-40].
Tappet Bore ID 10,000 -10,015mm

(0.39370 - 0.39429 in)
Clearance
Between Tappet 0,020 - 0,050 mm
and Tappet Bore (0.00079 - 0.0019 in)

CYLINDER HEAD (CONT'D) Bridge Arm And Bridge Arm Shaft - Checking
Rocker Arm And Shaft - Checking Figure 70-80-43
Figure 70-80-42
1
2
P-85177
Measure the bridge arm ID (Item 1) [Figure 70-80-43].
B-3697 If the clearance exceeds the allowable limit, replace the

bridge arm (Item 1) [Figure 70-80-43].
Measure the rocker arm I.D. (Item 1) [Figure 70-80-42]
Bridge arm ID. 8,050 - 8,080 mm
with an inside micrometer.
(0.3170 - 0.3181 in)

Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
80-42] with an outside micrometer. Figure 70-80-44

bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between 0,016 - 0,045 mm

Rocker Arm & Shaft (0.00063 - 0.0017 in)
(0.0059 in)
Rocker Arm Shaft O.D. 13,973 - 13,984 mm
(0.55012 - 0.55055 in)
1
Rocker Arm I.D. 14,0 - 14,018 mm P-85176
(0.55119 - 0.55188 in)
Measure the bridge arm shaft OD (Item 1) [Figure 70-80-

44].

bridge arm shaft (item 1) [Figure 70-80-44].
Oil Clearance 0,018 - 0,057 mm

between Bridge arm (0.0.00071 - 0.0022 in)
and Bridge arm shaft.
Bridge arm shaft OD. 8,023 - 8,8032 mm
(0.3159 - 0.3162 in)

CYLINDER HEAD (CONT'D) e 5,0 mm radius (0.20 in radius)
Bridge Arm Shaft Removal And Installation f under 0,30 mm radius (0.012 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
Figure 70-80-45
Figure 70-80-46
1
1
2
P-85219
Make bridge arm shaft replacement tool as shown above

(Item 1) intake side and (Item 2) is exhaust side [Figure 3

70-80-45]. 1 P-85221
A 170 mm (6.69 in)

Remove the used bridge arm shaft (Item 1), then clean
B 40,0 mm (1.57 in) bridge arm shaft mounting hole. Apply an anaerobic
C 25,0 mm (0.984 in) sealant to the tip of the bridge arm shaft. Intake side
D 105 mm (4.13 in) (Item 2) and exhaust side (Item 3) [Figure 70-80-46].
E 25,0 mm (0.984 in) Figure 70-80-47

F 10,0 mm (0.394 in)
G 3,0 mm (0.12 in)
H 0,35 rad. (20°) 1
I 18,45 - 18,55 mm (0.7264 - 0.7303 in)
J 20,95 - 21,05 mm (0.8248 - 0.8287 in)
K 17,057 - 17,084 mm dia.
(0.67154 - 0.67259 in dia.)
L 16,0 mm dia. (0.630 india)
M 35,0 mm dia. (1.38 in dia.)
N 60,0 mm dia. (2.36 in dia.)
O SR 50,0 mm (1.97 in)
P 8,10 - 8,15 mm dia. (0.319 - 0.320 in dia.) P-85220
Q 16,4 - 16,6 mm (0.646 - 0.653 in)

R 25,0 mm (0.984 in) Install bridge arm shaft using the tool (Item 1) [Figure
70-80-47] to the proper depth in [Figure 70-80-48].
S 70,0 mm (2.76 in) Knurled
T 10,0 mm (0.394 in)
a Ra = 6.3 a
b Ra = 1.6 a
c Ra = 3.2 a
d 0,50 mm radius (0.020 in radius)

CYLINDER HEAD (CONT'D) Push Rod Alignment - Checking
Bridge Arm Shaft Removal And Installation (Cont’d) Figure 70-80-49
Figure 70-80-48
P-76926
P-85223
Place the push rod on V blocks [Figure 70-80-49].
Set the depth of the bridge arm shaft (Item 1) to 31,30 - Measure the push rod alignment [Figure 70-80-49].
31,70 mm (1.233 - 1.248 in), (Item 2) shaft hole is

through to the coolant passage and (Item 3) is not If the push rod exceeds the allowable limit, replace the
[Figure 70-80-48]. push rod.
Push Rod Allowable Limit 0,25 mm

Alignment (0.0098 in)


CRANKSHAFT AND PISTONS Figure 70-90-3
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

1
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan and oil pump strainer. (See Oil Pan
Figure 70-90-1
P-85143
1 Remove the connecting rod bolts (Item 1) [Figure 70-90-

3].
NOTE: Mark the location of the rod bearings to

prevent them from becoming interchanged.

Installation: Tighten the connecting rod bolts to 44 - 49
Installation: Apply engine oil to the connecting rod bolts

and lightly screw in by hand.
P-85141
Installation: Install the rod bearing with the centrally
lined groove towards the connecting rod, and the non
Figure 70-90-2 grooved side towards the cap.
Top View of Crankcase
Installation: Make sure the marks on the connecting rod
and bearing are aligned and facing the injection pump
when installing the bearing cap.
P-85142
Remove the tappet (Item 1) [Figure 70-90-1] from the

tappet bore (Item 2) [Figure 70-90-2] using a magnetic
tool.
Installation: Apply engine oil to the tappet during

installation.
NOTE: Mark the location of the tappets to prevent

them from becoming interchanged.

CRANKSHAFT AND PISTONS (CONT’D) Piston And Connecting Rod - Servicing
Piston And Connecting Rod Removal And Figure 70-90-6

1
Figure 70-90-4
P-85145
P-51633 Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2) [Figure 70-
90-6].
Use a hammer handle and push the piston / connecting

rod assembly out of the cylinder bore [Figure 70-90-4]. NOTE: Assemble the piston to the connecting rod
with the mark (Item 2) and the connecting rod
NOTE: Make sure the pistons are marked so they will mark (Item 1) [Figure 70-90-6] facing the
be returned to the same cylinder bore. injection pump side.
Figure 70-90-5
P-85144
Installation: Make sure the marks on the connecting rod

and bearing (Item 1) [Figure 70-90-5] are aligned and
facing the injection pump when installing the bearing cap.
Repeat the procedure to remove the other piston /

connecting rod assemblies from the engine block.

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-8
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-7 2
1 2 3 4 5 6
1
3
7
4 PI-10015
Installation: When installing new rings, assemble the

P-85146 ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
Remove the top ring (Item 1), the second ring (Item 2) 3) [Figure 70-90-8].
and the oil ring (Item 3) [Figure 70-90-7].

Figure 70-90-9
Remove the snap rings (Item 4) and piston pin (Item 7)
[Figure 70-90-7].
Separate the piston (Item 5) from the connecting rod

(Item 6) [Figure 70-90-7].
Installation: Heat the piston in clean engine oil to 80°C

(176°F) and tap the piston pin into position. Place the
piston rings so that there are gaps every 120 degrees
with no gap facing the piston pin in the cylinder.
NOTE: Mark the piston (Item 5) and connecting rod

(Item 6) [Figure 70-90-7] with the same
number to ensure correct installation and
proper cylinder placement. P-47272
Measure the I.D. of the piston pin bore in both horizontal

and vertical directions [Figure 70-90-9].
If the measurement exceeds the allowable limit, replace

the piston.
Piston Bore I.D. 26,0 - 26,013 mm

(1.0237 - 1.0241 in)
(1.026 in)

Figure 70-90-10
P-47273
Measure the O.D. of the piston pin (Item 1) [Figure 70-

90-10].

P-85147
Measure the I.D. of the connecting rod small end bushing
(Item 2) [Figure 70-90-10]. To replace the connecting rod small end bushing, make a
driver tool as shown in figure [Figure 70-90-11].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the Shaft Material: SS400 (Item 1) [Figure 70-90-11].
specifications, replace the piston pin. Guide Material: STKM12A (Item 2) [Figure 70-90-11]
Piston Pin O.D. 26,006 - 26,011 mm A 140 mm (5.51 in)

(1.0239 - 1.0240 in) B 27,2 - 27,5 mm (1.07 - 1.08 in)
Bushing I.D. 26,025 - 26,040 mm C 75 mm (2.95 in)
(1.0246 - 1.0252 in) D 20 mm (0.787 in)
Oil Clearance Between 0,014 - 0,034 mm E 0,52 rad (30 degrees)
Piston Pin & Bushing (0.00056 - 0.0013 in) F 25,967 - 25,980 mm dia.
Allowable Limit 0,15 mm (1.0224 - 1.0228 in dia.)
(0.0059 in) G 34 mm dia. (1.34 in dia.)
H 2 mm (0.079 in)
I 0,35 rad (20 degrees)
J 2,5 mm (0.098 in)
K 0,15 - 0,25 mm (0.0059 - 0.0098 in)
L 0,35 rad (20 degrees)
M 1,0 mm (0.039 in)
N 14,5 mm (0.571 in)
O 1,0 mm (0.039 in)
P 0,35 rad (20 degrees)
Q 26 - 26,021 mm (1.0237 - 1.0244 in)
R 28,9 - 28,950 mm (1.1378 - 1.1397 in)
a Ra=3.2a
b Ra=1.6a
c 1 mm radius (0.039 in radius)
C0.3 Chamfer 0,3 mm (0.012 in)
C1 Chamfer 1 mm (0.039 in)

Figure 70-90-12
B-3622
Install a piston ring into the lower part of the cylinder

PI-10016 bore. Measure the ring gap with a feeler gauge [Figure
70-90-13].
Use a press and special driver tool to remove the small
If the gap exceeds the allowable limit, replace the ring.
end bushing [Figure 70-90-12].

Top Ring Gap 0,2 - 0,35 mm
Installation: Clean the small end bushing and bore. Put
(0.0079 - 0.013 in)
oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-12]. Oil Ring Gap 0,25 - 0,45 mm
(0.0099 - 0.017 in)
(0.0492 in)
Second Ring Gap 0,30 - 0,45 mm
(0.012 - 0.017 in)

CRANKSHAFT AND PISTONS (CONT’D) Cylinder Bore - Checking
Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-15
Figure 70-90-14
B-4066
PI-10017
Use a gauge to check the inside measurement of the
cylinder bore [Figure 70-90-15].
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler Figure 70-90-16

gauge [Figure 70-90-14].

ring. If the clearance still exceeds the allowable limit,
replace the piston.
Top Ring 0,050 - 0,090 mm

(0.0020 - 0.0035 in)
Second Ring 0,090 - 0,12 mm
(0.0036 - 0.0047 in)
Oil Ring 0,020 - 0,060 mm
(0.0079 - 0.0023 in) P-37163
Measure the six points as shown in figure [Figure 70-90-

16] to find the maximum wear.
The factory specifications are:
94 - 94,022 mm (3.7008 - 3.7016 in).
The allowable limit is 94,15 mm (3.707 in).
If the cylinder bore is not within specifications, bore and

hone to oversize dimension.

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft Gear Removal And Installation
Connecting Rod Alignment Remove the crankshaft. (See Crankshaft And Bearings
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before Figure 70-90-18
doing this check.
Install the piston pin into the connecting rod. 3
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate. 1
2
Figure 70-90-17 4
2
P-85149
Remove the crankshaft sleeve (Item 1), the crankshaft

gears (Item 2), the seal (Item 3) and the key (Item 4)
[Figure 70-90-18].
Installation: Install a new seal (Item 3) when servicing

[Figure 70-90-18].
B-4067 Figure 70-90-19
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-17].
If the measurement exceeds the allowable limit, replace

the connecting rod.
Rod Alignment 0,05 mm (0.002 in)
1
2
3
P-85148
Installation: Heat the crankshaft sleeve (Item 1) [Figure

70-90-18] and [Figure 70-90-19] to 150 - 200°C (302 -
392°F). Install the crankshaft sleeve onto the crankshaft
using the crankshaft sleeve guide (Item 2) and the
crankshaft replacing tool (Item 3) MEL - 1660 [Figure 70-
90-19].
Installation: Install the crankshaft sleeve (Item 1) with

the chamfered surface facing outward [Figure 70-90-19].

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings Removal And Installation
Crankshaft Gear Removal And Installation (Cont’d) Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Figure 70-90-20 Page 70-90-1.)
0,850 - 1,15 mm (0.0335 - 0.0452 in) Figure 70-90-21

2
P-85150
P-85151
Installation: When installing the crankshaft sleeve
(Item 1) allow for a space (Item 2) [Figure 70-90-20] from

the end of the crankshaft to the edge of the crankshaft Remove the crankcase mounting screws in order from Z
sleeve. to A [Figure 70-90-21].
Installation: Tighten the crankcase mounting bolts from

A to J to 128 - 137 N•m (94.1 - 101 ft-lb)
Installation: Tighten the crankcase mounting bolts from

K to Z to 49 - 55 N•m (37 - 41 ft-lb).
Figure 70-90-22
1 3
P-85153
Remove crankcase 2 (Item 2) from crankcase 1 (Item 1)

[Figure 70-90-22].
Remove the crankshaft (Item 3) [Figure 70-90-22].

CRANKSHAFT AND PISTONS (CONT’D)
Crankshaft And Bearings Removal And Installation (Cont’d)
Figure 70-90-23
P-85154

This tool is used for aligning the crankcase 1 and AB 4 X 40 mm dia. (1.57 in dia.), Chamfer
crankcase 2. 0,50 mm (0.020 in)
AC 16 mm dia. (0.630 in dia.), Chamfer
A 115 mm (4.53 in) 0,50 mm (0.020 in)
B 106,5 mm (4.193 in) a 15 mm radius
C 108 mm (4.25 in) b Ra = 3.2 a
D 78 mm (3.07 in) c Ra = 6.3 a
E 115 mm (4.53 in) d 0,05 mm (0.002 in)
F 91 mm (3.58 in)
G 24 mm (0.945 in) Material (Item 1) [Figure 70-90-23]: SS400
H 26 mm (1.02 in)
I 53 mm (2.09 in)
J 140 mm dia. (5.51 in dia.)
K 20 mm (0.787 in)
L 260 mm dia. (10.2 in dia.)
M 14,5 mm (0.571 in)
N 53 mm (2.09 in)
O 75 mm (2.95 in)
P 108 mm (4.25 in)
Q 117 mm (4.61 in)
R 25 mm (0.984 in)
S 15 mm (0.591 in)
T 70 mm (2.76 in)
U 48 mm (1.89 in)
V 83 mm (3.27 in)
W 11 mm (0.433 in)
X 32 mm (1.26 in)
Y 6 mm (0.24 in)
Z 2 mm (0.079 in)
AA 5 X 13 mm dia. (0.512 in dia.), Chamfer
0,50 mm (0.020 in)

Crankshaft And Bearings Removal And Installation

(Cont’d)
1
Figure 70-90-24
P-85156
Apply oil to the thrust bearings and install the crankshaft

(Item 1) [Figure 70-90-26].
1
P-85157 Figure 70-90-27
NOTE: Make sure both crankcases are clean and dry

3

before assembling.
Install the bearings (Item 1) into the crankcase 2 (Item 2) 2

[Figure 70-90-24].
Install the thrust bearings (Item 3) [Figure 70-90-24] with

1
the groove facing out.
Figure 70-90-25
1 4 P-85158
Align and install crankcase 2 (Item 2) to crankcase 1

2 (Item 1) [Figure 70-90-27].
Apply engine oil to the crankcase mounting bolts and

hand tighten from A to J and then K to Z [Figure 70-90-
21].
3 Install the jig (Item 3) [Figure 70-90-27] and tighten to 78
- 90 N•m (58 - 66 ft-lb)
P-85155 NOTE: The jig helps to minimize the level difference

between the crankcase 1 and crankcase 2 at
the flywheel side. The gap must be 0,05 mm
Install the bearings (Item 2) into the crankcase 1 (Item 1) (0.002 in) or smaller.
[Figure 70-90-25].
Tighten the crankcase mounting bolts from A to J to 128 -
Install the thrust bearings (Item 3) [Figure 70-90-25] with 137 N•m (94.1 - 101 ft-lb)
the groove facing out.
Tighten the crankcase mounting bolts from K to Z to 49 -
Carefully apply liquid gasket evenly (Item 4) to the 55 N•m (37 - 41 ft-lb).
crankcase 1 (Item 1) [Figure 70-90-25].
Remove the jig (Item 3) [Figure 70-90-27].

Crankshaft And Bearings - Servicing
Figure 70-90-28
A-2763
Put the crankshaft on V-blocks. Install a dial indicator on

P-85159 the center journal [Figure 70-90-28].
Turn the crankshaft at a slow rate to obtain the

Set a dial indicator with its tip on the end of the misalignment (one half of the alignment measurement).
crankshaft (Item 1) [Figure 70-90-28].

If the misalignment exceeds the allowable limit, replace
Measure the side clearance by moving the crankshaft the crankshaft.
side to side (Item 2) [Figure 70-90-28].
Alignment 0,02 mm (0.0008 in)
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Side clearance Factory Spec. 0,15 - 0,35 mm

of crankshaft (0.0059 - 0.013 in)

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-30
3 P-85161
1
Reference of under size dimensions of crankshaft journal
P-85160 [Figure 70-90-31].
Oversize 0,2 mm 0,4 mm

Place plastigage on the crankshaft (Item 3) [Figure 70- (0.0079 in) (0.016 in)
90-30].
Dimension A 2,8 - 3,2 mm 2,8 - 3,2 mm

Place crankcase 2 (Item 2) on crankcase 1 (Item 1) radius radius
[Figure 70-90-30] and torque the bolts. (0.11 - 0.12 in (0.11 - 0.12 in
radius) radius)
Torque the bolts A to Z [Figure 70-90-21]. (See *Dimension 1,0 - 1,5 mm relief 1,0 - 1,5 mm
Crankshaft And Bearings Removal And Installation on B (0.040 - 0.059 in relief
Page 70-90-8.) relief) (0.040 - 0.059 in
relief)
Remove crankcase 2 (Item 2) [Figure 70-90-30] and
Dimension C 72,777 - 72,790 72,577 - 72,590
measure the amount of the flattening with the scale to
mm dia. mm dia.
determine the oil clearance.
(2.8653 - 2.8657 (2.8574 - 2.8578
in dia.) in dia.)
Crankshaft Factory Spec. 72,977 - 72,990 mm
Journal O.D. (2.8732 - 2.8736 in)
The crankshaft journal must be fine-finished to higher
Oil clearance Factory Spec. 0,030 - 0,051 mm than ————(0.8-S)
between (0.0012 - 0.0020 in) *Holes are to be de-burred and edges rounded with
crankshaft journal Allowable limit 0,20 mm relief
and crankshaft (0.079 in) 1,0 - 1,5 mm (0.040 - 0.059 in)
bearing


1
Figure 70-90-32
P-37147
NOTE: To replace it with a specific STD service part,

P-37145 make sure the crank pin bearing has the same
ID color as the connecting rod [Figure 70-90-
33].
Clean the crank pin and crank pin bearing.
ID Connecting Crank pin bearing

Put a strip of plastigage [Figure 70-90-32] on the center Color rod
of the crank pin.
Large-end in. Class Part Center
NOTE: Never insert the plastigage into the crank pin dia. code wall thick
oil hole. Be sure not to move the crankshaft Blue 50,010 - L 1,496 -
while the connecting rod screws are 50,020 mm 1,501
tightened. (1.9689 - mm
1.9692 in) (0.05890
Install the connecting rod cap and tighten the connecting - 0.05909
rod screws to the specified torque, and remove the cap in)
again.
with- 50,000 - S 1,491 -
out 50,010 mm 1,496
Measure the amount of the flattening with the scale, and
Color (1.9685 - mm
get the oil clearance.
1.9688 in) (0.05870
- 0.05889
If the oil clearance exceeds the allowable limit, replace
in)
the crank pin bearing.
If the same size bearing cannot be used because of the

crank pin wear, replace it with an undersized one
referring to the table.
Crankpin Factory spec. 46,980 - 46,991 mm

O.D. (1.8496 - 1.8500 in)
Oil clear- Factory spec. 0,011 - 0,058 mm

ance (0.00044 - 0.0022 in)
between Allowable 0,20 mm (0.0079 in)
crank pin and limit
crank pin
bearing

CRANKSHAFT AND PISTONS (CONT’D)
Figure 70-90-34
P-85162
Under size dimensions of crankpin.

Undersize 0,2 mm 0,4 mm
(0.0079 in) (0.016 in)
Dimension 3,3 - 3,7 mm radius 3,3 - 3,7 mm
A (0.13 - 0.14 in radius
radius) (0.13 - 0.14 in
radius)
*Dimen- 1,0 - 1,5 mm relief 1,0 - 1,5 mm
sion B (0.040 - 0.059 in relief
relief) (0.040 - 0.059 in
relief)
Dimension 48,780 - 46,791 46,580 - 46,591
C mm dia. mm dia.
(1.8418 - 1.8421 in (1.8339 - 1.8342
dia.) in dia.)
(0.8-S)
The crank pin must be fine-finished to higher than ——
——
*Holes to be de-burred and edges rounded with relief.
1,0 -1,5 mm (0.040 - 0.059 in)

CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal

Remove the housing. (See Housing Removal And

Figure 70-100-1

3 P-85194
Remove the seven outside timing gearcase cover

mounting bolts (Item 1) [Figure 70-100-1].
Remove the six inside timing gearcase cover mounting

Remove the timing gearcase cover (Item 3) [Figure 70-

100-1].

CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation
Figure 70-100-2
P-85201
A 70,0 mm (2.76 in)

B 30,0 mm (1.18 in)

C 30,0 mm (1.18 in)
D 8,0 mm (0.31 in)
E 78,60 - 78,70 mm dia.
(3.095 - 3.098 in dia.)
F 73,8 - 74,2 mm dia.
(2.91 - 2.92 in dia.)
G 32,009 - 32,034 mm dia.
(1.2602 - 1.2611 in dia.)
H 20,0 mm dia. (0.787 in dia.)
I 30,0 mm dia. (1.18 in dia.)
J 75,5 mm dia. (2.97 in dia.)
K 30,0 mm (1.18 in)
L 7,0 mm dia., 8,0 mm depth
(0.28 in dia., 0.31 in depth)
M 1,1 - 1,3 mm (0.044 - 0.051 in)
N 20,0 mm (0.787 in)
a Ra = 3.2 a
b Ra = 1.6 a
c 0,40 mm radius (0.016 in radius)
e 0,20 mm radius (0.0079 in radius)
f 1,5 mm radius (0.059 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
Make timing gearcase cover guide tool [Figure 70-100-

2].

CAMSHAFT AND TIMING GEARS (CONT’D) Make timing gearcase oil seal replacing tool [Figure 70-
100-3].
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-4
Figure 70-100-3
P-85218
Make timing gearcase guide screws as shown above

[Figure 70-100-4].

Figure 70-100-5
P-85202
A 117 mm (4.61 in) 1

B 12,0 mm (0.472 in)
C 10,0 mm (0.394 in)
D 75,0 mm (2.95 in)
E 10,0 mm (0.394 in)
F 105 mm dia. (4.13 in dia.)
G 78,9971 - 78,9990 mm dia. P-85195
(3.11013 - 3.11019 in dia.)
H 68,0 mm dia. (2.68 in dia.)
Apply engine oil to the timing gearcase oil seal (Item 1)
I 15,0 mm dia. (0.591 in dia.) [Figure 70-100-5].
J 30,0 mm dia. (1.18 in dia.)
Install timing gearcase guide screws (Item 2) [Figure 70-
K 90,0 mm (3.54 in) 100-5].
L 2,5 mm (0.098 in)
M 0,35 rad. (20 degrees)
N 0,15 - 0,25 mm
(0.0059 - 0.0098 in)
a Ra = 3.2 a
b Ra = 1.6 a
c 0,80 mm radius (0.031 in radius)

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-8
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-6
3 P-85194
1
Tighten the seven outside timing gearcase cover
P-85196 mounting bolts (Item 1) [Figure 70-100-8].
Tighten the six inside timing gearcase cover mounting

Apply a liquid gasket (Three Bond 1217H) (Item 1) bolts (Item 2) [Figure 70-100-8].
[Figure 70-100-6] to the two crankcase seams.

Installation: Tighten the timing gearcase cover bolts to
Figure 70-100-7 78 - 90 N•m (58 - 66 ft-lb) [Figure 70-100-8].
P-85217
Install timing gearcase oil seal using the timing gearcase

oil seal replacing tool (Item 1) [Figure 70-100-7].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
When the gears are installed, check the backlash of the
gears. Remove the valve tappets. (See Valve Tappets on Page
70-80-12.)
Figure 70-100-9
Figure 70-100-10
1 2 3
1
2
P-85205
3 1
P-85193

Install a dial indicator to individually check backlash for
cam gear (Item 1), idle gear (Item 2), injection pump gear Rotate entire engine with the crankshaft (Item 1) [Figure
(Item 3) and crank gear (Item 4) [Figure 70-100-9]. 70-100-10] facing up to remove the tappets
Hold one gear while turning the other gear [Figure 70- Remove the three camshaft set bolts (Item 2) and
100-9]. remove the cam (Item 3) [Figure 70-100-10].
If the backlash exceeds the allowable limit, check the oil Remove the idle gear mounting bolt (Item 4) and remove
clearance of the shaft and gear. If the oil clearance is idle gear (Item 5) [Figure 70-100-10].
correct, replace the gear.
Installation: Make sure the timing marks are in correct
Crank Gear & Cam Gear 0,0400 - 0,137 mm alignment when installing the timing gears.
(0.00158 - 0.00539 in)
(0.0087 in)
Cam Gear & Idler Gear 0,0460 - 0,136 mm
(0.00182 - 0.00535 in)
(0.0087 in)
Injection Pump Gear & 0,0460 - 0,136 mm
Idler Gear (0.00182 - 0.00535 in)
(0.0087 in)

Camshaft - Servicing
Figure 70-100-11
1 2
1
P-85212
2
Measure the camshaft journal (Item 1) and journal (Item

P-85209 2) [Figure 70-100-13].
Calculate the oil clearance. If the clearance exceeds the

Mount a dial indicator and check cam gear (Item 1) end allowable limit, replace the camshaft.
play (Item 2) [Figure 70-100-11].

Cylinder Block Bore 1 35,000 - 35,025 mm
Installation: Check the camshaft end play. If clearance I.D. (1.3780 - 1.3789 in)
exceeds the allowable limit, replace the camshaft retainer Cylinder Block Bore 2 42,000 - 42,025 mm
plate [Figure 70-100-11]. I.D. (1.6536 - 1.6545 in)
Camshaft Journal 1 O.D. 34,934 - 34,950 mm
Camshaft End Play 0,10 mm (0.0039 in)
(1.3754 - 1.3759 in)
Allowable Limit
Camshaft Journal 2 O.D. 41,934 - 41,950 mm
Figure 70-100-12 (1.6510 - 1.6515 in)
Oil Clearance of Cam- 0,050 - 0,091 mm
shaft Journal (0.0020 - 0.0035 in)
(0.0059 in)
P-47263
Measure the cylinder block bore in the engine block

[Figure 70-100-12].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Shaft - Servicing
Camshaft - Servicing (Cont’d) Figure 70-100-16
Figure 70-100-14
1 2
P-85207
P-85214
Mount a dial indicator and check idle gear (Item 1) end
play (Item 2) [Figure 70-100-16].
Measure the cam lobes at their highest point (Item 2)
[Figure 70-100-14]. Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear

If the measurement is less than the allowable limit, collar.
replace the camshaft (Item 1) [Figure 70-100-14].
Idler Gear End Play 0,050 - 0,020 mm
Cam Lobe Height Intake 32,56 mm (1.282 in) (0.0020 - 0.0078 in)
Cam Lobe Height Exhaust 33,00 mm (1.299 in) Allowable Limit 0,90 mm (0.035 in)
Allowable Limit Intake 32,10 mm (1.264 in)
Allowable Limit Exhaust 32,50 mm (1.280 in)
Figure 70-100-15
P-85213
Put the camshaft (Item 1) in V-blocks. Install a dial

indicator [Figure 70-100-15].
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Camshaft Alignment Allowable Limit 0,01 mm

(0.0004 in)

Idler Gear And Shaft - Servicing (Cont’d)
Figure 70-100-17
1 2
P-85211
Make this idle gear bushing replacing tool as shown

P-85208 above [Figure 70-100-18].
A 196 mm (7.72 in)

Measure idle gear bushing ID (Item 1) and idle gear shaft B 25,00 mm (0.984 in)
OD (Item 2) [Figure 70-100-17].
C 150 mm (5.91 in)

Idler Gear Shaft O.D. 34,959 - 34,975 mm D 34,5 mm dia. (1.36 in dia.)
(1.3764 - 1.3769 in) E 38,075 - 38,100 mm dia.
Idler Gear Bushing I.D. 35,000 - 35,055 mm (1.4991 - 1.5000 in dia.)
(1.3780 - 1.3801 in) F 20 mm dia. (0.79 in dia.)
Oil Clearance Between 0,25 - 0,096 mm a 0,0063 mm (0.000248 in)
Idler Shaft & Gear Bushing (0.00099 - 0.0037 in) b 0,0063 mm (0.000248 in)
Allowable Limit 0,10 mm C1 Chamfer 1,0 mm (0.039 in)
(0.0039 in) C2 Chamfer 1,0 mm (0.039 in)
Installation: If the oil clearance exceeds the allowable Figure 70-100-19

limit, replace the idle gear bushing.
1 2
P-85210
When removing idle gear bushing, press out bushing as

shown above (item 1) [Figure 70-100-19].
When replacing idle gear bushing, press in bushing as

shown above (item 2) [Figure 70-100-19].

TURBOCHARGER Testing
Description Remove the turbocharger. (See Removal And Installation

on Page 70-110-2.)
Figure 70-110-1
Radial Clearance
Figure 70-110-2
1
P-85125
The turbocharger is placed between the exhaust and

P-76099
intake manifolds. It is driven by hot exhaust gases and

supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The Move the compressor / turbine wheel (up and down / right
location of the turbo is between the engine and the and left) (Item 1) [Figure 70-110-2].
blower housing.
If the wheel contacts the housing, replace the
The oil flows to the turbo by a tubeline (Item 1) and turbocharger assembly with a new one.
returns to the engine block through another tubeline
(Item 2) [Figure 70-110-1]. Check the oil tubelines for leaks.
The turbocharger internal components are not

serviceable.

TURBOCHARGER (CONT’D) Figure 70-110-4
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact 1 1
with hot surfaces.
W-2257-1196
Remove the muffler. (See Removal And Installation on P-85136

Page 70-30-1.)
Remove the air cleaner. (See Housing Removal And Remove the eight exhaust manifold bolts (Item 1) [Figure
Installation on Page 70-40-1.) 70-110-4].
Figure 70-110-3 Installation: Tighten the eight bolts (Item 1) [Figure 70-
110-3] to 24 - 27 N•m (17.7 - 19.9 ft-lb) torque.

Figure 70-110-5
P-85131
1
Disconnect the two oil pipes (Item 1) [Figure 70-110-3]. P-85127
Installation: Tighten the two tubelines (Item 1) [Figure

70-110-3] to 16 - 19 N•m (12 - 14 ft-lb) torque. Remove the turbocharger assembly (Item 1) [Figure 70-
110-5].
Installation: During installation replace all gaskets with

new ones.

FLYWHEEL AND HOUSING Figure 70-120-2
Flywheel Removal And Installation
Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-8.)
Remove the drive belt shield. (See Shield Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See Belt Removal And

Installation on Page 30-60-3.) P-85215
Figure 70-120-1
Make flywheel stop tool as shown above in [Figure 70-
120-2].
A 144 mm (5.67 in)

B 104 mm (4.09 in)

C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
E 12,0 mm dia. (0.472 in dia.)
F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
1 2
H 32,0 mm (1.26 in)
P-85138
I 16,0 mm (0.630 in)
Figure 70-120-3
Remove the six mounting bolts (Item 1) from the pulley
(Item 2) [Figure 70-120-1].
Remove the pulley (Item 2) [Figure 70-120-1].
P-85218
Make flywheel guide bolts as shown above to aid in

removal and installation of flywheel [Figure 70-120-3].

FLYWHEEL AND HOUSING (CONT’D) Ring Gear Removal And Installation
Flywheel Removal And Installation (Cont’d) Figure 70-120-6
Figure 70-120-4
1
P-48850
P-85074
The ring gear (Item 1) [Figure 70-120-6] on the flywheel
is an interference fit. Heat the ring gear enough to
Install flywheel stop tool (Item 1) [Figure 70-120-4].
expand the gear. Hit the ring gear evenly around the gear
Remove two flywheel bolts and replace them with the to remove it from the flywheel.

flywheel guides bolts to aid in removal (Item 1) [Figure
70-120-5]. Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Remove the seven mounting bolts (Item 2)[Figure 70-
120-4] from the flywheel. Clean the new ring gear and heat it to a temperature of
232 - 260°C (450 - 500°F)
Installation: Apply engine oil to the bolts and tighten to
98,1 - 107 N•m (72.4 - 79.5 ft-lb) torque.
Fit the ring on the flywheel and be sure the gear is seated
NOTE: Do not use a impact wrench. Serious damage correctly.
will occur. There is one positioning pin in the
crankshaft gear and it is installed in the
flywheel.
Figure 70-120-5
P-85140
Install two guide bolts (Item 1) [Figure 70-120-5] to aid in

installation of the flywheel.
Reverse the removal procedure to install the flywheel.

FLYWHEEL AND HOUSING (CONT’D)
Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-8.)
Remove the drive belt shield. (See Shield Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See Belt Removal And

Remove the starter. (See Removal And Installation on

Page 60-40-2.)

Figure 70-120-7

1
2
P-85137
Remove the four mounting bolts (Item 1) and the housing

(Item 2) [Figure 70-120-7].



EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
3
12
11

2
1
7 5
13
2
7
9
15
10
9
14
P-85105
The items listed below refer to Page 70-130-1 [Figure

70-130-1].
9. Cooled EGR Gas
1. Thermo Valve 10. To The Intake Manifold
2. Mechanical EGR Valve 11. Fresh Air
3. Cylinder Head 12. Cooled EGR Gas Merges With Fresh Air
4. Reed Valve 13. Exhaust Gas
5. EGR Cooler 14. Coolant Inlet
6. Intake Manifold 15. Coolant Outlet
7. Boost Pressure
8. Coolant Temperature

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Cold Engine Coolant Temperature Test
(CONT'D)
Start the engine and run at low idle.
Testing
Start Service Analyzer and select [Monitor].
There are two tests for checking the EGR system. Both Select [Engine Temperature].
tests will need to be performed and the coolant
temperature must be monitored through the Service
Analyzer.
WARNING
The Cold Engine Coolant Temperature Test will need to
be performed with the engine coolant below 55°C AVOID BURNS
(131°F). The Hot Engine Coolant Temperature Test will Some surfaces of the Exhaust Gas Recirculation
need to be performed with the engine coolant above system can be hot. Use caution when conducting
70°C (158°F). diagnostic tests.
Allow the engine to cool before servicing.

W-2716-0208
WARNING
NOTE: Verify the engine temperature is below 55°C
AVOID INJURY OR DEATH (131°F). If the engine temperature is above
When the engine is running during service, the 55°C (131°F), let the engine cool down and
steering levers or joysticks must be in neutral and restart the Cold Engine Coolant temperature
the parking brake engaged. Test.

W-2717-0208
NOTE: Monitor the engine coolant temperature using
the Service Analyzer.
MACHINE FALLING OR MOVING CAN CAUSE

Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
1
1.)
Open the rear door.
Connect the Service PC (See SERVICE PC (LAPTOP

COMPUTER) on Page 60-150-1.) P-85108
Measure the surface temperature of the EGR system

(Item 1) [Figure 70-130-2] with an Infrared
WARNING Thermometer.
AVOID INJURY OR DEATH If the engine coolant temperature is below 55°C (131°F)
When an engine is running in an enclosed area, fresh and the surface temperature of the EGR system is 50°C
air must be added to avoid concentration of exhaust (122°F) or below, the EGR system is OK, Continue with
fumes. If the engine is stationary, vent the exhaust the Hot Engine Coolant temperature Test.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. If the surface temperature of the EGR system reads
W-2050-0807 100°C (212°F) or above continue this Cold Engine
Coolant Temperature Test.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-130-5
(CONT'D)
Testing (Cont’d)
Figure 70-130-3
P-85108

P-85107 Thermometer.
With the engine coolant temperature above 70°C (158°F)

Disconnect the boost hose (Item 1) [Figure 70-130-3] and the surface temperature of the EGR system 100°C

from the EGR valve. (212°F) or above, the EGR system is OK.
Figure 70-130-4 If the surface temperature of the EGR system is 50°C

(122°F) or below continue this Hot Engine Coolant
Temperature Test.
Figure 70-130-6
P-85108
1

Thermometer. P-85107
If the surface temperature of the EGR system declines,

the thermo valve has failed. Disconnect the two hoses (Item 1) [Figure 70-130-6].
If the surface temperature of the EGR system stays
above 100°C (212°F), the EGR valve has failed.
Hot Engine Coolant Temperature Test
Verify the engine temperature is above 70°C (158°F), if

the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
continue with the Hot Engine Coolant Temperature Test.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(CONT'D)
Testing (Cont’d)
Figure 70-130-7
1
2
P-85106
Connect a hose (Item 1) directly between the intake

manifold (Item 2) and the EGR valve (Item 3) [Figure 70-
130-7].
Figure 70-130-8
P-85108

Thermometer.
If the surface temperature of the EGR system increases,

the thermo valve has failed.
If the surface temperature of the EGR system is 50°C

(122°F) or below, the EGR valve has failed.

(CONT'D)
1 1
2
1
WARNING
4
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting 3
diagnostic tests.
1
Allow the engine to cool before servicing.
W-2716-0208 P-85110
Allow the engine to cool before working on the EGR

Remove the four EGR cooler mounting bolts (Item 1) and
system.
the EGR system assembly (Item 2) [Figure 70-130-10].
Figure 70-130-9
Installation: Replace the gaskets (Items 3 and 4)
[Figure 70-130-10] with new ones.

1 Figure 70-130-11
4
3
1
2
P-85109
2
Disconnect and cap the EGR valve coolant hoses (Item
P-85113
1) [Figure 70-130-9].
Disconnect the boost pressure hose (Item 2) [Figure 70-

NOTE: The gasket (Item 3) [Figure 70-130-10] and
130-9].
[Figure 70-130-11] is marked with the letter
“F” and must be installed downward.

(CONT'D)
Figure 70-130-12 3
6
4
8 5
4
2
1 7
6 1
5 P-85111
3
2
4 Remove the two mounting bolts (Item 1) from the EGR
valve (Item 2) and EGR valve flange (Item 6) [Figure 70-
P-85112 130-13].
Remove the two mounting bolts (Item 3) from the reed

Remove the two mounting bolts (Item 1) from the EGR valve (Item 5) [Figure 70-130-13].

cooler flange (Item 2) [Figure 70-130-12].
Remove and replace the gaskets (Item 4) [Figure 70-
Remove and replace the gasket (Item 3) [Figure 70-130- 130-13].
12].
Installation: When reassembling replace with new
Remove the four bolts (Item 4) from the EGR cooler (Item gaskets.
5) and the EGR valve (Item 7) [Figure 70-130-12].
Remove and replace the gasket (Item 6) [Figure 70-130-

12].
Remove the thermo valve (Item 8) [Figure 70-130-12].
Installation: When reassembling replace with new

gaskets.
NOTE: If the thermo valve is dropped it must be

replaced with a new one.
Installation: Tighten the thermo valve to 30 - 39 N•m (22

- 28 ft-lb) torque.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1

The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-19
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
Charging With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-5
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schraeder® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

Removal And Installation With A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-3
BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-4

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.) As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air 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.

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

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
2
Figure 80-10-1
P-82688
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P-82687 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3688,7 kPa (36,9
P-48011 bar) (535 psi).
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
Figure 80-10-5
N-22087
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-24227 10-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.

cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat and A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Figure 80-10-8
P-21902
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the Heater / Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-10-8] is used to push air through the heater and
evaporator coils and into the cab.

Components (Cont'd)
1
Figure 80-10-9
2
3 4
P-82688
Pressure Switch: The pressure switch (Item 1) [Figure

N-22261 80-10-11] will disengage the compressor clutch at high
pressure readings over 2647,6 kPa (26,5 bar) (384 psi)
on the high side, or at very low pressure of 193,1 kPa
Control Panel: The panel (Item 1) [Figure 80-10-9] has (1,9 bar) (28 psi) or less on the high side, which indicates
three separate components. loss of refrigerant.

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-9]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-9]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-9] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-10
P-66919
Heater Valve: The heater valve (Item 1) [Figure 80-10-

10] is used to control the amount of engine coolant that
flows to the heater coil.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment WARNING

Figure 80-10-12
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
DEGREES “INSTANTLY”. If it spills on your skin or in
your eyes you should flood the area with cool water and
SEEK MEDICAL ATTENTION FAST! It is a good idea to
wear gloves [Figure 80-10-13] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-13
WARNING

HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
P16399 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-12] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Compressor Drive Belt Adjustment
Filters Stop the engine and open the rear door.
3
1
2
P-48012
The Fresh Air Filter (Item 1) [Figure 80-20-1] is located

below the rear window outside the cab. Remove the
P-76967
clamping knobs, filter cover and filter.
Shake the filter or use low pressure air to remove dirt. Remove bolt (Item 3) [Figure 80-20-3] holding harness
This can be done several times before replacement is clamp.

required. Install the filter, filter cover and clamping knobs.
Remove nuts (Item 1) and remove belt shield (Item 2)
Figure 80-20-2 [Figure 80-20-3].
Figure 80-20-4
1
1 P-48005
The Recirculation Filter (Item 2) [Figure 80-20-2] is

located in front of the rear window inside the cab.
Remove the clamping knobs, filter cover, and filter. P-76968
Shake the filter or use a vacuum to clean. This can be Loosen the mounting nut (Item 1) [Figure 80-20-4] at
done several times before replacement is required. Install bottom of compressor.
the filter with the arrows pointing forward (Inset) [Figure
80-20-2], install the filter cover and clamping knobs.

REGULAR MAINTENANCE (CONT’D) Compressor Drive Belt Replacement
Compressor Drive Belt Adjustment (Cont’d) Stop the engine and open the rear door.
Figure 80-20-5 Remove bolt (Item 3) [Figure 80-20-3] holding harness

clamp.
Remove nuts (Item 1) and remove belt shield (Item 2)

[Figure 80-20-3].
2 Loosen the mounting nut (Item 1) [Figure 80-20-4] at

bottom of compressor.
Loosen the adjustment nut (Item 1) [Figure 80-20-5] at

1 top of compressor.
Move the air conditioning compressor toward the front of

the machine to loosen the belt.
P-76969
Remove the belt from the pulleys and inspect the pulleys
for wear. Replace as needed.
Loosen the adjustment nut (Item 1) [Figure 80-20-5] at
top of compressor. Install new air conditioning belt.

Move the air conditioning compressor toward the rear of Adjust the belt.
machine to tighten the belt. The tension is correct when
there is 4,0 mm (0.16 in) movement at the middle of the Close the rear door before operating the loader.
belt span (Item 2) [Figure 80-20-5] with 16,5 - 17,7 N
(3.72 - 3.98 lb) of force. Condenser
Tighten the mounting and adjustment nuts, install belt (See ENGINE COOLING SYSTEM on Page 10-90-1.)
shield and install harness clamp and bolt.
Air Conditioning Lubrication
Run the air conditioning for about five minutes every
week to lubricate the internal components.

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

REGULAR MAINTENANCE (CONT’D)
Evaporator / Heater Coil
Figure 80-20-6
P-76565
Remove the cover screws (Item 1) [Figure 80-20-6] and

remove the cover.
Figure 80-20-7

1
2
P-76201
Use low pressure air or water to remove debris from the

evaporator (Item 1) and heater coil (Item 2) [Figure 80-
20-7].
Install the cover and lower the operator cab. (See

Lowering on Page 10-30-2.)

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch mal- Check power into and out of the fan switch. Replace Fan Switch.
function.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.

3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab filter condition. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the 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 compressor mal- The compressor is locked up and the belt slips. Replace compressor.
function.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open Coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness compo- Test the conductance of the pressure switch, ther- Check operation / thermostat
nents. mostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 1448 - 1827 kPa (14,5 - 18,3 bar) (210 - 265 psi)
Low pressure side pressure: 103,4 - 227,5 kPa (1 - 2,3 bar) (15 - 33 psi)
As a rule of thumb, the high side pressure will be around eight times greater than the low side pressure.

Low pressure side too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equal- Replace compressor.
sor. ize when the compressor is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct

level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
formance. Operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.
High pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct
level.

Gauge Pressure Related Troubleshooting (Cont'd)

System pressures equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
B-21491

Troubleshooting Tree (Cont’d)
B-21491A

B-21492

B-21493

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 -13 - 12°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4°C (40°F) to the ambient temperature to
get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Example: Ambient Temperature=32°C (90°F)

32°C (90°F)
+ 4°C (40°F)
54°C (130°F) condenser temperature=200 psig
Conditions and pressures will vary from system to system.

TROUBLESHOOTING (CONT'D) Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Adjustment on Page 80-20-1.)
Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if
Figure 80-30-1 necessary. (See Condenser on Page 80-20-2.)
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Air Conditioning Service Chart on Page
80-20-3.)
Inspect the sight glass located on the receiver / drier for

air bubbles. (See Receiver / Drier Removal And
1 Installation on Page 80-70-1.)
Check the engine coolant to see if it is bypassing the

heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-18.)
N-22273
WARNING
Figure 80-30-2

W-2059-0598
N-22411
Start the loader, engage the parking brake. Engage the

A/C system with the blower fan on high. Run the loader at
full rpm for approximately 15 minutes, with the loader cab
door closed.
Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 2,2 - 11,6°C

(36 - 53°F) depending on the amount of humidity in the
air.
If louver temperature is too high, (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower fan for proper operation or noise, and

replace if necessary. (See BLOWER FAN on Page 80-
130-1.)

HVAC Repair And Leaks
Figure 80-30-3
P-82688
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /

drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT'D) NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
Electrical System for both the Heater and the A/C systems.
2
2 1
N-22284 P-82677
Check to see if the compressor clutch is engaging. Raise the lift arms and install an approved lift arm

With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN (Standard Panel) Raise the operator cab. (See Raising on Page 10-30-1.)
OR press the RUN / ENTER Button (Deluxe Panel),
without starting the loader. Remove the tie strap (Item 1) and disconnect the loader
harness (Item 2) [Figure 80-30-6] from the compressor
Push the A/C switch (Item 1) to the ON position. Turn the clutch wire.
blower fan switch (Item 2) [Figure 80-30-4] to the first On
position. Installation: Secure the harness with a new tie strap
(Item 1) [Figure 80-30-6] after reconnecting.
The compressor clutch should make a click sound, which
indicates the clutch is engaging. Figure 80-30-7
Figure 80-30-5
P-82689
P-21912
With a multi meter, check the resistance to the
compressor clutch (Item 1) [Figure 80-30-7].
If the compressor clutch does not engage, check the
loader fuse (Item 1) [Figure 80-30-5] located on the
If there is no resistance value, replace the compressor
control panel in the loader cab.
clutch. (See Clutch Disassembly And Assembly on Page
80-50-5.)
Replace the fuse if burned out.

TROUBLESHOOTING (CONT'D) Figure 80-30-10
Electrical System (Cont'd)
Figure 80-30-8
P-24315
Using a multi meter check the loader wiring harness

P-82689 (Item 1) [Figure 80-30-10] for voltage.
The voltage should be around 12 volts.

With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8] If there is no voltage at the wiring harness, check the

harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-30-11
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Figure 80-30-9
2
1
P-24315
If there is voltage at the harness, check the resistance at

the pressure switch (Item 1) [Figure 80-30-11].
1
If there is no resistance value, check for low refrigerant
P-82688 level. (See Refrigerant Identification on Page 80-40-1.)
If a resistance value is observed, the pressure switch is

Disconnect the loader harness (Item 1) from the pressure good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

Figure 80-30-12
1 1
P-68448
Check the loader harness (Item 1) [Figure 80-30-14] for

P-66829 voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

Remove the access cover (Item 1) [Figure 80-30-12] harness for broken wires.
from the loader.

If there is voltage at the wiring harness, check the
Figure 80-30-13 thermostat (Item 2) [Figure 80-30-14] for resistance.
The resistance value of the thermostat should be 10 ohm

at 20°C (68°F).
If there is no resistance value, replace the thermostat.

If there is a resistance value, check the blower fan.
P-68118
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-30-13] from the loader wiring harness.

Figure 80-30-15
N-22261
Remove the three mount screws (Item 1) [Figure 80-30-

P-68118 17] from the cab control panel.
Disconnect the blower fan wiring connector (Item 1)


Figure 80-30-16
P-68444
Check the loader harness (Item 1) [Figure 80-30-16] for

voltage. The voltage should be 12 volts.

If there is voltage at the wiring harness, check the

resistance to the blower fan at the blower fan wiring
If there is no resistance value replace the blower fan.

If there is a resistance value check the climate controls at

the control panel inside the loader cab.

Figure 80-30-18
H C
M B
N-22288
If there is voltage at the wiring harness, check the blower

N-22262 switch [Figure 80-30-20] for resistance.
With the switch in the OFF position, there should be zero

Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-30-18].

With the switch in the 1 position, there should be
Figure 80-30-19 resistance between C terminal and the B terminal,
between the C terminal and the L terminal, and also
between the B terminal and the L terminal frame [Figure
80-30-20].

resistance between C terminal and the B terminal,
1 between the C terminal and the M terminal, and also
between the B terminal and the M terminal frame [Figure
80-30-20].

resistance between C terminal and the B terminal,
between the C terminal and the H terminal, and also
between the B terminal and the H terminal frame [Figure
N-22265 80-30-20].
If any of the above resistance tests fail, replace the

Disconnect the loader wiring harness (Item 1) [Figure blower switch.
80-30-19] from the blower switch.
If the above resistance tests are good, check the A/C
Check the loader harness for voltage. The voltage should switch.
be 12 volts.


TROUBLESHOOTING (CONT'D) If no resistance value is found, replace the A/C switch.
Electrical System (Cont'd) If a resistance value is found, check the potentiometer.
Figure 80-30-21 Figure 80-30-23
N-22264 N-22262
At the loader cab, disconnect the loader harness (Item 1)

The potentiometer will effect the A/C system and also
[Figure 80-30-21] from the A/C switch.
effect the operation of the heater.

Check the harness for voltage. The voltage should be 12
If heater valve does not open, or close, or the A/C does
volts.
not work, check the potentiometer.
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-23] from the potentiometer.
Figure 80-30-22
Figure 80-30-24
1
2 1
N-22289
N-22263
If there is voltage at the wiring harness, check the A/C

switch [Figure 80-30-22] for resistance. Check the loader harness (Item 1) [Figure 80-30-24] for
voltage. The voltage should be 12 volts.
With the switch in the OFF position there should be no
resistance between any of the three terminals on the A/C If there is no voltage at the wiring harness, check the
switch. harness for broken wires.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-22].

Figure 80-30-25
C 1
A
N-22175
B
To check the resistance of the white wire, turn the
N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-30-27].
If there is voltage at the wiring harness, check the Figure 80-30-28

potentiometer [Figure 80-30-25] for resistance.

The resistance should be 10K ohm between wire
terminal A and wire terminal C frame [Figure 80-30-25].
If no resistance is found, replace the potentiometer.

C
Figure 80-30-26 A
N-22290
The resistance between the wire terminal A and wire

1 terminal B frame [Figure 80-30-28] should be
approximately 49K ohm.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-30-28] should be
The white wire B, (Item 1) [Figure 80-30-26], on the

potentiometer, is a resistor wire.

TROUBLESHOOTING (CONT'D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Figure 80-30-31
Figure 80-30-29
2 3
1
1
N-22284
N-22175
support device.(See Installing on Page 10-20-1.)
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-30-29] to the Push the A/C switch (Item 1) to the OFF position. Turn

full Heater position. the fan switch (Item 2) to the High Speed position. Turn
the temperature control (Item 3) [Figure 80-30-31] to the
Figure 80-30-30 High A/C position, with the loader ignition switch OFF.
Figure 80-30-32
C
A
1
N-22290
P-68119
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-30] should be
approximately 39K ohm. Raise the operator cab.(See Raising on Page 10-30-1.)
Check the resistance between the wire terminal C and Connect the remote start tool to the loader. (See
wire terminal B frame [Figure 80-30-30] should be REMOTE START TOOL KIT-1563 on Page 10-60-1.)
Start the loader and run at high idle, for ten minutes.
If the resistance is not found, replace the potentiometer.
Check the heater hose (Item 1) [Figure 80-30-32] for
temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replaced.

Heater Valve Not Opening Or Closing
Figure 80-30-33
2 3
1 P-68117
Place the remote start tool on the left fender of the

N-22284 loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-34], as the key of
the remote start is turned to the ON position without
Raise the lift arms and install an approved lift arm starting the loader. The heater valve should rotate.

If it does not rotate, check the potentiometer (See
Push the A/C switch (Item 1) to the OFF position. Turn Electrical System on Page 80-30-11.) for proper function.
the fan switch (Item 2) to position 1. Turn the temperature
control (Item 3) [Figure 80-30-33] to the High A/C Replace the heater valve. (See Removal And Installation
position, with the loader ignition switch OFF. on Page 80-140-1.)

REMOTE START TOOL KIT-1563 on Page 10-60-1.)
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-34], as the key of
the remote start tool is turned to the ON position without
starting the loader. The heater valve should rotate. Place
a mark on the loader shaft.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-30-33]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.


SYSTEM CHARGING AND RECLAMATION Figure 80-40-2
Refrigerant Identification
WARNING
1
gas.
W-2371-0611
Figure 80-40-1 P-82690
1
Connect the Refrigerant Identifier to the low pressure

hose (Item 1) [Figure 80-40-2].
Connect the Refrigerant Identifier to its power source.
Follow the steps displayed on the refrigerant identifier

screen.
N-23024
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
NOTE: It is recommended to identify the type of sound if potentially flammable hydrocarbons are present
refrigerant that is in the A/C system and if it is and will also indicate on the visual display.
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-3] Disconnect the refrigerant identifier from the loader A/C.
will determine, the kind of refrigerant and any
possible harmful or dangerous substances If the refrigerant is dangerous or flammable, it must be
that may be present in the system. Thus evacuated from the A/C system into a separate container
preventing mixing of dangerous material with and properly and safely disposed of.
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems If R134a is found, evacuate the system.
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-5
Reclamation And Charging With Recovery / Charging

Unit
Figure 80-40-3
N-22291
IMPORTANT: Only A/C trained technicians should

2 perform the reclaiming and recharging.
P-82685
Open the rear door and locate the low pressure port WARNING

(Item 1), and high pressure port (Item 2) [Figure 80-40-
3].
HFC R-134a refrigerant can be dangerous if not
Figure 80-40-4 properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
1
of R-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-2373-0611
P-24230 Use an approved recovery / charging unit [Figure 80-40-

5] to evacuate the system.
NOTE: Do not use this port (Item 1) [Figure 80-40-4]

for testing or charging.


Unit (Cont'd)
Figure 80-40-6
N-22381
2
1 NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-8] to
P-82691 follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they may very
Connect the reclaimer to the loader A/C charge ports. slightly depending on the model and brand of

reclaimer used.
Connect the Red hose (Item 1) [Figure 80-40-6] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-6] to the

low pressure port and open the valve.
Figure 80-40-7
N-22292
Turn the reclaimer unit [Figure 80-40-7] to the ON

position and follow the on screen instructions.

Charging With A Manifold Gauge Set
WARNING
gas.
W-2371-0611
1
Figure 80-40-9 P-82692
Connect the gauges to the loader A/C charge ports.
Connect the Red hose (Item 1) [Figure 80-40-10] to the

high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-10] to the

low pressure port and open the valve.
Figure 80-40-11
1
P-82696
1
Open the rear door.
Check to see that the hand valves (Item 1) [Figure 80-

40-9] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.) P-82694
Connect the Yellow hose (Item 1) [Figure 80-40-11] to

the vacuum pump.

Charging With A Manifold Gauge Set (Cont’d)
Figure 80-40-12
1
1
P-24322
A thermistor vacuum gauge (Item 1) [Figure 80-40-14]

P-82695 can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
Start the vacuum pump and open ISO-valve (Item 1)
[Figure 80-40-12] on the vacuum pump. The thermistor vacuum gauge is used with the vacuum

pump [Figure 80-40-14].
Run the vacuum pump for at least 5 - 10 minutes to
insure that a vacuum has been pulled on the system. Start the vacuum pump and open ISO-valve on the
vacuum pump.
Close the ISO-valve (Item 1) [Figure 80-40-12] (which
isolates the vacuum pump from the A/C system) and turn Be sure that both hand valves, and both charge port
OFF the vacuum pump. valves are open.
Figure 80-40-13 Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
1 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.
P-82696
NOTE: Vacuum pressure indicated on the low

pressure (Blue) gauge (Item 1) [Figure 80-40-
13]. Let stand for 5 - 10 minutes and recheck
the pressure for changes.
If the pressure drops, this may be an indication of a leak

in the A/C system.
Determine the problem with the A/C system and repair it.

Charging With A Manifold Gauge Set (Cont’d)
Figure 80-40-15
2
3 1
1
N-22284
2
P-82697 REMOTE START TOOL KIT-1563 on Page 10-60-1.)
Press the A/C (Item 1) [Figure 80-40-17] switch to ON

Place a refrigerant container with R134a (Item 1) on a position.
charging scale (Item 2) [Figure 80-40-15] and zero out

the scale. Turn fan switch (Item 2) [Figure 80-40-17] to HIGH
position.
Connect the yellow hose (Item 3) [Figure 80-40-15] from
the manifold gauge set to the valve on the refrigerant Start loader engine, with the remote start switch, and run
tank. at medium speed.
Figure 80-40-16 Watch the scale and run system until the predetermined
amount of refrigerant is added to the A/C system.
The A/C system holds 0,91 kg (2.0 lb) of refrigerant.
Turn OFF the valve on the refrigerant container, and hand

2 valves on the manifold gauge set.
1 Turn OFF the engine, and remove the A/C charging

equipment from the loader.
P-82698
Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-40-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

COMPRESSOR Figure 80-50-2
Figure 80-50-1 2
2 1
3
1
P-82685
4 5
Disconnect the high pressure compressor hose (Item 1)
P-82677 and low pressure compressor hose (Item 2) [Figure 80-
50-2] from the compressor.
Remove the tie strap (Item 1) and disconnect the clutch Installation: Tighten the compressor hoses to 29,8 N•m
harness (Item 2). Remove the bolt (Item 3)[Figure 80-50- (22 ft-lb) torque.

1] holding the harness clamp.
Cap and plug the compressor hoses and the fittings with
Remove the nuts (Item 4) and remove the belt shield with the proper A/C caps and plugs.
(Item 5) [Figure 80-50-1].
Mark the compressor hoses for proper installation.
WARNING
gas.
W-2371-0611
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-40-1.)

COMPRESSOR (CONT'D)
Figure 80-50-3
P-82668
Remove the compressor adjustment nut and bolt (Item 1)

[Figure 80-50-3].

Installation: Tighten the compressor adjustment bolt to
46 N•m (34 ft-lb) torque.
Remove the compressor belt (Item 2) [Figure 80-50-3].
Figure 80-50-4
P-82665
Remove the compressor mount bolt (Item 1) [Figure 80-

50-4].
Remove the compressor from the loader.

COMPRESSOR (CONT'D) Oil Check
Oil The compressor oil should be checked as follows when

oil is being added to an in service loader.
Figure 80-50-5
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
1 amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-40-1.)
Open the cab door and windows.
Run the blower at maximum speed.

P-82700
Run the compressor for at least 20 minutes at 800 - 1200
rpm.
The compressor (Item 1) [Figure 80-50-5] is factory filled
with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol). Remove the compressor from the loader. (See Removal

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil. Figure 80-50-6
It is necessary to check, replenish or replace the
compressor oil in the following cases: 2
When ever the evaporator, condenser or receiver-drier is

replaced.
Whenever the refrigerant has leaked from the system.
Whenever the refrigerant is suddenly released from the

cooling cycle.
1
Whenever any oil-related problems occur in the cooling
cycle.
P-82701
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced. Remove the oil drain plug (Item 1) [Figure 80-50-6].
If the A/C compressor is changed, no oil should be added Turn the compressor over and drain the oil through the
to the system, because the compressor comes factory hose connector fittings (Item 2) [Figure 80-50-6] and the
filled with oil. oil drain hole.
NOTE: Only PAG 100 oil should be used, and never Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4
mix R-12 and R-134a Oils. - 10.8 ft-lb) torque.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check (Cont'd)
Figure 80-50-7
1
P-82701
1 Add new compressor oil through the suction side

P-82702 connector (Item 1) [Figure 80-50-8].
Installation: Add 150 - 170 cc's of PAG 100 oil.

NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil NOTE: The suction port on the compressor is marked

through the discharge-side connector by with an S and is the larger port on the
rotating the drive pulley (Item 1) [Figure 80-50- compressor.
7] 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.

Clutch Disassembly And Assembly
Figure 80-50-9 33,5 mm

(1.32”)
33,5 mm (1.32”)
33,5 mm (1.32”)
2
1
N-22275
1
The armature plate puller, (Item 1) can be constructed by

P-82706 drilling three 10 mm (0.4 in) holes in a flat circular plate,
located 33,5 mm (1.32 in) apart [Figure 80-50-11].
Remove the center armature bolt (Item 1) [Figure 80-50- Attach the puller to the armature plate using three 8 mm
9]. bolts (Item 2) [Figure 80-50-11].

Installation: Tighten the armature bolt to 12 - 14 N•m (8 - Figure 80-50-12
10 ft-lb) torque.
Figure 80-50-10
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-50-10] on the armature plate as shown in [Figure 80-
50-12].
To remove the armature plate (Item 1) [Figure 80-50-10]
from the clutch face, you must make an armature plate
puller.

Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-13
1
N-22283
1

N-22279A the pulley assembly.
Figure 80-50-16
Attach a slide hammer puller (Item 1) [Figure 80-50-13]
to the armature puller disk.

Remove the armature plate from the compressor clutch.
Figure 80-50-14
1
N-22369
Install the pulley puller tool MEL 1595 on the compressor

pulley [Figure 80-50-16].
N-22280A
Remove the shims (Item 1) [Figure 80-50-14] from either

the armature shaft or armature plate.
Installation: Insure that the clutch has the correct

clearance by adding the shims (Item 1) [Figure 80-50-
14].
The specified clearance for the clutch is 0,3 - 0,6 mm

(0.01 - 0.02 in). Adjusting shims are available in the
following thicknesses:
0,1 mm (0.0039 in)
0,3 mm (0.0118 in)
0,5 mm (0.0197 in)

Figure 80-50-17
N-22373B
Slide the wire grommet (Item 1) [Figure 80-50-19] from

N-22370 the wire holder.
Figure 80-50-20
Remove the pulley from the compressor [Figure 80-50-
17].

Figure 80-50-18
N-22374B
Remove the coil lead wire (Item 1) [Figure 80-50-20]

N-22371 from the wire holder on the compressor.
The pulley assembly and bearing [Figure 80-50-18] must

be replaced as a complete unit.

Figure 80-50-21
N-22375A
1
The compressor [Figure 80-50-23] must be replaced as
N-22372A a complete unit.
Remove the three coil mount bolts (Item 1) [Figure 80-

50-21] from the compressor.

Installation: Tighten the mount bolts to 4 - 6 N•m (2.9 -
4.3 ft-lb) torque.
Remove the coil from the compressor.
Figure 80-50-22
3 3
1
P-82705
Remove the bolt (Item 1) and hose connection block

(Item 2) [Figure 80-50-22].
Replace the O-rings (Item 3) [Figure 80-50-22] with new.
Installation: Tighten the bolt (Item 3) [Figure 80-50-22]

to 43 - 47 N•m (32 - 35 ft-lb) torque.

CONDENSER Figure 80-60-2
Figure 80-60-1
LIFT HERE
P-48011
Lift the rear of the condenser [Figure 80-60-2], and pull

P-48011 toward the rear of the loader until the front tabs (Item 1)
[Figure 80-60-4] slide out of bracket (Item 2) [Figure 80-
60-4]
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging Figure 80-60-3

Unit on Page 80-40-2.)
Open the rear grille on the loader.
Mark the two A/C hoses (Item 1) [Figure 80-60-1] for

proper installation.
WARNING
P-48010
gas. Remove the condenser from the loader [Figure 80-60-3].
W-2371-0611
Disconnect the two hoses from the condenser (Item 1)

[Figure 80-60-1].
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.

CONDENSER (CONT’D)
Figure 80-60-4
P-24303
Installation: Make sure to insert tabs (Item 1), into the

mounts (Item 2) [Figure 80-60-4], evenly for ease of

installation.

RECEIVER / DRIER Figure 80-70-2
Receiver / Drier Removal And Installation
WARNING 2

W-2059-0598
P-24298
Figure 80-70-1
Note the flow direction on the drier (Item 1) [Figure 80-

70-2] for proper installation.
1 WARNING

gas.
W-2371-0611
P-82688
Remove the two A/C hoses (Item 2) [Figure 80-70-2]
from the receiver / drier.
support device. (See Installing on Page 10-20-1.) Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
Loosen the hose clamps (Item 3) [Figure 80-70-2] that
Remove the refrigerant from the A/C system.(See holds the receiver / drier to the mount.
Unit on Page 80-40-2.) Remove the receiver / drier from the loader.
Mark the A/C hoses (Item 1) [Figure 80-70-1] for proper NOTE: When replacing a receiver / drier in an A/C
installation. system 30 cm3 (1 U.S. fl oz) of PAG 100 oil
must be added to the system when
Both fittings on the drier are the same size, so the hoses recharging.
can be hooked up incorrectly.

RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-4
Figure 80-70-3
1
N-22205
P-24295
The pressure relief valve (Item 1) [Figure 80-70-4] is
located on the receiver drier assembly.
from the receiver / drier mount bracket. Figure 80-70-5

N-22206
The pressure relief valve [Figure 80-70-5] is designed to

open and release the A/C charge if the pressure reaches
3689 kPa (36,9 bar) (535 psi).
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 2648 kPa (26,5 bar) (384
psi).
NOTE: If a Pressure Relief Valve is found open, check

the A/C system for problems. Replace the
complete receiver / drier unit.

RECEIVER / DRIER (CONT’D) Figure 80-70-7
Pressure Switch Removal And Installation
Figure 80-70-6
P-24298
1
Remove the pressure switch (Item 1) [Figure 80-70-7]

P-82688 from the A/C high pressure hose.
Remove the pressure switch from the loader.


Disconnect the loader wire harness (Item 1) [Figure 80-

70-6] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0611

RECEIVER / DRIER (CONT’D)
Schraeder® Valve Removal And Installation
Figure 80-70-8
N-22166
The Schraeder® valve (Item 1) [Figure 80-70-8] is

located in the A/C high pressure hose and is located

under the pressure switch.
Remove the refrigerant from the A/C system.(See

Unit on Page 80-40-2.)
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.

EVAPORATOR / HEATER UNIT Figure 80-80-2

Evacuate the A/C system. (See Reclamation And 1

Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 80-80-1
N-22119
3 Remove the two mounting nuts (Item 1) [Figure 80-80-

2].
1 Figure 80-80-3

2
P-66918 1
At the rear of the cab, disconnect the heater valve wiring

Disconnect the blower fan wiring connector (Item 2)

N-22120
Disconnect the thermostat connector (Item 3) [Figure
80-80-1] from the loader wiring harness.
Remove the two mounting nuts (Item 1) [Figure 80-80-
3].

EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-80-5
Figure 80-80-4
1
1
1
P-66921
Remove the heater hoses (Item 1) [Figure 80-80-5] from

N-22126 the heater coil.
Installation: Tighten the Heater hoses to 29,8 N•m (22

Remove the Evaporator / Heater Unit from the rear of the ft-lb) torque.
cab and place it on the fenders of the loader supported

by 2 X 4's [Figure 80-80-4]. Remove the evaporator / heater unit from the loader.
NOTE: Mark the tubelines for correct installation.

from the expansion valve.
Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)

torque.
Cap and plug the hoses and the expansion valve fittings

THERMOSTAT 4. Short circuit protection (Output shorted to ground)
Description 5. Temperature sensor open and short detection
The Electronic De-icing Thermostat (EDT) is a micro

DETECTION
controller based module that measures evaporator coil MALFUNCTION STATUS LED
INTERVAL
temperature and cycles the compressor clutch to
maintain a constant evaporator pressure. Onboard circuit Temperature Continuous 1x per second
protection and diagnostics are also built into the module. sensor
Temperature At A/C start up 2x per second
NOTE: The EDT has a six second delay before start sensor open and
up to protect the compressor clutch. short detection
The EDT will turn the clutch on when the evaporator coil Compressor Continuous 3x per second
temperature is above 2°C (35.6°F). If the EDT does not clutch short to
detect any malfunction, it will continue to operate and the battery
status LED will be lit continuously. When the evaporator
temperature is below -2°C (28.4°F), the EDT will turn off
the clutch and status LED.
Figure 80-90-1

1
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.
The EDT has the following protection built in:

1. Over temperature
2. Over current from clutch output
3. Voltage (Above and below operational limits or

reverse voltage)

THERMOSTAT (CONT’D) Figure 80-90-4

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the 1
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P-92613
Figure 80-90-2
Remove the thermostat probe (Item 1) [Figure 80-90-4]

from the A/C evaporator coil.
Figure 80-90-5

1 2
P-92606
Remove the nine screws (Item 1) and cover (Item 2)

[Figure 80-90-2].
P-92609
Figure 80-90-3
Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-5].
P-92603
Remove the three screws (Item 1) and left cover (Item 2)

[Figure 80-90-3].

EXPANSION VALVE Figure 80-100-2
Figure 80-100-1
N-22073
Remove the two evaporator fittings (Item 1) [Figure 80-

N-22150 100-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 29,8

NOTE: The expansion valve can be changed without N•m (22 ft-lb) torque.
removing the evaporator / heater unit from the

loader. Remove the two mount bolts (Item 2) [Figure 80-100-2].
Raise the lift arms and install an approved lift arm Remove the expansion valve from the loader.
Figure 80-100-3

1
WARNING
gas.
W-2371-0611
N-22074

from the expansion valve. Cap and plug the evaporator tubelines (Item 1) [Figure
80-100-3] and the expansion valve fittings with the proper
Installation: Tighten the two A/C hose fittings to 29,8 A/C caps and plugs.
Cap and plug the hoses and the expansion valve fittings

EXPANSION VALVE (CONT'D)
Figure 80-100-4
1
1
N-22074

from the expansion valve mount.

Remove the expansion valve mount from the unit.
Figure 80-100-5
N-22085
The expansion valve [Figure 80-100-5] is replaced as a

complete unit.

EVAPORATOR COIL Figure 80-110-3
Figure 80-110-1
N-22075
1 Remove the two mount bolts (Item 1) from the mount

N-22073 plate (Item 2) [Figure 80-110-3].
Remove the mount plate from the unit.

support device. (See Installing on Page 10-20-1.) Figure 80-110-4


Remove the evaporator / heater unit from the back of the

cab. (See Removal And Installation on Page 80-80-1.)
Remove the expansion valve (Item 1) [Figure 80-110-1]

from the unit. (See Removal And Installation on Page 80-
100-1.)
Figure 80-110-2 1
N-22076
Remove the two retaining clips (Item 1) [Figure 80-110-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)

[Figure 80-110-2] from the unit.

EVAPORATOR COIL (CONT'D)
Figure 80-110-5
N-22078
Inspect the evaporator coil [Figure 80-110-5] for leaks,

and replace as needed.

Clean with low water or air pressure.

HEATER COIL Figure 80-120-2
Removal And Installation With A/C

1
Remove the heater unit from the back of the cab. (See
Figure 80-120-1
1
N-22086
1

from the heater coil at the expansion valve end of the
unit.
2 Figure 80-120-3
2

P-66921
Remove the heater valve (Item 1) [Figure 80-120-1].

Mark the heater hoses (Item 2) [Figure 80-120-1] for

1
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system. N-22087
Remove the rear cover from the evaporator / heater unit.

(See Evaporator / Heater Coil on Page 80-20-4.) Remove the two retaining clips (Item 1) [Figure 80-120-
3] that connect the evaporator coil, to the heater coil.

HEATER COIL (CONT'D)
Removal And Installation With A/C (Cont'd)
Figure 80-120-4
1 1
N-22089
Remove the three mount bolts (Item 1) [Figure 80-120-4]

and remove the mount plate from the end of the unit.

Remove the heater coil from the unit.
Figure 80-120-5
N-22090
The heater coil [Figure 80-120-5] can be cleaned with

low air or water pressure.
If the heater coil needs replacement it must be replaced

as complete unit.

HEATER COIL (CONT'D) Figure 80-120-7
Removal And Installation Without A/C
Figure 80-120-6
1 1
2
2 N-22093
Remove the three mount bolts (Item 1) [Figure 80-120-7]

P-66921 and remove the mount plate from the end of the unit.
Figure 80-120-8

Remove the heater unit from the back of the cab. (See
Removal And Installation on Page 80-80-1.) 1
Remove the heater valve (Item 1) [Figure 80-120-6].
Mark the heater hoses (Item 2) [Figure 80-120-6] for

Cap the hoses and the heater coil with hydraulic caps N-22094
and plugs to prevent oil loss from the system.
Remove the rear cover from the evaporator / heater unit. Remove the two mount bolts (Item 1) [Figure 80-120-8]
(See Evaporator / Heater Coil on Page 80-20-4.) from the heater coil.
Remove the heater coil from the unit.


BLOWER FAN Figure 80-130-3
Raise the lift arms and install an approved lift arm 1

NOTE: The blower fan assembly can be removed

from the evaporator / heater unit without
disconnecting the heater or A/C plumbing.
The unit is remove here for photo clarity.
Figure 80-130-1
P-39553
Remove the two flange mount bolts (Item 1) [Figure 80-

1
130-3] from the evaporator / heater unit.
Figure 80-130-4

P-39550
1
Remove the cover (Item 1) [Figure 80-130-1] from the
evaporator / heater unit.
Figure 80-130-2
P-39554
1 Remove the flange and attached foam (Item 1) [Figure

80-130-4] from the unit.
P-68120
Remove the two flange mount bolts (Item 1) [Figure 80-

130-2] from the evaporator / heater unit.

BLOWER FAN (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 80-130-7
Figure 80-130-5
1 1
2 N-22102
P-68120A
Remove the eight mount bolts (Item 1) [Figure 80-130-7]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-130-5] from the unit. Remove the blower wheel cover from the housings.

Figure 80-130-6 Remove the four mount bolts (Item 2) [Figure 80-130-7]
from the blower motor mount.
1
Remove the blower motor mount.
Remove the blower motor assembly from the housing.
Figure 80-130-8
P-39556
Remove the three mount bolts (Item 1) [Figure 80-130-6] 1

from the blower fan housing.
2
Remove the blower fan housing from the evaporator /
heater unit.
N-22107
Check the blower housing (Item 1) and blower motor

mount (Item 2) [Figure 80-130-8] for wear and replace
as needed.

BLOWER FAN (CONT'D) Figure 80-130-11
Figure 80-130-9
N-22110
2 Figure 80-130-12
N-22108
Remove the outside rings (Item 1) and blower wheel

covers (Item 2) [Figure 80-130-9] from the blower motor

and blower wheels.
Figure 80-130-10
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-130-11] and [Figure 80-130-12] from the blower
wheel.
N-22109
Inspect the end rings and blower wheel covers for wear
and replace as needed [Figure 80-130-10].

BLOWER FAN (CONT'D) Connector Identification
Disassembly And Assembly (Cont'd) Figure 80-130-15
Figure 80-130-13
P-68118
N-22111
The wiring code for the blower fan connector (Item 1)
[Figure 80-130-15] is:
Remove the inside blower wheel clamp (Item 1) [Figure
80-130-13] from the blower wheel. Number on Connector Wire Color

A Orange
Figure 80-130-14
B Red
C Yellow
D Black
N-22116
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-130-14] from the blower motor shaft.
Repeat the procedure for the other blower wheel.

HEATER VALVE Figure 80-140-2

Remove the Evaporator / Heater Unit from under the cab

and place it across the mainframe supported by blocks
Remove any tie-straps that hold the heater hoses. 1
Figure 80-140-1 P-66922
Disconnect the loader wiring harness (Item 1) [Figure

80-140-2] from the heater valve.

1
3
P-66921
Remove the mount bolts (Item 1) [Figure 80-140-1] from

the heater valve mount.
Remove the heater hose clamps (Item 2) and (Item 3)

[Figure 80-140-1].
Remove the heater hoses from the heater valve.
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.

HEATER VALVE (CONT'D) Figure 80-140-5
Figure 80-140-3 1
P-66925
Remove the three mounting bolts (Item 1) [Figure 80-

P-66923 140-5] from the heater valve mount plate.
Remove the mount plate (Item 2) [Figure 80-140-5] from

Remove the three mount bolts (Item 1) [Figure 80-140-3] the heater valve bracket.
from the heater valve actuator.

Figure 80-140-6
Figure 80-140-4
1
1 1
2
2
P-66926
P-66924

Remove the actuator (Item 1) and the three mounting 6] from the heater valve.
spacers (Item 2) [Figure 80-140-4] from the heater valve
mount plate.

SPECIFICATIONS
(S185) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-3
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-2
Mainframe And Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-4
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-5
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-5
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-10
965 of 994 SPEC-01 S185 Service Manual

966 of 994 SPEC-02 S185 Service Manual

(S185) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 68 in. Construction & Industrial bucket and may vary
with other bucket types.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
95°
3862 mm
(152.1 in)
42°
3002 mm
753 mm (118.2 in)
(29.6 in)
1938 mm 2310 mm
(76.3 in) (91 in)

23° 27°
190 mm 1030 mm
(7.5 in) (40.6 in)
2588 mm
(102 in)
3309 mm B-16433
(130.3 in)
1727 mm
(68 in)
2001 mm
(78.8 in)
1433 mm
(56.4 in)
1676 mm
(66 in) B-16432
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.
967 of 994 SPEC-10-1 S185 Service Manual

(S185) LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity (ISO) 839 kg (1850 lb)

with 200 Pound Frame Mounted 907 kg (2000 lb)
Counterweight Kit
Tipping Load (ISO) 1849 kg (4076 lb)
Operating Weight 2821 kg (6220 lb)
Travel Speed
- Single Speed Loader 11,8 km/h (7.3 mph)
- Two-Speed Loader (Opt.) Low/High 12,1 km/h (7.5 mph) / 17,9 km/h (11.1 mph)
SAE Breakout Force - Lift 1588 kg (3500 lb)
SAE Breakout Force - Tilt 1554 kg (3425 lb)
Push Force 1905 kg (4200 lb)
Engine
Make / Model Kubota / V2607-DI-TE3B Interim Tier 4

Fuel / Cooling Diesel / Liquid
Horsepower (SAE Net) 43,3 kW (58 hp) @ 2700 rpm

Torque (SAE Net) 193,9 N•m (143 ft-lb) @ 1425 rpm
Number of Cylinders 4
Displacement 2,6 L (158.7 in3)
Bore / Stroke 87 mm / 110 mm (3.425 in / 4.33 in)
Lubrication Gear Pump Pressure system with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element.
Ignition Diesel Compression
Air Induction Turbo-Charged
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Low Idle 1175 - 1325 rpm
High Idle 2760 - 2900 rpm
Drive System
Main Drive Hydrostatic 4-wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully
reversing hydrostatic motors.
Final Drive Chains Prestressed #80 HSOC endless roller chain (no master link) and sprockets
in sealed chaincase with oil lubrication (No adjustment need ed). Two
chains per side with no idler sprocket.
Total Engine to Wheel Reduction 33:1
Axle Size 50,8 mm (2.00 in), heat treated
Wheel Bolts Eight - 9/16 in. Wheel Bolts fixed to axle hubs

Controls
Vehicle Steering Direction and speed controlled by two hand operated steering levers or optional
joystick(s).
Loader Hydraulics - Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System
(ACS) or optional Selectable Joystick Control (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or optional Right
Hand Selectable Joystick Control (SJC)
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or optional Left Hand
Selectable Joystick Control (SJC)
Auxiliary Pressure Release Pressure relieved through front quick couplers. Push couplers in, hold for 5
seconds.
Engine Hand lever speed control; key-type start switch or optional Deluxe
Instrumentation Panel and function error shutdown.
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s).
Secondary Brake One of the hydrostatic transmissions.
Parking Brake (Standard on Single Mechanical disc, manually operated switch on front instrument panel.
Speed and Two-Speed Loaders)
Hydraulic System

Pump Type Engine driven gear type
Pump Capacity - Standard 64 L/min (16.9 U.S. gpm) @ 2850 Engine rpm @ 91% efficiency
- High-Flow Option 100 L/min (26.4 U.S. gpm) @ 2850 Engine rpm @ 91% efficiency
System Relief at Quick Couplers 22,4 - 23,1 MPa (224 - 231 bar) (3250 - 3350 psi)
Filters Full flow replaceable, 3-micron synthetic media element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 63,5 mm (2.5 in)
Tilt Cylinder (2) 69,8 mm (2.75 in)
Rod Diameter: Lift Cylinder (2) 38,1 mm (1.50 in)
Tilt Cylinder (2) 34,9 mm (1.375 in)
Stroke: Lift Cylinder (2) 601 mm (23.67 in)
Tilt Cylinder (2) 335 mm (13.19 in)
Control Valve 3 spool, open center type with float detent on lift and electrically controlled
auxiliary spool.
Fluid Type BOBCAT FLUID, Hydraulic/Hydrostatic
6903117 - (2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Fluid Lines SAE Standard tubelines, hoses and fittings
Hydraulic Function Time:
Raise Lift Arms 3.5 Seconds
Lower Lift Arms 2.4 Seconds
Bucket Dump 2.4 Seconds
Bucket Rollback 1.9 Seconds

Electrical
Alternator Belt driven, 90 amperes ventilated

Battery 12 volt, 600 cold cranking amperes @ -18°C (0°F)
115 minute reserve capacity at 25 amperes
Starter 12 volt, gear type, 2,7 kW (3.62 hp)
Instrumentation Gauges: Engine Coolant Temperature, Fuel Level.
Warning lights: Fuel Level, Seat Belt, Engine Coolant Temperature,
Engine Malfunction, Hydraulic Malfunction, General Warning.
Indicators: BICS™ Functions, Two-Speed, 3-Point Shoulder Belt, Turn
Signals, Engine Preheat.
Data Display: Operating Hours, Engine rpm, Speed Management Setting,
Maintenance Clock Countdown, Battery Voltage, Service Codes, Engine
Preheat Countdown, Steering Drift Compensation Setting.
Other: Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:

*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock,
Attachment Control Information, High-Flow / Two-Speed / Password

Lockouts, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.
Capacities
Fuel Tank 90,8 L (24 U.S. gal)

Engine Oil with filter 9,7 L (10.25 qt)
Engine Cooling System Propylene Glycol / water mixture (53% PG / 47% water)
without heater 12,6 L (13.3 qt)
with Heater 13,7 L (14.5 qt)
Hydraulic / Hydrostatic Reservoir 18,2 L (4.8 U.S. gal)
Hydraulic / Hydrostatic System (including
Reservoir) 34,1 L (9 U.S. gal)
Chaincase Reservoir 30,3 L (8 U.S. gal)
Air Conditioning Refrigerant (R-134a) 0,91 kg (2.0 lb)
Tires
Bobcat Standard Duty Bobcat Standard Duty 10 - 16.5 8 Ply Rating

Bobcat Severe Duty Bobcat Severe Duty 10 - 16.5 10 Ply Rating
Bulky Hulk Bobcat Super Float 31 x 12 - 16.5 10 Ply Rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO
NOT mix brands of tires used on the same loader.

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE Grade 5 SAE Grade 8
Size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27-1
(180 - 200) (215 - 240)
0.375 34 - 38 47 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 -100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)

0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
N•m (475 - 525) (725 - 800)
(ft-lb) 1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Tightening Torque
O-ring Face Seal Connection
x x *
Tubeline x TORQUE
Outside x N•m
IMPORTANT Diameter
1/4”
Thread Size
9/16” - 18
(ft-lb)
18 (13)
When repairing hydrostatic and hydraulic systems, 3/8” 11/16” - 16 30 (22)
clean the work area before disassembly and keep all 1/2” 13/16” - 16 54 (40)
parts clean. Always use caps and plugs on hoses, 5/8” 1” - 14 81 (60)
damage the system. 3/4” 1-3/16” - 12 114 (84)
I-2003-0888 7/8” 1-3/16” - 12 133 (98)
1” 1-7/16” - 12 160 (118)
Figure SPEC-30-1 1-1/4” 1-11/16” - 12 209 (154)
1-1/2” 2” - 12 221 (163)

B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].

HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-30-4
Straight Thread O-ring Fitting
Figure SPEC-30-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
A-1852 Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts

the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-30-4]
the washer is tight against the surface [Figure SPEC-30-
3]. Use the chart [Figure SPEC-30-5] to find the correct
tightness needed (Item 2) [Figure SPEC-30-4]. If the
Tubelines And Hoses fitting leaks after tightening, disconnect it and inspect the
seat area for damage.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause Figure SPEC-30-5
heat.
Flare Fitting Tightening Torque
Replace hoses which show signs of wear, damage or Tubeline x TORQUE
weather cracked rubber. Outside x N•m
Diameter Thread Size (ft-lb)
Always use two wrenches when loosening and tightening 1/4” 7/16” - 20 18 (13)
hose or tubeline fittings.
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-7
(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting Tightening Torque
x TORQUE
Figure SPEC-30-6 x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
Nut Seals 1-3/16” - 12 133 (98)
To Fitting 1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
Nut Seals 1-5/8” - 12 221 (163)
To Port Use the following procedure to tighten the port seal
fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.

Secondary O-ring Seal P-13008
If a torque wrench cannot be used, use the following
method.
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at Tighten the nut until it just makes metal to metal contact,
the connection [Figure SPEC-30-6]. you can feel the resistance.
The hex portion of the nut does not contact the surface of Tighten the nut with a wrench no more than one hex flat
the component when the nut is tight. maximum.
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.


HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid

[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart


SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing loaders.
Remote Start Tools
TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool S70 This tool has been replaced by
S450 - S850 the new remote start tool
T450 - T870 7003031, see below. MEL1563
A770 includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness S70 Used with MEL1563 to connect
S450 - S850 remote start tool to machine
T450 - T870
MEL1566 Service Tool Harness S70 Used with MEL1563 to connect

Communicator S450 - S850 remote start tool to PC
T450 - T870
A770
7217666 Remote Start Tool S70 This tool replaced the original
KIT S450 - S850 remote start tool kit MEL1563
(Was 7003031) T450 - T870 and 7003031. Kit 7217666

A770 includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.
7022042 Remote Start Tool This tool replaces remote start

tool 6689778 and 7003030.
(Was 7003030)
(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to loader
6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.
6689745 BOSS Service Tool Included with 7003031 but only

Harness used on early model loaders
equipped with BOSS.
7152935 Service Tool Harness Loaders with the Used to connect the 7 pin
7 pin attachment attachment harness to remote
harness. start tool.
See BobcatNET for parts ordering information. (For Europe dealers, see the Bobcat Special Tools Catalogue for additional
information and part numbers.)
ST LDR-1014

SERVICE TOOLS REQUIRED (CONT’D)
Hydraulic Tools
TOOL PART MODELS

NUMBER USED ON
MEL10003 Hydraulic Tester S70 Either hydraulic tester, MEL10003 or
(Flow Meter) S450 - S850 TWX-RFIK200-S-6 can be used for
T450 - T870 hydraulic testing.
A770
TWX-RFIK200- Hydraulic Tester TWX-RFIK200-S-6 is no longer

S-6 (Flow Meter) available, order MEL10003.
MEL1074 O-Ring Seal Hook
MEL1075 Adjustable Gland Includes MEL1075-1 and MEL1075-2

NUt Wrench

MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2
MEL1396-2 Piston Ring

Compressor
MEL1033 Rod Seal Installation

Tool
MEL1418 Cylinder Hone = S510 - S850

2.00 in T550 - T870
OEM6275 Cylinder Hone =
2.75 - 3.00 in
3.00 - 3.50 in
3.50 - 4.00 in
ST LDR-1014

Hydraulic Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL10006 Hydraulic Test Kit S70 This test kit includes various adapters
S450 - S850 and couplers that are used when
T450 - T870 testing hydraulic functions. MEL10006
A770 Includes: MEL10006-1 thru
MEL10006-7
MEL1278 Detent Tool S70

S450 - S850
T450 - T870
MEL1285 Detent Spring Tool S70

S450 - S850
T450 - T870
A770
MEL1355-2 Pressure Gauge, S450 - S850
1000 psi T450 - T870

MEL1355-3 Pressure Gauge, A770
5000 psi
MEL1562 Bearing Installation T630 - T870
Tool
MEL1431 Seal Driver Tool S630 - S770

A770
MEL1723 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.
MEL1420 Carrier Seal S510 - S590

installation Tool
MEL1612 Bearing Removal T550 - T590

Tool
MEL1173A Hydraulic Test Kit S70 This test kit includes various adapters
and couplers that are used when
testing hydraulic functions.
MEL1723A Includes: MEL1723-1 thru
MEL1723-17
ST LDR-1014

Mainframe And Drive Tools
TOOL PART MODELS

NUMBER USED ON
MEL1407 Seal Driver Tool S510 - S770
MEL1399 Seal Driver Tool S450
MEL1525 Seal Driver Tool S70
MEL1242 Power Ram S450 - S850
MEL1202 Axle Bearing Service S70 MEL1202 Includes:

Set S450 - S770 MEL1202-1 thru MEL1202-13

MEL1714 Axle Seal Installation S750 - S850
Tool
MEL1560 Bleed Tool T550 - T870
MEL1246 Chain Link Tool S450 - S850

A770
MEL1604 Seal Driver A770
MEL1269 Chain Breaker S450 - S590
MEL1364 Chain Link Tool S450 - S590
MEL1685 Pivot Point Tapered S630 - S850

Reamer T630 - T870
MEL1734 Pivot Point Tapered S450 - S590

Reamer T450 - T590
ST LDR-1014

Electrical Tools
TOOL PART MODELS

NUMBER USED ON
MEL1609 Wheel Speed S630 - S850
T630 - T870
A770
MEL1428 Sensor Tester S70

S450 - S850
T450 - T870
A770
MEL1567 Seat Bar Adapter S450 - S850

T450 - T870
A770
Engine Tools
TOOL PART MODELS


NUMBER USED ON
7024161 Diagmaster Kit S750 - S850 Includes:
(iT4 engine only) T750 - T870 DST-i (Diagmaster Service Tool)
A770 Vehicle cable (7024272)
USB cable (7024271)
Diagmaster Diagnostic Software
MEL10630 Engine Compression S70 Includes: MEL1352, MEL1433,

Test Kit S450 - S650, MEL1489, MEL1546, MEL1551,
T450 - T650 MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14
MEL1655 Compression S450 - S650, Used in glow plug port for testing
Adapter T550 - T650 compression, NOT included with
MEL10630
MEL1614 Compression S750 - S850 Used in glow plug port for testing
Adapter T750 - T870 compression, NOT included with
A770 MEL10630
MEL1656 Fuel Injection Pump

Degree Restoring
Tool
MEL1657 Timing Gear Puller

Tool
ST LDR-1014

Engine Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool
Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357)
7031370 Rear Main Seal T4 Bobcat Used for installing rear main seal
Installer Engine
Applications
7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications

7031371 Valve Spring T4 Bobcat Used for compressing valve springs
Compressor Engine
Applications
MEL1733 Pivot Busing Installer S510 - S590, Use to install pivot bushing into
S630, S650, flywheel housing
T550 - T590,
T630, T650
4200 Injector Nozzle S70,
Tester S450 - S850
T550 - T870
A770
4201 Injector Nozzle

Tester Adapter Kit
MEL1173-1 Pressure Gauge S450 - S850

10000 psi T550 - T870
ST LDR-1014

TOOL PART MODELS

NUMBER USED ON
MEL1637 Governor Connecting S750 - S850
Rod Tool T750 - T870
A770
MEL1667 Governor Connecting S510 - S590,

Rod Tool S750 - S850
T550, T590,
T750 - T870
MEL1660 Crankshaft S510 - S650,
Replacement Tool T550 - T650
MEL1237 Fuel Line Adapter S450 - S550

T450 - T590

MEL1420 Bearing Driver S510 - S550,
A770
MEL1605 Bearing Race A770

Installer
MEL1730 Bearing Race S850

Remover
MEL1731 Bearing Race S850

Installer
MEL1606 Seal Installer
MEL1607 Snap Ring Installer
MEL1724 Crankshaft Position S750 - S850 For checking crankshaft sensor on

Sensor Measuring T750 - T870 IT4 Kubota engine
Tool A770
ST LDR-1014

TOOL PART MODELS

NUMBER USED ON
MEL1725 Compression S750 - S850 For checking compression on IT4
Adapter T750 - T870 Kubota engine
A770
MEL1666 Camshaft Gear S510 - S550
Puller T550 - T590
MEL1653 Engine Removal Tool S450 - S850, Includes:

T450 - T870, MEL1653-1, MEL1653-2,
A770 MEL1653-3, MEL1653-4,
MEL1653-5 and MEL1653-6
MEL1653-1 Engine Removal Tool S450 - S850,

T450 - T870,
A770

T750 - T870,
A770

T450 - T590

T550 - T590
MEL1653-5 Engine Removal Tool S630, S650,

T630, T650
MEL1653-6 Engine Removal Tool S750 - S850

T750 - T870,
A770
(IT4 Engines)
ST LDR-1014

TOOL PART MODELS

NUMBER USED ON
MEL1686 Engine Removal Tool S750 - S850 Used with MEL1653-2
T750 - T870
A770

Handle T740 - T870
A770

T740 - T870
A770
MEL1653-9 Engine Removal Tool S510 - S590, 2.4L Bobcat Engine Tier 4
S630, S650,

T550 - T590,
T630, T650
MEL1653-11 Engine Removal Tool S740 - S850, 3.4L Bobcat Engine Tier 4
T740 - T870,
A770
MEL1712 Push Button Starter S450 - S850,

Switch T450 - T870,
A770
MEL1270 Fuel Line Removal S70
Tool
MEL1271 Delivery Valve

Removal Tool
MEL1485 Injector Removal

Socket
ST LDR-1014

HVAC Tools
TOOL PART MODELS

NUMBER USED ON
MEL1581 HVAC Recover, S450 - S850
Recycling, T450 - T870
Recharging Machine A770
MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine
MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine
MEL1592 HVAC Refrigerant

Identification Tool
MEL1595 AC Compressor S630 - S850

Pulley Puller T630 - T870
ST LDR-1014

ALPHABETICAL INDEX
(S185) LOADER SPECIFICATIONS SPEC-10- CONVERSIONS . . . . . . . . . . . . . . .SPEC-50-1

1 CRANKSHAFT AND PISTONS . . . . . .70-90-1
ACCESS PANEL (INSIDE) (SJC) . . . . 50-121-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
AIR CONDITIONING SYSTEM FLOW . 80-10-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DIAGNOSTIC SERVICE CODES . . . . .60-90-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-60-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 DRIVE COMPONENTS . . . . . . . . . . . .40-20-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 (ACS) . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
BOBCAT CONTROLLER (GATEWAY AND ELECTRICAL / HYDRAULIC CONTROLS
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
BOBCAT CONTROLLER (SJC) (DRIVE) . . 60- ELECTRICAL / HYDRAULIC CONTROLS . 60-
72-1 140-1
BOBCAT INTERLOCK CONTROL SYSTEM ELECTRICAL SYSTEM INFORMATION 60-10-

(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 1
BOB-TACH (HAND LEVER) . . . . . . . . 10-140-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-210-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BOB-TACH (POWER) BLOCK . . . . . . 20-130-1 ENGINE COOLING SYSTEM . . . . . . .70-50-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-141-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 ENGINE LUBRICATION SYSTEM . . .10-110-1
BRAKE (SINGLE SPEED) . . . . . . . . . . 40-10-1 ENGINE SPEED CONTROL (SJC) . . .70-21-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . 40-11-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1
BUCKET POSITION VALVE . . . . . . . . 20-110-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1 EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 EXHAUST GAS RECIRCULATION (EGR)
CAMSHAFT AND TIMING GEARS . . 70-100-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
CASE DRAIN FILTER . . . . . . . . . . . . . 30-80-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . 40-30-1 FINAL DRIVE TRANSMISSION
(CHAINCASE) . . . . . . . . . . . . . . . . . .10-130-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-40-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1
FLYWHEEL AND HOUSING . . . . . . .70-120-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1
FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
CONTROL HANDLE / LEVER (ACS) . 50-111-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONTROL HANDLE / LEVER (SJC) . 50-112-1
FRONT AUXILIARY HYDRAULIC COUPLER
CONTROL HANDLE / LEVER . . . . . . 50-110-1 BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-140-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-101-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CONTROL PANEL SETUP . . . . . . . . 60-180-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
CONTROL PANEL . . . . . . . . . . . . . . . 50-100-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1
CONTROL PEDALS (ACS) . . . . . . . . . 50-91-1 HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1
CONTROL PEDALS AND LINKAGES . 50-90-1 HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1
CONTROL SYSTEM (ACS) . . . . . . . . 60-130-1 HIGH FLOW VALVE . . . . . . . . . . . . . .20-150-1
991 of 994 INDEX-01 S185 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS 20-80- MUFFLER . . . . . . . . . . . . . . . . . . . . . . 70-30-1
1 OIL COOLER . . . . . . . . . . . . . . . . . . 20-100-1
HYDRAULIC / HYDROSTATIC FLUID OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
HYDRAULIC / HYDROSTATIC SYSTEM . . 10-
120-1 OPERATOR SEAT (SUSPENSION) . . 50-31-1
HYDRAULIC CONNECTION OPERATOR SEAT . . . . . . . . . . . . . . . 50-30-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-30-1 PASSWORD SETUP (DELUXE
HYDRAULIC CONTROL VALVE (ACS) OR INSTRUMENTATION PANEL) . . . . . . 60-190-1
(SJC) . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1 PASSWORD SETUP (KEYLESS START
HYDRAULIC CONTROL VALVE (STANDARD) PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
20-40-1 PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-180-1
HYDRAULIC FLUID RESERVOIR . . . .20-90-1 REAR AUXILIARY DIVERTER VALVE 20-120-
HYDRAULIC PUMP (SJC) (HIGH FLOW) . 20- 1
71-1 REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
HYDRAULIC PUMP (SJC) . . . . . . . . . .20-70-1 REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC PUMP (STANDARD) (HIGH RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
FLOW) . . . . . . . . . . . . . . . . . . . . . . . . .20-61-1 REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC PUMP (STANDARD) . . . .20-60-1 REMOTE START TOOL (SERVICE TOOL) KIT
HYDRAULIC SYSTEM INFORMATION 20-10-1 - 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

HYDROSTATIC DRIVE MOTOR (TWO- REMOTE START TOOL KIT-1563 . . . 10-60-1
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1 SEAT BAR SENSOR . . . . . . . . . . . . 60-110-1
HYDROSTATIC MOTOR CARRIER (SINGLE SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
AND TWO-SPEED WITH MANUAL
CONTROLS) . . . . . . . . . . . . . . . . . . . .30-30-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-220-1
HYDROSTATIC MOTOR CARRIER (SINGLE SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
AND TWO-SPEED WITH SJC CONTROLS) . . SERVICE PC (LAPTOP COMPUTER) 60-150-
30-31-1 1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-51-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1 SERVICE TOOLS REQUIRED . . . .SPEC-50-1
HYDROSTATIC SYSTEM INFORMATION . 30- SPARK ARRESTER MUFFLER . . . . 10-170-1
10-1 SPEED SENSORS (SJC) . . . . . . . . . . 60-80-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 STEERING DRIFT COMPENSATION 60-161-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 STOPPING THE ENGINE AND LEAVING THE
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
LIFTING AND BLOCKING THE LOADER . 10- SYSTEM CHARGING AND RECLAMATION . .
10-1 80-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16 TIRE MAINTENANCE . . . . . . . . . . . 10-160-1
LOADER STORAGE AND RETURN TO TORQUE SPECIFICATIONS FOR BOLTS . . . .
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-190-1 SPEC-20-1
LUBRICATING THE LOADER . . . . . .10-150-1 TOWING THE LOADER . . . . . . . . . . . 10-50-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-30-1 TRANSPORTING LOADER ON A TRAILER . .
MAINTENANCE CLOCK . . . . . . . . . .60-200-1 10-40-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 TROUBLESHOOTING . . . . . . . . . . . . 80-30-1

TURBOCHARGER . . . . . . . . . . . . . . . 70-110-1
TWO-SPEED VALVE . . . . . . . . . . . . . . 30-70-1
WINDOW (CAB DOOR) . . . . . . . . . . . 50-133-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1


Bobcat Manual de Servicio S185 6987049

Uploaded by

Copyright:

Available Formats

Bobcat Manual de Servicio S185 6987049

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bobcat Manual de Servicio S185 6987049

Uploaded by

Copyright:

Available Formats

What safety precautions are outlined in the document?

What safety precautions are outlined in the document?

What types of maintenance are discussed?

What types of maintenance are discussed?

Service Manual

S185 Skid-Steer Loader

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 B-15535 B-15524

Dealer Copy -- Not for Resale

B-15733 B-15523 B-6589

3 of 994 1-1 S185 Service Manual

4 of 994 1-2 S185 Service Manual

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 994 1-3 S185 Service Manual

6 of 994 1-4 S185 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 994 1-5 S185 Service Manual

8 of 994 1-6 S185 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 994 1-7 S185 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 994 1-8 S185 Service Manual

11 of 994 1-9 S185 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

12 of 994 1-10 S185 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

13 of 994 1-11 S185 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System