Service Manual S100 Skid-Steer Loader: S/N A2G811001 & Above S/N A8ET11001 - A8ET19999

EN
Service Manual
S100 Skid-Steer Loader
S/N A2G811001 & Above

S/N A8ET11001 - A8ET19999
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6904926enGB (01-09) (B) Printed in Europe © Bobcat Company 2009
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and

understand the Operation & Maintenance Manual, Operator’s Handbook and
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
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-15590 B-15591
Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-15592 B-15593 B-15599

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner /
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01 HYDRAULIC / HYDROSTATIC SYSTEM ................10-01

AIR CLEANER SERVICE ....................................... 10-01 HYDRAULIC PUMP .................................................20-01
ALTERNATOR ......................................................... 60-01 HYDRAULIC SYSTEM INFORMATION ................. 20-01
HYDROSTATIC MOTOR .........................................30-01
BACK-UP ALARM SYSTEM ........................ 10-01, 60-01 HYDROSTATIC PUMP ............................................30-01
BATTERY. ................................................................60-01 HYDROSTATIC SYSTEM INFORMATION .............30-01
BLOWER FAN ......................................................... 20-01
BOBCAT CONTROLLER (MAIN) ............................ 60-01 INSTRUMENT PANELS...........................................60-01
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS) ...................................................... 60-01 LIFT ARM BYPASS CONTROL VALVE ...................20-01
BOB-TACH (HAND LEVER)......................... 10-01, 50-01 LIFT ARMS. .............................................................. 50-01
BOB-TACH (POWER) BLOCK ................................ 20-01 LIFT ARM SUPPORT DEVICE ................................10-01
BOB-TACH (POWER-OPTION).....................10-01, 50-01 LIFTING AND BLOCKING THE LOADER ...............10-01
BRAKE ..................................................................... 40-01 LIGHTS ....................................................................60-01
BUCKET POSITION VALVE .................................... 20-01 LOADER SPECIFICATIONS ............................. SPEC-01
LOADER STORAGE AND RETURN TO SERVICE.10-01
CAB DOOR .............................................................. 50-01 LUBRICATING THE LOADER .................................10-01
CAMSHAFT AND TIMING GEARS. ........................ 70-01 LUBRICATION SYSTEM .........................................70-01
CASE DRAIN FILTER .............................................. 30-01
CHAINCASE ............................................................ 40-01 MAINTENANCE CLOCK ..........................................60-01
CHARGE PRESSURE ............................................. 30-01 MAIN RELIEF VALVE ...............................................20-01
CONTROL HANDLE / LEVER ................................. 50-01 MUFFLER ................................................................70-01
CONTROL PANEL ................................................... 50-01
CONTROL PANEL SETUP ...................................... 60-01 OIL COOLER ...........................................................20-01
CONTROL PEDALS AND LINKAGE ....................... 50-01 OPERATOR CAB ......................................... 10-01, 50-01
CONVERSIONS.................................................SPEC-01 OPERATOR SEAT ......................................................50-01
CRANKSHAFT AND PISTONS ............................... 70-01 OPERATOR SEAT (SUSPENSION) ........................50-01
CYLINDER (BOB-TACH) ......................................... 20-01
CYLINDER HEAD .................................................... 70-01 PASSWORD SETUP ...............................................60-01
CYLINDER (LIFT) .................................................... 20-01 PIVOT PINS ............................................................. 10-01
CYLINDER (TILT) .................................................... 20-01
REAR DOOR ............................................................50-01
DIAGNOSTICS SERVICE CODES .......................... 60-01 REAR GRILL ............................................................50-01
DRIVE BELT ............................................................ 30-01 REGULAR MAINTENANCE .....................................80-01
DRIVE COMPONENETS ......................................... 40-01 REMOTE START TOOL ...........................................10-01
ELECTRICAL SYSTEM INFORMATION ................. 60-01 SEAT BAR ................................................................50-01

ENGINE COOLING SYSTEM ...................... 10-01, 70-01 SEAT BAR SENSOR ................................................60-01
ENGINE INFORMATION ......................................... 70-01 SERVICE PC (LAPTOP COMPUTER) ....................60-01
ENGINE LUBRICATION SYSTEM ........................... 10-01 SERVICE SCHEDULE ............................................ 10-01
ENGINE SPEED CONTROL ................................... 70-01 SPARK ARRESTOR MUFFLER ..............................10-01
STARTER .................................................................60-01
FINAL DRIVE TRANSMISSION (CHAINCASE) ...... 10-01 STOPPING THE ENGINE AND
FLYWHEEL AND HOUSING ................................... 70-01 LEAVING THE LOADER ..........................................10-01
FLYWHEEL RPM SENSOR......................................60-01
FRONT AUXILIARY HYDRAULIC COUPLER TIRE MAINTENANCE ..............................................10-01
BLOCK. ..................................................................... 20-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
FUEL SYSTEM..............................................10-01, 70-01 TOWING THE LOADER ...........................................10-01
FUEL TANK .............................................................. 50-01 TRACTION LOCK ....................................................60-01
TRANSPORTING THE BOBCAT LOADER .............10-01
HEATER COIL ......................................................... 80-01 TROUBLESHOOTING .............................................80-01
HEATER FAN........................................................... 80-01
HEATER SYSTEM ................................................... 80-01 WINDOW (FRONT DOOR) ......................................50-01
HEATER UNIT ......................................................... 80-01 WINDOW (REAR) ....................................................50-01
HEATER VALVE............................................................ 80-01 WINDOW (SIDE) ......................................................50-01
HYDRAULIC CONNECTION SPECS ................SPEC-01 WINDOW (TOP) .......................................................50-01
HYDRAULIC CONTROL VALVE ............................. 20-01
HYDRAULIC FLUID RESERVOIR ........................... 20-01
HYDRAULIC / HYDROSTATIC FILTERS................. 20-01
HYDRAULIC / HYDROSTATIC
FLUID SPECIFICATIONS ..................................SPEC-01
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CONTENTS
SAFETY &
MAINTENANCE
FOREWORD ...................................................................................... II
SAFETY INSTRUCTIONS ................................................................. V

HYDRAULIC
FIRE PREVENTION......................................................................... VII SYSTEM
SERIAL NUMBER LOCATIONS ....................................................... IX

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

DRIVE
SAFETY AND MAINTENANCE .................................................. 10-01 SYSTEM
HYDRAULIC SYSTEM................................................................ 20-01
HYDROSTATIC SYSTEM ........................................................... 30-01 MAIN FRAME
DRIVE SYSTEM ......................................................................... 40-01

ELECTRICAL
MAIN FRAME ............................................................................. 50-01 SYSTEM &
ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS ........................................ 60-01
ENGINE SERVICE...................................................................... 70-01 ENGINE

SERVICE
HEATER ..................................................................................... 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER
SPECIFICATIONS
7 of 521 I S100 Service Manual

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-0308 SM
8 of 521 II S100 Service Manual

17. Check the condition of the 22. Check for any field
battery and cables. modification not completed.
18. Inspect the air cleaner for 23. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: back-
approved tires or tracks. up alarm, fire extinguisher,
rotating beacon, lift kits, etc.).
21. Inspect for loose or broken 26. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
FW SSL-0308 SM
9 of 521 III S100 Service Manual

FW SSL-0308 SM
10 of 521 IV S100 Service Manual

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

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

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

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-0308 SM
11 of 521 V S100 Service Manual

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.
SI SSL-0308 SM
12 of 521 VI S100 Service Manual

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
Stop the engine and let it cool before adding fuel. No
compartment is a potential fire hazard.
smoking! Do not refuel a machine near open flames or
sparks. Fill the fuel tank outdoors.
The operator’s area, engine compartment and engine
cooling system must be inspected every day and cleaned
Starting
if necessary to prevent fire hazards and overheating.
Do not use ether or starting fluids on any engine that has
All fuels, most lubricants and some coolants mixtures are
glow plugs. These starting aids can cause explosion and
flammable. Flammable fluids that are leaking or spilled
injure you or bystanders.
onto hot surfaces or onto electrical components can
cause a fire.
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Operation
Do not use the machine where exhaust, arcs, sparks or

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

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use the
procedure in the Operation & Maintenance Manual for
connecting the battery and for jump starting. Do not jump
start or charge a frozen or damaged battery. Keep any
open flames or sparks away from batteries. Do not smoke
in battery charging area.
SI SSL-0308 SM
13 of 521 VII S100 Service Manual

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-0308 SM
14 of 521 VIII S100 Service Manual

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.
Figure 1
S4043
1
The engine serial number is located on top of the engine

(Item 1) [Figure 2].
S4464
Loader Serial Number
The loader serial number plate (Item 1) [Figure 1] is

located inside the cab on the right-hand side.
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.
15 of 521 IX S100 Service Manual

DELIVERY REPORT
Figure 3
B-16315
The delivery report must be filled out by the dealer and

signed by the owner or operator when the Bobcat Loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure 3].
16 of 521 X S100 Service Manual

LOADER IDENTIFICATION
FRONT LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
FRONT AUXILIARY
QUICK COUPLERS
TILT
CYLINDER
STEPS
BUCKET † S0183
BUCKET STEP
● OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
DEVICE
LIFT ARM
REAR
GRILL
LIFT
BACK-UP CYLINDER
ALARM
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
S0184
* TIRES
* TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.
Level II is available.
† Bucket - Several different Buckets and other Attachments are available.
17 of 521 XI S100 Service Manual

18 of 521 XII S100 Service Manual
SAFETY AND MAINTENANCE
SAFETY AND
AIR CLEANER SERVICE......................................................................... 10-80-1 MAINTENANCE
Replacing Filter Elements ................................................................... 10-80-1
BACK-UP ALARM SYSTEM .................................................................. 10-210-1

Description ........................................................................................ 10-210-1
Operation .......................................................................................... 10-210-1
BOB-TACH (HAND LEVER)................................................................... 10-140-1

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

Inspection And Maintenance ............................................................. 10-141-1
ENGINE COOLING SYSTEM .................................................................. 10-90-1

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

Checking And Adding Engine Oil ...................................................... 10-110-1
Engine Oil Chart ............................................................................... 10-110-1
Removing And Replacing Oil And Filter ............................................ 10-110-1
FINAL DRIVE TRANSMISSION (CHAINCASE) ..................................... 10-130-1

Checking And Adding Oil .................................................................. 10-130-1
Removing And Replacing Oil ............................................................ 10-130-1
FUEL SYSTEM ...................................................................................... 10-100-1

Filling The Fuel Tank......................................................................... 10-100-1
Fuel Filter .......................................................................................... 10-100-2
Fuel Specifications............................................................................ 10-100-1
Removing Air From The Fuel System ............................................... 10-100-2
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 and Case Drain Filters . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter .................... 10-120-1
LIFT ARM SUPPORT DEVICE ................................................................ 10-20-1

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

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

Return To Service ............................................................................. 10-190-1
Storage ............................................................................................. 10-190-1
Continued On Next Page
19 of 521 10-02 S100 Service Manual

SAFETY AND MAINTENANCE (CONT’D)
LUBRICATING THE LOADER ...............................................................10-150-1

Lubrication Locations ........................................................................10-150-1
OPERATOR CAB .....................................................................................10-30-1

Cab Door Sensor (If Equipped) ...........................................................10-30-3
Description ..........................................................................................10-30-1
Lowering .............................................................................................10-30-2
Raising ................................................................................................10-30-1
PIVOT PINS ...........................................................................................10-180-1

Inspection And Maintenance .............................................................10-180-1
REMOTE START TOOL KIT-MEL1563 ...................................................10-60-1

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

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

Chart ...................................................................................................10-70-1
SPARK ARRESTOR MUFFLER ............................................................10-170-1

Cleaning Procedure ..........................................................................10-170-1
STOPPING THE ENGINE AND LEAVING THE LOADER .....................10-200-1

Emergency Exit .................................................................................10-200-2
Procedure .........................................................................................10-200-1
TIRE MAINTENANCE ............................................................................10-160-1

Mounting ...........................................................................................10-160-1
Rotating ............................................................................................10-160-1
Wheel Nuts .......................................................................................10-160-1
TOWING THE LOADER ...........................................................................10-50-1

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

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

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.

LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
S6030
Put the floor jack under the rear of the loader.

B-7023A
Lift the rear of the loader and install jack stands [Figure
10-10-2].
Figure 10-10-3
WARNING
AVOID INJURY OR DEATH
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
S6031
Always park the loader on a level surface.

Put the floor jack under the front of the loader [Figure 10-
10-3].
WARNING Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners NOTE: Make sure the jack stands do not touch the
of the frame before running the engine for service. tires. Make sure tires clear floor or any
Failure to use jackstands can allow the machine to fall obstacles.
or move and cause injury or death.
W-2017-0286
21 of 521 10-10-1 S100 Service Manual

LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
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
1
to fall and cause injury or death.
W-2059-0598
1
P43747
Install jackstands (Item 1) [Figure 10-20-1] under the rear
WARNING corners of the loader frame.
Figure 10-20-2
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or with
missing parts can cause lift arms to drop causing
injury or death.
W-2271-1197
P54468
Disconnect the spring (Item 1) from the lift arm support

device retaining pin. Support the lift arm support device
(Item 2) with your hand and remove the retaining pin (Item
3) [Figure 10-20-2].

LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) Remove the retaining pin (Item 1) [Figure 10-20-4] from
the lift arm support device.
Figure 10-20-3
Figure 10-20-5
P54469
P54472
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure Connect the spring (Item 1) [Figure 10-20-5] from the lift
10-20-3] to the lift arm support device so the spring does arm support device to the bracket below the lift arms.
not interfere with the support device engagement.
Sit in the operator’s seat, fasten the seat belt and lower
Sit in the operator seat, fasten the seat belt and lower the the seat bar. Start the engine.
seat bar. Start the engine.
Figure 10-20-6
Figure 10-20-4
P54468
P54470 N20524
Raise the lift arms a small amount. The spring will lift the
Raise the lift arms until the lift arm support device drops support device off the lift cylinder rod. Lower the lift arms.
onto the lift cylinder rod [Figure 10-20-4]. Stop the engine.
Lower the lift arms slowly until the support device is held Raise the seat bar, unbuckle the seat belt, move the
between the lift arm and the lift cylinder. Stop the engine. pedals until both lock and exit the cab.
Raise the seat bar and move the pedals until both lock.
Disconnect the spring from the bracket.
Install the retaining pin (Item 1) [Figure 10-20-4] into the
rear of the lift arm support device below the cylinder rod. Raise the support device into storage position and insert
the retaining pin (Item 1) [Figure 10-20-6] through the lift
arm support device and through the bracket. Connect the
spring to the retaining pin.
Remove the jackstands.

OPERATOR CAB Raising
Description Always stop the engine before raising or lowering the cab.
The Bobcat loader has an operator cab (ROPS and Stop the loader on a level surface and lower the lift arms.
FOPS) as standard equipment to protect the operator If the lift arms must be up while raising the operator cab,
from rollover and falling objects. Check with your dealer if install the lift arm support device. (See LIFT ARM
the operator cab has been damaged. The seat belt must SUPPORT DEVICE on Page 10-20-1.)
be worn for rollover protection.
Figure 10-30-1
ROPS / FOPS - Roll Over Protective Structure per ISO
3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
Level I - Protection from falling bricks, small concrete

blocks, and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.
Level II - Protection from falling trees, rocks: for machines

involved in site clearing, overhead demolition or forestry.
1
1
WARNING P43747
Never modify operator cab by welding, grinding, Install jackstands (Item 1) [Figure 10-30-1] under the rear
drilling holes or adding attachments unless corners of the loader frame.
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from Figure 10-30-2
rollover and falling objects, and result in injury or
death.
W-2069-0200
1 2
S4011 S4012
Remove the nut and plate (Items 1 and 2) [Figure 10-30-

2] on the inside front corner of the cab (Both sides).

OPERATOR CAB (CONT’D)
Raising (Cont’d)
Figure 10-30-3
WARNING
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Support the cab and release the latching mechanism

(Inset) [Figure 10-30-4]. Remove your hand from the
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way.
NOTE: Always use the grab handles (once you can

reach them) to lower the cab.
Figure 10-30-5
S4078
Lift on the grab handle and bottom of the operator cab 2

slowly until the cab is all the way up and the latching 1
mechanism engages [Figure 10-30-3].
Lowering 2
Always stop the engine before raising or lowering the cab. 1
Figure 10-30-4 S4012 S4011

SXXXX SXXXX
Install the plates and nuts (Items 1 and 2) [Figure 10-30-

5] (both sides).
Tighten the nuts to 40-50 ft.-lb. (54-68 N•m) torque.
S4013
N20120
Pull down on the bottom of the operator cab until it stops

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

equipped with options and accessories such
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 10-30-7
Cab Door Sensor (If Equipped)
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
S3999A
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] will
be ON when the door is open, the key switch is turned to
RUN or the RUN / ENTER button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER button
1
is pressed.
2
[DOOR] will appear in the data display [Figure 10-30-7].
P-68116
P-68115
The cab door (option) has a sensor (Item 1) [Figure 10-

30-6] installed which deactivates the lift and tilt valves
when the door is open.
A decal is located on the latch mechanism (Item 2)

[Figure 10-30-6].
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] 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.

TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when S4759 S4758
loading onto a transport vehicle. Wood ramps can

break and cause personal injury.
W-2058-0807
Be sure the transport and towing vehicles are of adequate

size and capacity for the weight of the loader. (See
Weights on Page SPEC-10-2.)
Figure 10-40-1 Alternate Front

Tie Down
S1848 S1075
Use the following procedure to fasten the Bobcat Loader

to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].
• Lower the bucket or attachment to the floor.

S1077
• Stop the engine.
A loader with an empty bucket or no attachment must be • Engage the parking brake.
loaded backward onto the transport vehicle [Figure 10-
40-1]. • Install chains at the front and rear loader tie down
positions [Figure 10-40-2].
The rear of the trailer must be blocked or supported
[Figure 10-40-1] when loading or unloading the loader to • Fasten each end of the chain to the transport vehicle.
prevent the front end of the trailer from raising up.

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
wheels will not turn.) There might be slight wear to the
wheels when the loader is skidded.
The towing chain (or cable) must be rated at 1 and 1/

2 times the weight of the loader. (See Weights on
Page SPEC-10-2.)

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

are: The traction lock switch (Item 1) [Figure 10-60-2] is used
to turn traction lock ON or OFF. Push the switch to the
MEL1563 - Remote Start Tool override position. The switch will illuminate to indicate
MEL1565 - Service Tool Harness Control traction lock OVERRIDE, in this position the wheels are
MEL1566 - Service Tool Harness Communicator able to turn.
(Computer Interface)
The maximum flow/variable flow switch (Item 2) [Figure
Remote Start Tool - MEL1563 10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
Figure 10-60-1 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF. The
switch is used when checking pressures and flow rate.
1
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.
P16114
The remote start tool (Item 1) [Figure 10-60-1] is required

when the service technician is checking the hydraulic/
hydrostatic system or adjusting the steering linkage.
2
3
1
P16117
10-60-1 S100 Service Manual

33 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
P16116
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-5] to
Figure 10-60-4 the electrical system on the loader.
1 Figure 10-60-6
P16120
S6014
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the cap (Item 1) [Figure 10-60-6] from the loader
harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-4].

34 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566
Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8
Figure 10-60-7 2
2
1 1
P16119
EM1024
The service tool harness communicator (Item 1) is
required to connect remote start tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-8].
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-7].
Connect the service tool harness to the ACD connector

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

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

35 of 521
REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-11
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
1
MEL1563: Remote Start Tool Kit
Figure 10-60-9
EM1024
Remove the cap (Item 1) [Figure 10-60-10] or disconnect

the attachment control harness (Item 1) [Figure 10-60-
11] if connected.
Figure 10-60-12
P16115
The remote start tool (Item 1) [Figure 10-60-9] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch on
or start the engine. Example: adjusting the steering
linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).

S6035
Open the rear door of the loader.
Connect the remote start tool to the loader harness
Figure 10-60-10 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.
1
WARNING
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
S6014 start tool in the run position disconnects the operator
panel key switch from the start circuit. If the service
technician will be working in the engine area it is
important to remove the operator panel keys.
W-2357-0899

36 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) The auxiliary pressure release (Item 3) [Figure 10-60-14]
is used to release hydraulic pressure to the front and/or
Remote Start Procedure (Cont'd) rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
Figure 10-60-13
NOTE: With the engine running; pushing and holding
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
P16116
The remote start tool (Item 1) [Figure 10-60-13] has three

rocker switches.
Figure 10-60-14 NOTE: With the engine running; pushing and holding
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
2 Figure 10-60-15
3 1
P16118
The traction lock switch (Item 1) [Figure 10-60-14] 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.
P-34661
The maximum flow/variable flow switch (Item 2) [Figure

10-60-14] is used to activate the auxiliary hydraulics. Push the couplers on the front auxiliary block toward the
Pressing the switch once will activate variable flow. block and hold for five seconds to release the front
Pressing the switch again will activate maximum flow. The auxiliary pressure [Figure 10-60-15].
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.

37 of 521
38 of 521
REMOTE START TOOL (SERVICE TOOL) KIT -
6689779
Description
The Remote Start Tool (Service Tool) Kit is a replacement

tool for MEL 1563 Remote Start Tool and MEL 1400B -
BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 6689779,

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

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

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

39 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
6689779 (CONT'D)
2
Tools that will be needed to complete the following steps
are:
5 3
Order from Bobcat Parts P/N: 6689779 - Remote Start
Tool (Service Tool) Kit
6 4
Kit Includes:
6689778 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness 1
6689745 - BOSS® Service Tool Harness
Remote Start Tool (Service Tool) - 6689778

P-76439
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
1 loader ignition power. The button will illuminate to 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 required button will illuminate indicating the traction lock is disabled
when the service technician is checking the hydraulic / in which the wheels or tracks are able to turn.
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.

40 of 521
6689779 (CONT'D)
2
Loader Service Tool Harness - 6689747
Figure 10-61-3
1
EM1024
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) is used to When the remote start procedure is completed, replace
connect the remote start tool (service tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. reconnect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
S6014
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), to the loader harness
connector.

41 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
6689779 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
3 1
2
P-76450
1
S6035 The computer service tool harness (Item 1) 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. This
connector is not used on the S100.
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 (Standard Key

Panel or Deluxe Instrumentation Panel) must
be in the off position or the Remote Start Tool
(Service Tool) will not operate.
P-76454

42 of 521
6689779 (CONT'D)
Remote Start Procedure
WARNING 1

With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
S6014
Pressing the RUN button on the Remote Start Tool
disconnects the operator panel from the start circuit.
If the service technician will be working in the engine Loaders without an attachment control harness, remove
area it is important to remove the operator panel key the loader harness cap (Item 1) [Figure 10-61-9] and
or lock the keypad with a unique password. connect the Loader Service Tool Harness, from the
W-2647-0707 Remote Start Tool (Service Tool), to the loader harness
connector.
Figure 10-61-10
procedure:
6689779: Remote Start Tool (Service Tool) Kit
Figure 10-61-8 2
1
EM1024
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76450 disconnected from the loader harness (Item 2) [Figure
10-61-10].
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-8] is required when the operator cab is in the raised When the remote start procedure is completed, replace
position for service and the service technician needs to the loader connector cap (Item 1) [Figure 10-61-10] or
turn on the loader or start the engine. Example: adjusting reconnect the attachment control harness to the loader
the steering linkage. harness [Figure 10-61-10].
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).

43 of 521
6689779 (CONT'D)
Remote Start Procedure (Cont'd) The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-12] has five buttons.
Figure 10-61-11
The STOP button (Item 2) [Figure 10-61-12] is used to
3 stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
The RUN button (Item 3) [Figure 10-61-12] is used to turn

the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to indicate
the service tool is active.
2
The START button (Item 4) [Figure 10-61-12] is used to
start the loader engine.
1 The traction lock button (Item 5) [Figure 10-61-12] is

used to turn traction lock ON or OFF. Push the button and
S6035 the button will illuminate indicating the traction lock is
disabled in which the wheels or tracks are able to turn.
NOTE: The Remote Start Tool (Service Tool) The auxiliary button (Item 6) [Figure 10-61-12] is used to
connection harness has two connectors (Item activate the auxiliary hydraulics. The button will illuminate
1) and (Item 3). The main connector (Item 1) to indicate the auxiliary hydraulics are active. Pressing the
[Figure 10-61-11] is always used for button a second time will turn the flow OFF. The button is
connection to the loader harness. used when checking pressures and flow rate.
The second connector (Item 3) [Figure 10-61-

11] 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 10-61-11].
NOTE: The right instrument panel (Standard Key

Panel or Deluxe Instrumentation Panel) must
be in the off position or the Remote Start Tool
(Service Tool) will not operate.
5 3
6 4
P-76439

44 of 521
6689779 (CONT'D)
P-76454

44 of 521
6689779 (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 to the right and left several
times.

45 of 521
46 of 521
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 condition indicator, replace element when required. Check for leaks and
damaged components. Empty dust cup as needed.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Seat Belt, Seat Belt Retractors, Check the condition of seat belt. Clean or replace seat belt retractors as
Seat Bar needed. Clean dirt and debris from moving parts. Check the seat bar and
control interlocks for correct operation.
Bobcat Interlock Control Check that four BICS indicator lights and functions are activated. See details in
Systems (BICS) 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.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on sidewall of tire.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater Filter (If equipped) Clean or replace filter as needed.
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 oil level and add oil as needed. Check for correct operation. Repair or
Foot Pedals, Steering Levers adjust as needed.
Parking Brake Check operation.
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. ❏
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. ❍
Alternator Belt Check condition and tension. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. Use CF/CG4 or better grade oil and Bobcat filter. ✵
Hydrostatic Filter, Charge Filter Replace the hydrostatic filter and the charge filter. ▼
Engine Valves Adjust the engine valves.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Coolant Replace the coolant. Every 2 years.
■ Or every 12 months.
❏ Check every 8-10 hours for the first 50 hours, then 50 hour intervals thereafter.
❍ Inspect new belt after first 50 hours.
▼ Replace the hydraulic / hydrostatic filter element after the first 50 hours; and thereafter when the transmission warning light
comes ON while operating or at the 500 hour interval.
✵ First oil and filter change must occur at 50 hours; every 250 hours thereafter.

AIR CLEANER SERVICE Figure 10-80-3
Replacing Filter Elements
Figure 10-80-1
S4020
1 2
Pull the element straight out (Item 1) [Figure 10-80-3].
Install a new outer element.

S4051
Install the dust cover (Item 2) [Figure 10-80-2].
Replace the large (outer) filter element only when the red
Check the air intake hose and the air cleaner housing for
ring shows in the window of the condition indicator (Item
damage. Make sure all connections are tight.
1) [Figure 10-80-1].
Inner Filter
NOTE: Before replacing the filter element, push the
button on the condition indicator (Item 2)
Replace the inner filter every third time the outer filter is
[Figure 10-80-1]. Start the engine. If the red
replaced or when the red ring still shows in the indicator
ring does not show, do not replace the filter
window after the outer filter has been replaced.
element.
Figure 10-80-4
Outer Filter
Figure 10-80-2
1
S4019
S4021
Remove the inner filter (Item 1) [Figure 10-80-4].
S4014 NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Open the evacuator valve (Item 1) [Figure 10-80-2] to get
rid of large particles of dust and dirt. Install a new inner element.
Remove the dust cover by lifting the lever (Item 2) [Figure Install the outer element.
10-80-2].
Install the dust cover [Figure 10-80-2].

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

heating, loss of performance or engine damage. 1
Cleaning
Open the rear door and raise the rear grill.
NOTE: Be careful when raising and lowering the rear

grill so that it does not fall on the radiator and
damage the fins.
Figure 10-90-1
S0297
Remove the coolant fill cap (Item 1) [Figure 10-90-2].

Check the coolant level. The level markers are on the
tank. Coolant must be at the bottom marker when the
engine is cold and on the top marker when hot.
Use a refractometer to check the condition of propylene

1 glycol in your cooling system.
Close the rear door before operating the loader.

S4082
Use low air pressure or water pressure to clean the top of

the radiator (Item 1) [Figure 10-90-1].
IMPORTANT
Check the cooling system for leaks.
AVOID ENGINE DAMAGE
Lower the rear grill and close the rear door. Always use the correct ratio of water to antifreeze.
Checking Level Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
Open the rear door and remove the rear grill (See REAR damage.
GRILL on Page 50-60-1).
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
WARNING Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
AVOID INJURY OR DEATH engine damage.
I-2124-0497
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

ENGINE COOLING SYSTEM (CONT’D) Use a refractometer to check the condition of propylene
glycol in your cooling system.
Removing And Replacing Coolant
Run the engine until it is at operating temperature. After
Open the rear door and remove the rear grill. stopping the engine, let it cool down and check the
coolant level again. Add coolant as needed.
Figure 10-90-3
Install the rear grill and close the rear door.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
S0297
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Remove the coolant fill cap (Item 1) [Figure 10-90-3].
Always add a premixed solution. Adding full strength
Connect a hose to the engine block drain valve. Open the concentrated coolant can cause serious premature
drain valve, connect a hose to it and drain the coolant into engine damage.
a container. I-2124-0497
After all the coolant is removed, close the drain valve and
remove the hose.
NOTE: Fluids such as engine oil, hydraulic fluid,

coolant, etc. must be disposed of in an
environmentally safe manner. Some
regulations require that certain spills and
leaks on the ground must be cleaned in a
specific manner. See local, state and federal
regulations for correct disposal.
Mix the coolant in a separate container. (See Fluid

Specifications on Page SPEC-10-5.) Use 53% propylene
glycol and 47% water.
1 gallon and one pint of propylene glycol mixed with 1

gallon of water is the correct ratio (53% / 47%) to
provide -34°F (-37°C) freeze protection.
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Fill the recovery tank with premixed coolant until it is at the

lower marker on the tank. Install the coolant fill cap (Item
1) [Figure 10-90-3].

FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG
Use only clean, high quality diesel fuel, Grade No. 2 or

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

should prevent fuel gelling during cold temperatures:
TEMPERATURE F° (C°) NO. 2 NO. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B15650
Contact your fuel supplier for local recommendations.
Filling The Fuel Tank Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has free
movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Inset) [Figure 10-100-
WARNING 1].

Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire. WARNING
W-2063-0807
Figure 10-100-1 Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
S4014
Open the rear door.
Remove the fuel fill cap (Inset) [Figure 10-100-1].

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter
For the service interval for removing water from, or

replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.).
WARNING
Removing Water
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Figure 10-100-3
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
S4014
3
After replacing the filter element or when the fuel tank has
run out of fuel, the air must be removed from the fuel
4 system before starting the engine.
1
S4017
2 Figure 10-100-4
S4014
Loosen the drain (Item 1) [Figure 10-100-3] at the bottom

of the filter element to remove water from the filter.
Replacing Element
S4018
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten. S4014
Remove air from the fuel system. (See Removing Air

From The Fuel System below.) Open the vent (Item 3) [Figure 10-100-3] on the fuel filter
housing.
Squeeze the hand pump (priming bulb) (Inset) [Figure

10-100-4] until air bubbles do not come up any more.
Close the vent (Item 3) [Figure 10-100-3] on the fuel filter

housing.
Open the vent (Item 4) [Figure 10-100-3] on the fuel

injection pump.
Squeeze the hand pump (priming bulb) (Inset) [Figure

10-100-4] until air bubbles do not come up any more.
Close the vent (Item 4) [Figure 10-100-3] on the fuel

injection pump.
Start the engine.
It may be necessary to open the vent plug briefly while the

engine is running. Close the vent when the engine runs
smoothly.

ENGINE LUBRICATION SYSTEM Removing And Replacing Oil And Filter
Checking And Adding Engine Oil For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-110-1
Figure 10-110-3
2
S4023
1
S4024
2 S4014
Open the rear door.
Open the rear door and remove the dipstick (Item 1) Remove the drain hose from its storage position. Remove
[Figure 10-110-1]. the drain plug (Item 1) [Figure 10-110-3].
Keep the oil level between the marks on the dipstick. Drain the oil into a container and dispose of used oil in an
environmentally safe manner.
Engine Oil Chart Remove the oil filter (Item 2) [Figure 10-110-3].
Figure 10-110-2 Clean the filter housing surface.

Put clean oil on the new oil filter gasket.
Install the filter and hand tighten.
Install and tighten the drain plug.
Add engine oil.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
B16320 Failure to use care around combustibles can cause
explosion or fire.
Use a good quality motor oil that meets API Service W-2103-0508
Classification of CD or better. (See Engine Oil Chart
[Figure 10-110-2].)

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-2
Use only recommended fluid in the hydraulic system. (See

Specifications on Page SPEC-40-1.)
Stop the loader on a level surface.
Lower the lift arms and tilt the Bob-Tach fully back.
Stop the engine.

Figure 10-120-1
P64023A
Use the correct hydraulic / hydrostatic fluid shown in chart

[Figure 10-120-2].
1
S4028
Removing And Replacing Hydraulic / Hydrostatic
Filter
For the correct service interval (See SERVICE

S4031 SCHEDULE on Page 10-70-1.)
Stop the engine and open the rear door.
Figure 10-120-3
2
3
S4029 S4030
Remove the fill cap (Item 1) [Figure 10-120-1].
Add oil until it is at the center of the sight gauge (Item 2) S4080
[Figure 10-120-1]. Do not overfill.
Remove the screen (Item 3) [Figure 10-120-1] and clean

with solvent as needed.
Install the fill cap (Item 1) [Figure 10-120-1].

S4014
Remove the filter (Inset) [Figure 10-120-3].
Clean the surface of the filter housing where the filter seal
contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-4
Removing And Replacing Hydraulic / Hydrostatic

Filter (Cont’d)
WARNING 1
S4028
S4031
enters skin or eyes, get immediate medical attention Raise the operator cab. (See Raising on Page 10-30-1.)
W-2072-0807 Remove the fill cap (Item 1) [Figure 10-120-4].
Start the engine and operate the loader hydraulic controls. Figure 10-120-5
Stop the engine and check for leaks at the filter.
Check the fluid level in the reservoir and add as needed.
Close the rear door.
WARNING 1
sparks or lighted tobacco away from fuel and oil. S4033 S4032
explosion or fire.
Disconnect the hose (Item 1) [Figure 10-120-5] from the
W-2103-0508
hydraulic reservoir and drain the fluid into a container.
Removing And Replacing Hydraulic Fluid and Case Reconnect the hose when the reservoir is empty.
Drain Filters
NOTE: Fluids such as engine oil, hydraulic fluid,
For the correct service interval (See SERVICE coolant, etc. must be disposed of in an
SCHEDULE on Page 10-70-1.) environmentally safe manner. Some
regulations require that certain spills and
Replace the fluid if it becomes contaminated or after leaks on the ground must be cleaned in a
major repair. specific manner. See local, state and federal
regulations for correct disposal.
Always replace the hydraulic / hydrostatic filter and the
case drain filters whenever the hydraulic fluid is replaced.
(See Removing And Replacing Hydraulic / Hydrostatic
Filter on Page 10-120-1)

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

Drain Filters (Cont’d) WARNING
Figure 10-120-6 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
1 physician familiar with this injury is not received
immediately.
W-2145-0290
S4034
Removing And Replacing Charge Filter
Figure 10-120-7
S4032
1
The case drain filters are located under the cab, next to 2
the transmission, one on each side (Item 1) [Figure 10-
120-6].
1
Disconnect the fittings at the end of the case drain filters
and remove both filters.
S4254
Remove the hydraulic connections (Item 1) and remove

WARNING the charge filter (Item 2) [Figure 10-120-7]. Replace the
entire filter.
explosion or fire.
W-2103-0508
Disassemble the case drain filters and discard the filter

elements. Thoroughly clean the filter housings with
solvent. Install new filter elements and reassemble. Install
the filters into the loader and reconnect the fittings. Lower
the cab. (See Lowering on Page 10-30-2.)
Replace the hydraulic / hydrostatic filter. (See Removing

And Replacing Hydraulic / Hydrostatic Filter on Page 10-
120-1)
Add the correct fluid to the reservoir until it is at the center

of the sight gauge. Do not overfill.
Start the engine and operate the loader hydraulic controls.

Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil
Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains. Use the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system. (See Fluid Specifications on Page
SPEC-10-5.)
Stop the loader on a level surface.
Stop the engine.
Figure 10-130-1
P31287A
Use a pump to suction the oil from the chaincase [Figure

10-130-2].
Recycle or dispose of the used oil in an environmentally

safe manner.
P31287
Add new oil until you can reach the oil with the tip of your
finger through the hole.
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing. Install and tighten the plug.
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 lubricant through the check plug

hole until it reaches the desired level.
Install and tighten the plug.

BOB-TACH (HAND LEVER) Figure 10-140-2
Inspection And Maintenance

1
Figure 10-140-1
Wedge must contact

lower edge of hole in
the attachment.
S4087 B15177
The wedges (Item 1) must extend through the holes in the

attachment mounting frame (Item 2) [Figure 10-140-2].
N17027
The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Move the Bob-Tach levers down to engage the wedges 140-2].
[Figure 10-140-1].
If the wedge does not contact the lower edge of the hole
The levers and wedges must move freely. [Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
B17460
Inspect the mounting frame on the attachment and 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.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)

BOB-TACH (POWER OPTION) Figure 10-141-3
Figure 10-141-1
S2849 S4050
Push and hold the top of the BOB-TACH WEDGES UP / B17460

DOWN switch [Figure 10-141-1] until wedges are fully
raised. Push and hold the bottom of the BOB-TACH
Inspect the mounting frame on the attachment and the
WEDGES UP / DOWN switch until the wedges are fully
Bob-Tach, linkages and wedges for excessive wear or
down.
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
The levers and wedges must move freely.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
WARNING Lubricate the wedges (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Figure 10-141-2
Wedge must contact

lower edge of hole in the
attachment.
S4087 B15177
The wedges (Item 1) must extend through the holes in the

attachment mounting frame (Item 2) [Figure 10-141-2].
The spring loaded wedge (Item 1) must contact the lower

edge of the hole in the attachment (Item 2) [Figure 10-
141-2].
If the wedge does not contact the lower edge of the hole
[Figure 10-141-2], the attachment will be loose and can
come off the Bob-Tach.

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

of the loader. (See SERVICE SCHEDULE on Page 10-70-
1.) 2
Record the operating hours each time you lubricate the

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

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
S4085
Lubricate the following locations on the loader:
Figure 10-150-1 2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure
10-150-2] and [Figure 10-150-3].
Figure 10-150-4
3
2
4
1 3
S4036
S4086
Figure 10-150-2 3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure 10-
150-1] and [Figure 10-150-4].
S1080
1. Rod End Lift Cylinder (Both Sides) (Item 1) [Figure 10-

150-1] and [Figure 10-150-2].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-7
Lubrication Locations (Cont’d)
Figure 10-150-5
4 8
8
S4039
8. 250 Hours: Steering Lever Shaft (two) under the cab

S4037 (Item 8) [Figure 10-150-7].
4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure Figure 10-150-8
10-150-1] and [Figure 10-150-5].
Figure 10-150-6 9
7 9
5
P43829 P43830
9. Power Bob-Tach Pivot Pins (If Equipped) [Figure 10-

150-8].
S4038
5. Rod End Tilt Cylinder (Both Sides) (Item 5) [Figure 10-

150-6].
6. Bob-Tach Pivot Pin (Both Sides) (Item 6) [Figure 10-

150-6].
7. Bob-Tach Wedge (Both Sides) (Item 7) [Figure 10-

150-6].

TIRE MAINTENANCE Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Wheel Nuts capability. Check for the correct pressure before operating
the loader.
Figure 10-160-1
Mounting
Tires are to be repaired only by an authorized person

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

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

rubber lubricant before mounting the tire.
S4503 Avoid excessive pressure which can rupture the tire and
cause serious injury or death.
See the SERVICE SCHEDULE for the service interval to
During inflation of the tire, check the tire pressure
check the wheel nuts [Figure 10-160-1]. (See SERVICE
frequently to avoid overinflation.
SCHEDULE on Page 10-70-1.)
When installing wheel nuts, tighten to 160 ft.-lb. (217 N•m)

torque.
When checking wheel nut torque, set the torque wrench to

WARNING
140 ft.-lb. (190 N•m) to prevent over-tightening.
Rotating Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
Check the tires regularly for wear, damage and pressure. explosion which can result in injury or death.
W-2078-1007
Inflate tires to the maximum pressure shown on the
sidewall of the tire.
Figure 10-160-2
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
B9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires to
the front [Figure 10-160-2].
It is important to keep all tires the same size. If different

sizes are used, each tire will be turning at a different rate
and cause excessive wear. The tread bars of all the tires
must face the same direction.

SPARK ARRESTOR MUFFLER
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for

WARNING
cleaning the spark arrestor muffler. (See SERVICE AVOID INJURY OR DEATH
SCHEDULE on Page 10-70-1.) When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
Do not operate the loader with a defective exhaust fumes. If the engine is stationary, vent the exhaust
system. outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine and open the rear door. W-2050-0807
Figure 10-170-1
1
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
S4014
Never use machine in atmosphere with explosive dust
or gases or where exhaust can contact flammable
Remove the plug (Item 1) [Figure 10-170-1] from the
material. Failure to obey warnings can cause injury or
bottom of the muffler.
death.
W-2068-1285
WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
Start the engine and run for about 10 seconds while a

second person, wearing safety goggles, holds a piece of
wood over the outlet of the muffler. This will force
contaminants out through the cleanout hole.
Stop the engine.
Install and tighten the plug.

PIVOT PINS Figure 10-180-2
Figure 10-180-1
3
1 4
1 2
5
S4036
Figure 10-180-3
N20575A
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].
6
Check that the lock nuts are tightened to 25-28 ft.-lb. (34-
38 N•m) torque.
S4038
Check the following pivot pins (Items 1-6) [Figure 10-180-

2] and [Figure 10-180-3].

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 a observing the instrument panels and systems for
few minutes to circulate the stabilizer to the pump and correct operation.
fuel injectors.
• Operate machine, check for correct function.
• Drain and flush the cooling system. Refill with
premixed coolant. • Stop the engine and check for leaks. Repair as
needed.
• Replace all fluids and filters (engine, hyd. / hydro.).
• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is

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

condition.

STOPPING THE ENGINE AND LEAVING THE LOADER Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
Procedure personnel.
Stop the Bobcat Loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Deluxe Instrumentation
Lower the lift arms fully and put the attachment flat on the Panel allows operation of the loader without
ground. using a password.
Figure 10-200-1 Figure 10-200-3
S4006
Pull the engine speed control lever (Item 1) [Figure 10-

200-1] fully backward to decrease the engine speed.
Engage the parking brake.

P66668A
S0597
Figure 10-200-2
Exit the loader [Figure 10-200-3].
WARNING
Before you leave the operator’s seat:
2 • Lower the lift arms, put the attachment flat on the
ground.
• Stop the engine.
P-76603 B-15553L • Engage the parking brake.
• Raise the seat bar, move pedals until both lock.
Turn the key switch to the STOP position (Item 1) [Figure • Move auxiliary hydraulic control lever out of
10-200-2]. detent position.
W-2164-0108
Turn the key switch to the STOP position (Item 1)
(Standard Key Panel) or press the STOP button (Item 2)
(Deluxe Instrumentation Panel) [Figure 10-200-2].
NOTE: The loader lights will remain ON for

approximately 90 seconds after turning the
loader OFF.
Move auxiliary control out of detent position.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.

STOPPING THE ENGINE AND LEAVING THE LOADER Front Door (If Equipped)
(CONT’D)
NOTE: When an Operator Cab Enclosure Kit is
Emergency Exit installed, the window of the front door can be
used as an emergency exit [Figure 10-200-6].
The front opening on the operator cab and rear window
provide exits. NOTE: If the loader has a Special Application Door Kit
installed, the window of the front door is NOT
Rear Window (If Equipped) an emergency exit.
Figure 10-200-4 Figure 10-200-6
S4046 S4045 N20171
Pull the tag on the top of the rear window [Figure 10-200- Pull the plastic loop (Item 1) [Figure 10-200-6] at the top
4] to remove the rubber cord. of the window in the front door to remove the rubber cord.
Push the rear window out of the rear of the operator cab. Figure 10-200-7
Figure 10-200-5
1 1
1
1
6707852 S0363
Push the window out with your foot at any corner of the
P45260A window (Item 1) [Figure 10-200-7].
Exit through the front door.

Exit through the rear of the operator cab [Figure 10-200-
5].

BACK-UP ALARM SYSTEM Operation
Description Figure 10-210-2
Figure 10-210-1
S4006
The back-up alarm (Item 1) [Figure 10-210-1] is located The back-up alarm will sound when the operator moves
on the inside of the rear door. both steering levers into the reverse position [Figure 10-
210-2]. Slight movement of the steering levers into the
A back-up alarm is not a substitute for looking to the reverse position is required with hydrostatic
rear when operating the loader in reverse, or for transmissions, before the back-up alarm will sound.
keeping bystanders away from the work area.
Operators must always look in the direction of travel, If alarm does not sound or for adjustment instructions
including reverse, and must also keep bystanders away (See “Adjusting Switch Position” on page 60-170-2.)
from the work area, even though the loader is equiooed
with a back-up alarm.
Operators must be trained to always look in the direction

of travel, including when operating the loader in
reverse and to keep bystanders away from the work area.
Other workers should be trained to always keep away
from the operator’s work area and travel path.

79 of 521
80 of 521
HYDRAULIC SYSTEM
BOB-TACH (POWER) BLOCK..........................................................................20-110-1

Description ................................................................................................... 20-110-1 HYDRAULIC
Disassembly And Assembly ........................................................................ 20-110-3 SYSTEM
Removal And Installation ............................................................................. 20-110-1
BUCKET POSITION VALVE .............................................................................20-100-1

Description ................................................................................................... 20-100-1
Disassembly And Assembly ........................................................................ 20-100-5
Solenoid Removal And Installation .............................................................. 20-100-1
Solenoid Testing .......................................................................................... 20-100-2
CYLINDER (BOB-TACH) ................................................................................... 20-22-1

Disassembly and Assembly ........................................................................... 20-22-4
Parts Identification ......................................................................................... 20-22-3
Removal And Installation ............................................................................... 20-22-2
Testing ........................................................................................................... 20-22-1
CYLINDER (LIFT) .............................................................................................. 20-20-1

Disassembly And Assembly .......................................................................... 20-20-4
Testing ........................................................................................................... 20-20-1
CYLINDER (TILT) .............................................................................................. 20-21-1

Testing ........................................................................................................... 20-21-1
FRONT AUXILIARY HYDRAULIC COUPLERS ................................................20-120-1

Description ................................................................................................... 20-120-1

HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE........................................................................ 20-40-1

Anti-Cavitation Valve Removal And Installation (Lift, Rod End) .................... 20-40-6
Auxiliary Spool Removal And Installation .................................................... 20-40-21
Description .................................................................................................... 20-40-1
End Cap / Spool Lock Block Removal And Installation ................................. 20-40-9
Lift Spool And Detent Removal And Installation.......................................... 20-40-10
Load Check Valve Removal And Installation (Tilt and Auxiliary) ................... 20-40-5
Lock Valve Removal And Installation ...........................................................20-40-30
Main Relief Valve Removal And Installation................................................ 20-40-32
Port Relief Valve Removal And Installation ................................................... 20-40-8
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 20-40-8
Removal And Installation .............................................................................. 20-40-1
Rubber Boot Removal And Installation ......................................................... 20-40-9
Solenoid Removal And Installation ..............................................................20-40-29
Tilt Spool Removal And Installation ............................................................ 20-40-19
HYDRAULIC FLUID RESERVOIR ..................................................................... 20-80-1

Description .................................................................................................... 20-80-1
Hydraulic Fluid Screen .................................................................................. 20-80-2
HYDRAULIC / HYDROSTATIC FILTERS .......................................................... 20-70-1

Description .................................................................................................... 20-70-1
Hydraulic / Hydrostatic Filter Housing Removal And Installation ................... 20-70-1
HYDRAULIC PUMP ........................................................................................... 20-60-1

Description .................................................................................................... 20-60-1
Direct Pump Test (Charge Section) .............................................................. 20-60-3
Direct Pump Test .......................................................................................... 20-60-2
Disassembly And Assembly .........................................................................20-60-10
Hydraulic Pump Start Up ............................................................................ 20-60-14
Parts Identification ........................................................................................ 20-60-9
Pump Test at Quick Couplers ....................................................................... 20-60-1
HYDRAULIC SYSTEM INFORMATION ............................................................. 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols ............................................... 20-10-1
Troubleshooting ............................................................................................ 20-10-5

HYDRAULIC SYSTEM (CONT’D)
LIFT ARM BYPASS CONTROL VALVE ............................................................ 20-50-1

Description ..................................................................................................... 20-50-1
Removal and Installation ............................................................................... 20-50-1
Testing ........................................................................................................... 20-50-1
MAIN RELIEF VALVE ........................................................................................ 20-30-1

Adjusting ........................................................................................................ 20-30-2
Description ..................................................................................................... 20-30-1
Testing ........................................................................................................... 20-30-1
OIL COOLER ..................................................................................................... 20-90-1

Description ..................................................................................................... 20-90-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01)
UNLESS OTHERWISE SPECIFIED.

HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 – A8ET19999)
(PRINTED JANUARY 2009)

V-0887 legend
LEGEND
1 VARIABLE DISPLACEMENT BIDIRECTIONAL 17 RELIEF VALVE – MAIN: 34 INLET SCREEN / FILTER: Inside of Inlet
HYDROSTATIC PUMP: 17.5 GPM (66,4 L/min) 3000 PSI (206,84 bar) Fitting
2 HYDRAULIC PUMP ............. Gear Type: 18 RELIEF / ANTICAVITATION VALVE – 35 PULL BUTTON ACTIVATED
13.1 GPM (49,6 L/min) @ 3270 Pump RPM PORT: 4000 PSI (275,79 bar) DIRECTIONAL CONTROL VALVE:
3 CHARGE PUMP: Lift Arm Bypass Valve
19 ANTICAVITATION VALVE
6.4GPM (24,2 L/min) @ 3270 Pump RPM
36 FILTER – BOB-TACH: 100 Mesh
4 RELIEF / REPLENISHING VALVE – HIGH 20 LOAD CHECK VALVE
PRESSURE: 4250 PSI (293 bar)
21 QUICKCOUPLER MALE 37 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE –
5 RELIEF VALVE – CHARGE INLET: HYDRAULIC POWERED BOB-TACH VALVE: 30 PSI (2 bar)
290 PSI (20 bar) 22 QUICKCOUPLER FEMALE 38 RESTRICTION:
6 BIDIRECTIONAL HYDROSTATIC DRIVE MOTOR: 0.089 Inch (2,26 mm)
211.6 GPM (801,2 L/min) @ 3270 Pump RPM 23 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE: Bucket Positioning 39 RESTRICTION: 0.025 Inch (0,6 mm)
7 DRIVE MOTOR SHUTTLE VALVE On / Off
40 SOLENOID ACTIVATED DIRECTIONAL
24 FLOW DIVIDER ADJUSTMENT VALVE D
8 SHUTTLE RELIEF VALVE: CONTROL VALVE
220 PSI (15,2 bar) 25 PILOT ACTIVATED DIRECTIONAL CONTROL 41 RELIEF VALVE: 1200 PSI (85 bar)
VALVE: FLOW CONTROL SPOOL
9 FILTER - CASE DRAIN: 90 micron
42 PILOT OPEREATED CHECK VALVE:
26 CHECK VALVE – BUCKET POSITION VALVE
85 PSI (5,5 bar)
10 FILTER – CHARGE: 20 micron Nom,
40 micron Abs 27 43
PILOT ACTIVATED DIRECTIONAL RELIEF VALVE: 2000 PSI (137 bar)
CONTROL VALVE: UNLOADING SPOOL
11 FILTER BYPASS VALVE: 40 PSI (2,76 bar)
28 TILT CYLINDER 44 CHECK VALVE: 300 PSI (20,7 bar)
12 ATMOSPHERIC RESERVOIR
29 LIFT CYLINDER
45 RESTRICTION:
13 FILTER – HYDRAULIC: 11 micron 0.016 Inch (0,4 mm)
30 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE: BICS Cartridge
14 FILTER BYPASS VALVE: 50 PSI (3,45 bar) 46 POWER BOB-TACH CYLINDER: Optional
31 SOLENOID AVTIVATED DIRECTIONAL
15 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE – BICS Control
40 PSI (2,76 bar) 32 INLET SCREEN / FILTER
16 OIL COOLER 33 CHECK VALVE: Inside of Inlet Fitting

NOTE: Unless otherwise specified, springs have
NO significant pressure value.
V-0887 legend (01-01-09)

Printed in Europe
85 of 521
HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 – A8ET19999)
(PRINTED JANUARY 2009)
(V-0887)
QUICK COUPLERS
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE
HYDRAULIC FILTER
16
13 21
OIL
DRIVE MOTOR 12 14 COOLER
FEMALE
22
7 8 15
9
BUCKET POSITION VALVE (OPTIONAL)
D
26
6
B A HYDRAULIC
46 24
POWERED
BOB-TACH
HYDRAULIC AND (OPTIONAL)
HYDROSTATIC PUMPS
42 43 A
1 HYDRAULIC CONTROL VALVE
4 4 23 C
25
44
5 41
39 45 27
40 38
AUXILIARY
36 SPOOL B
B A
37
CHARGE
INLET
D
1
TILT CYLINDERS
19 20 BICS CONTROL VALVE
4 4
28
D C
2 TILT CYLINDER
B A SPOOL 30
3 OUTLET
INLET
19 20 28
18
LIFT CYLINDERS
6 18
30
LIFT CYLINDER
B A SPOOL
29
9
20
7 8 IN-LINE FILTER
10 34 33
32 31
17
DRIVE MOTOR LIFT ARM BY PASS VALVE
11 35
V-0887 (01-01-09)
86 of 521
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 fitting 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
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 OU T
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).

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 the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
bypass valve stuck. 12
bypass valve stem bent or broke. 13
KEY TO CORRECT THE 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.
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.

CYLINDER (LIFT) Figure 20-20-2
Testing
2
WARNING
1
enters skin or eyes, get immediate medical attention P-45266
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Figure 20-20-1
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
Repeat the procedure to check the other lift cylinder.
P-45265
WARNING
Lower the lift arms. Stop the engine. Pull up the lift arm
bypass control to release the hydraulic pressure. AVOID INJURY OR DEATH
Check only one cylinder at a time. Open the rear door. sparks or lighted tobacco away from fuel and oil.
Disconnect the negative ground cable from the battery. explosion or fire.
W-2103-0508
Disconnect the hose (Item 1) [Figure 20-20-1] from the lift

cylinder base end port.

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

Remove the retainer bolt (Item 1) and nut (Item 2) [Figure
The removal procedure will be explained for the right lift 20-20-4] from the lift arm pins (both rod and base end).
cylinder. The removal of the other cylinder is similar.
Installation: Tighten the bolt and nut to 25-28 ft.-lb. (35-
Figure 20-20-3 38 N•m) torque.
NOTE: Remove the air cleaner (See Removal And

Installation on Page 20-110-2) to remove the
right rear pivot pin. The pin must be driven out
1 from the engine compartment.
Figure 20-20-5
S4344
Stop the engine. Pull up the lift arm bypass control to

release the hydraulic pressure. 1
Open the rear door and disconnect the negative ground

cable from the battery. S4324
Disconnect and plug the hoses (Item 1) [Figure 20-20-3]

from the lift cylinder. To remove the lift cylinder rod end pivot pin use a pin
puller (Item 1) [Figure 20-20-5].
S3467

CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Rod 9. Tube Line Assy

2. Wiper Seal 10. Plug
3. Rod Seal 11. O-ring
4. Head 12. Nut
5. O-ring 13. O-ring
6. Bacup ring 14. Spacer
7. O-ring
8. Cylinder
S4379

Disassembly And Assembly

4
Use the following tools to service the cylinder:
3
2
• MEL1074 - O-ring Seal Hook.
1
• Spanner Wrench.
• MEL1033 - Rod Seal Installation Tool.
• MEL1396 - Seal Installation Tool.
• Piston Ring Compressor.

P-48036
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
damage. Replace any damaged parts. and head (Item 4) [Figure 20-20-7].
Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-20-7] to
600 ft.-lb. (814 N•m) torque.
Lubricate all O-rings and seals with hydraulic oil during
installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit. Use
Hold the hydraulic cylinder over a drain pan and move the locktite while tightening the nut.
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-20-8
Put the base end of the cylinder in a vise.
Figure 20-20-6 2
2
1 1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
20-8] from the piston.
Use a spanner wrench to loosen the head (Item 1) NOTE: If the fiber surface (Item 3) [Figure 20-20-8] on
[Figure 20-20-6] from the cylinder case. 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 the way into the cylinder (Item 1)
[Figure 20-20-6].

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

P7424 the cylinder head.
Figure 20-20-12
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-9]. 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 20-20-10
P-48041A P-48042
Assembly: Install the wiper seal, with the wiper side of

the seal (Item 1), toward the outside of the head (Item 2)
2
[Figure 20-20-12].
P-48039
Remove the two O-rings (Item 1) and the back-up washer

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

Figure 20-20-13
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 20-20-13] from the cylinder.
cylinder head.
Figure 20-20-14
P-48043A P7427
Assembly: Install the rod seal on the rod seal tool

[Figure 20-20-14].
NOTE: During installation the spring side of the seal

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

CYLINDER (TILT) Removal And Installation
Testing
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. WARNING
WARNING sparks or lighted tobacco away from fuel and oil.
explosion or fire.
Hydraulic fluid escaping under pressure can have W-2103-0508
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 Removal procedure will be explained for the right tilt
physician familiar with this injury is not received cylinder. Removal procedure for the left cylinder is similar.
immediately.
W-2145-0290 Figure 20-21-2
Figure 20-21-1
S4300
S4220 Remove the attachment. Roll the Bob-Tach forward and

lower the lift arms.
Disconnect the hose which goes to the base end of the tilt
Place the Bob-Tach flat on a pallet to allow the tilt cylinder
cylinder (Item 1) [Figure 20-21-1].
base end pin enough clearance to be removed [Figure
20-21-2].
Install a cap on the hose fitting and tighten.
Stop the engine. Move the tilt pedal to release the
Engage the parking brake. Lower the seat bar.
hydraulic pressure. Raise 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.

CYLINDER (TILT) (CONT’D) Figure 20-21-5
Removal And Installation (Cont’d)

Remove the retainer bolt (Item 2) and nut (Item 1) [Figure
Figure 20-21-3 20-21-5] from the rod end pivot pin.
Remove the rod end pivot pin.
Remove the cylinder.

1
2
WARNING
S4220 explosion or fire.
Disconnect both hydraulic hoses (Items 1 and 2) [Figure

20-21-3].
Figure 20-21-4
1
1
S4321
S4309
W-2103-0508
Remove the retainer nut (Item 1) and bolt (Item 2) [Figure

20-21-4] from the cylinder rod end pivot pin. Drive the pin
through with a punch.
Installation: Tighten the retainer nut to 25-28 ft.-lb. (34-

38 N•m) torque.

CYLINDER (TILT) (CONT’D)
1. Piston 9. Back-up ring

2. O-ring 1.0 O-ring
3. Seal 11. Head
4. Nut 12. Wiper Seal
5. Plug 13. Rod Seal
6. O-ring 14. Rod
7. Cylinder
8. O-ring
S4378


3
Use the following tools to service the cylinder: 2
• MEL1074 - O-ring Seal Hook.

1
• Spanner Wrench.
• MEL1033 - Rod Seal Installation Tool.
• MEL1396 - Seal Installation Tool.
• Piston Ring Compressor.

P-48071
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Hold the hydraulic cylinder over a drain pan and move the
Put the base end of the cylinder in a vise.
Figure 20-21-6
P-48034
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-6] from the cylinder case.

the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-6].

Remove the nut (Item 1), piston (Item 2) and head

(Item 3) [Figure 20-21-7].
Assembly: Tighten the nut (Item 1) [Figure 20-21-

7] to 100 ft.-lb. (136 N•m) torque.
NOTE: Clean and dry the threads before

installing thenut. Install the new nut
from the kit.
Figure 20-21-8
P-48088 P-48089
Assembly: Mark the end of the shaft and nut.

Tighten the nut an additional 135 degrees or 2-1/4
flats [Figure 20- 21-8]. Use locktite while tightening
the nut.


Figure 20-21-9 (Item 2) [Figure 20-21-11] from the cylinder head.
Figure 20-21-12
2
1
1
P-48073
P-48040
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
21-9] from the piston.
Remove the wiper seal (Item 1) [Figure 20-21-12] from
Figure 20-21-10 the cylinder head.
P7424

piston.

P-48039


Figure 20-21-13 [Figure 20-21-15].

2 toward the inside of the cylinder.
Figure 20-21-16
1
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
13].
P7425
Figure 20-21-14

handles to collapse the rod seal [Figure 20-21-16].
P-48042
Remove the rod seal (Item 1) [Figure 20-21-14] from the

cylinder head.
P-48043 P7427

CYLINDER (BOB-TACH) Figure 20-22-1
Testing
WARNING
explosion or fire. 1
W-2103-0508
S5919
Tilt the Bob-Tach forward, so it is parallel to the floor
WARNING [Figure 20-22-1].

AVOID INJURY OR DEATH power Bob-Tach cylinder base end port.
penetrate skin or eyes, causing serious injury or Install a plug in the hose (Item 1) [Figure 20-22-1] and
death. Fluid leaks under pressure may not be visible. tighten.
not use your bare hand. Wear safety goggles. If fluid Engage the parking brake. Lower the seat bar. Start the
enters skin or eyes, get immediate medical attention engine.
W-2072-0807 Push and hold the BOB-TACH “WEDGES UP” Switch
(Front Accessory Panel).
If there is any leakage from the base end cylinder port

(Item 2) [Figure 20-22-1], remove the Bob-Tach cylinder
for repair.
The verification of the rod end side of the cylinder is

similar.

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-3

Remove the bolts (Item 1) [Figure 20-22-3].
Figure 20-22-2
Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m)
torque.
Remove the washers and cylinder from the lever pivots.
Remove the cylinder.
2
1
S5919
Disconnect and cap the hoses (Items 1 and 2) [Figure 20-

22-2] from the cylinder fittings.
Cap the fittings.
1 1
S5918

CYLINDER (BOB-TACH) (CONT’D)
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod
3
2
14
13 12
11
10
9
8 7 6
5
4
15
PE1064

Disassembly and Assembly

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

damage. Replace any damaged parts.
P16294
Always install new O-rings and seals during assembly.

Remove the head and rod assembly from the cylinder
Lubricate all O-rings and seals with hydraulic oil during [Figure 20-22-5]. 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 20-22-5] from the rod.
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 20-22-5]. Use locktite while tightening
Figure 20-22-4 the nut.
Assembly: Tighten the nut to 90 ft.-lb. (122 N•m) torque.

2
Figure 20-22-6
3
2
1
1
4
P-43212
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-22-4].
P16295

the head is seated all of the way into the cylinder (Item 2) Remove the O-ring (Item 1), and seal (Item 2) from the
[Figure 20-22-4]. piston (Item 3) [Figure 20-22-6].
NOTE: The piston center hole (Item 4) [Figure 20-22-6]

has a bevel on one end. The bevel goes toward
the rod when assembling.

Figure 20-22-7
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-22-9] from the

P7424 cylinder head.
Figure 20-22-10
piston. 2

1
Figure 20-22-8
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2
10].
P-48039

(Item 2) [Figure 20-22-8] from the cylinder head.

Figure 20-22-11
P7425

P-48042 handles to collapse the rod seal [Figure 20-22-13].
Reverse the disassembly procedure to assemble the Bob-

Remove the rod seal (Item 1) [Figure 20-22-11] from the Tach cylinder.
cylinder head.
Figure 20-22-12
P-48043A P7427

[Figure 20-22-12].

toward the inside of the cylinder.

MAIN RELIEF VALVE Figure 20-30-1
Description
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
2 1
The main relief valve is adjustable and is located on the
hydraulic control valve near the bottom, facing the front of
the loader.
Testing
S2851
IMPORTANT Connect the IN port (Item 1) [Figure 20-30-1] of the

hydraulic tester to the bottom (female) quick coupler on
The hydraulic tester must be in the fully open position the loader.
before you start the engine.
I-2024-0284 Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
Figure 20-30-2
WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
WARNING
Put jackstands under the front axles and rear corners S0186
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall
Move the handle all the way to the right, to put the control
valve in the locked position for a constant flow of hydraulic
W-2017-0286
fluid under pressure to the quick couplers [Figure 20-30-
2].
The tools listed will be needed to do the following
procedure: Move the handle out of the locked position before leaving
the operator cab.
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

Turn the key switch to the OFF position. To release the
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for three
seconds.
Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)

MAIN RELIEF VALVE (CONT’D) Removal And Installation
Testing (Cont’d) Raise the operator cab (See Raising on Page 10-30-1.)
Watch the flow meter on the hydraulic tester to make sure Figure 20-30-4
the flow is correct. Increase the engine speed to full RPM.
Refer to Specifications, for both flow and pressure

specifications of the hydraulic system (See Hydraulic
System on Page SPEC-10-3.).
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.
1
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.
Adjusting
S4268
Figure 20-30-3
Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [Figure 20-30-4].
Remove the O-rings and back-up washers [Figure 20-30-

O-ring 3].
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
1
Install new O-rings and back-up washers. Install the main
relief valve (Item 1) [Figure 20-30-4] and tighten. Check
Back-up the pressure again.
Installation: Tighten the main relief valve to 35-40 ft.-lb.

B-6764 (47-54 N•m) torque.
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 1) [Figure 20-30-3].
WARNING
Turn the adjusting screw in or out until the pressure is
correct. AVOID INJURY OR DEATH
NOTE: If the correct pressure can not be reached, servicing machine. Read and understand the
replace the main relief valve. Check the Operation & Maintenance Manual, Operator’s
pressure setting of the new relief valve. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807

HYDRAULIC CONTROL VALVE Lift and block the loader .
Description Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
The hydraulic control valve is located inside the main 20-1).
frame, below the operator cab.
Raise the operator cab (See Raising on Page 10-30-1).
The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the Clean the area around the control valve.
lift, tilt and auxiliary functions.
Drain the hydraulic reservoir (See Removing And
The lift and tilt functions are operated using mechanical Replacing Hydraulic Fluid and Case Drain Filters on Page
linkages to connect the foot pedals to the lift and tilt 10-120-2).
spools.
The auxiliary functions are operated using mechanical
linkages to connect the right steering lever to the auxiliary NOTE: Before disconnecting the tubelines, first mark
spool. Move the lever to the right or left to activate the the tubelines and the fittings to make sure the
auxiliary hydraulics. tubelines are on the right fitting when
reconnecting.
The hydraulic control valve contains a main relief valve
which is adjustable. Remove the bucket position valve (See Removal And
Installation on Page 20-110-1).
Figure 20-40-1
WARNING
S4268
support device can allow the lift arms or attachment Remove the right and left steering linkage (Item 1)
to fall and cause injury or death. [Figure 20-40-1] by removing the bolts and nuts on both
W-2059-0598 ends of the steering linkage.
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

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-4
Figure 20-40-2
1
1 1 2 2
S4183
Remove the bar (Item 1) that connects the control valve

S4180 with the lever. Also remove the two chain links (Item 2)
[Figure 20-40-4].
Disconnect the three plugs (Item 1) [Figure 20-40-2] from Figure 20-40-5
the hydraulic control valve.
Figure 20-40-3 1
6 11 7
12 1
9
10
5 1
4
3 2
S2906
8
S4181 Remove the two screws (Item 1) [Figure 20-40-5].

Disconnect the 12 hydraulic tubelines (Items 1 to 12) torque.
[Figure 20-40-3] from the hydraulic control valve.
Upon disconnection, cap the tubeline and the fitting on the

hydraulic control valve.

HYDRAULIC CONTROL VALVE (CONT’D)
Figure 20-40-6
S4184
Remove the hydraulic control valve from the loader by

means of a hoist [Figure 20-40-6].
NOTE: Make sure the hydraulic control valve is well

supported when putting it down.

HYDRAULIC CONTROL VALVE (CONT’D)
Identification Chart
Figure 20-40-7
G1 E2 C1
J1
F4
F5
J3 B1 MR
E3
A1 F3
H1
H2
E1
B2
A2
A3
B3 D1 F1
E1 D5
C3 C2
D3 F2 D4
D2 J4 J5
J2
S5948
ITEM S100 LOADER ITEM S100 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 F5 Auxiliary Spool
C3 Load Check Valve Auxiliary Function G1 BICS Valve Solenoid
D1 Anti-Cavitation Valve
Lift (Rod End) H1 BICS Lock Valve (Tilt)
D2 Port Relief / Anti-Cavitation Valve – 3500 PSI H2 BICS Lock Valve (Lift)
Lift (Base End)
J1 Inlet Fluid Flow (From Pump)
D3 Port Relief / Anti-Cavitation Valve – 3500 PSI
Tilt (Base End) J2 Outlet Fluid Flow (Return to Tank)
D4 Port Relief / Anti-Cavitation Valve – 3500 PSI J3 Lift Arm bypass Orifice
Tilt (Rod End) J4 Hydraulic Reservoir
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) J5 Lift Arm bypass Valve (Drain)
3500 PSI (Optional)
MR Main Relief Valve – 2700 PSI

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: The tilt and auxiliary load check valves are
interchangeable.
Load Check Valve Removal And Installation (Tilt and
Auxiliary) Figure 20-40-9
Figure 20-40-8
2 1 3
1
2
2
1
S4188
S4185
Pull the springs (Item 1) and poppets (Item 2) [Figure 20-

40-9] out of the hydraulic control valve.
Locate the tilt section load check valve (Item 1) [Figure
20-40-8] on the hydraulic control valve. Check the orifice in the poppet to be sure it is not plugged.
Locate the auxiliary section load check valve (Item 2) Installation: Install a new O-ring (Item 3) [Figure 20-40-
[Figure 20-40-8] on the hydraulic control valve. 9] on the plug and lightly lubricate with oil before installing
and tighten the plug to 38-45 ft.-lb. (52-61 N•m) torque.

Anti-Cavitation Valve Removal And Installation (Lift,

Rod End) Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-11].
Figure 20-40-10
Check the orifice in the poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 3) [Figure 20-40-

11] on the plug and lightly lubricate with oil before
installing. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.
S4201
Remove the lift section anti-cavitation valve (Item 1)

[Figure 20-40-10] from the control valve.
IMPORTANT
damage the system.
2
1
S4203
I-2003-0888

HYDRAULIC CONTROL VALVE (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End) Figure 20-40-14
Figure 20-40-12
1
S5922
S5922
Loosen the tilt circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-14] from the control valve.
Loosen the lift circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-10] from the control valve. Figure 20-40-15
Figure 20-40-13
S4202
S4202
Replace the O-ring (Item 1) [Figure 20-40-17] before

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

HYDRAULIC CONTROL VALVE (CONT’D) Port Relief Valve Removal And Installation
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-18

Installation (Tilt, Rod End)
Figure 20-40-16
S4201
S4201 Remove the port relief plug (Item 1) [Figure 20-40-18]

from the control valve.
Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-40-19
Figure 20-40-17
1
S4204
S4202 Installation: Always use new O-rings (Item 1) [Figure 20-

40-19].Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

installation.

HYDRAULIC CONTROL VALVE (CONT’D) End Cap / Spool Lock Block Removal And Installation
Rubber Boot Removal And Installation Figure 20-40-21
Figure 20-40-20
1
2
3
1
S4189
S4189
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-21] from the
Remove the four screws (Item 1) [Figure 20-40-20] on the end cap / spool lock block.
rubber boot retainer plate.
Remove the four end cap / spool lock block mount screws
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3 (Item 3) [Figure 20-40-21].
N•m) torque.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Remove the rubber boots (Item 2) [Figure 20-40-20] from N•m) torque.
the retainer plate.
Remove the rubber boots and retainer plate from the lift
and tilt spools.
Figure 20-40-22
S4200
Remove the end cap / spool lock block (Item 1) [Figure

20-40-22] from the control valve.

Lift Spool And Detent Removal And Installation

procedure:
MEL 1278 - Detent Tool
MEL 1285 - Detent Spring Tool

1
Remove the end cap / spool lock block from the control 2
valve (See End Cap / Spool Lock Block Removal And
Figure 20-40-23 S5925
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-25].
Remove the washer (Item 2) [Figure 20-40-25].

2
1 Figure 20-40-26
S5923
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-23] from the lift spool.
Figure 20-40-24
1 2
S5926
1
Remove the screws (Item 1) [Figure 20-40-26] from the
detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-26].
Installation: Lubricate the screws and tighten to 90-100

in.-lb. (10-11,3 N•m) torque.
S5924
IMPORTANT
Remove the end cap (Item 1) [Figure 20-40-24]. The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-29

(Cont'd)
Figure 20-40-27
S5929
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-29] from the control valve.
S5927
Figure 20-40-30
Put a rag around the detent assembly [Figure 20-40-27].

This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
Figure 20-40-28
S5930
3 2 1
Remove the lift spool seal (Item 1) [Figure 20-40-30] from

the linkage end of the valve.
2 S5928
Remove the detent sleeve (Item 1), detent balls (Item 2)

and spring (Item 3) [Figure 20-40-28].


(Cont'd)
Figure 20-40-31
1
2
N-18916

P-8988 lost when the detent adapter is removed.
Remove the detent adapter with an Alan wrench.

Clamp the linkage end of the spool in a vise [Figure 20-
40-31]. Remove the back-up washer (Item 1) and spool seal (Item
2) [Figure 20-40-33].
NOTE: Protect spool before clamping in vise.
Figure 20-40-34
Figure 20-40-32
2 1
1
3
N-19004
N-18915
Remove the detent adapter (Item 1) [Figure 20-40-34]

Install the spring tool (Item 1) [Figure 20-40-32] over the from the spring assembly.
centering spring.
NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-40-32] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-32]

is white on all 700 series loaders.


(Cont'd)
Figure 20-40-35
N-18918
Remove the stud from the end of the spool [Figure 20-40-
37].
N-19009
Figure 20-40-38
Remove spring tool (Item 1) [Figure 20-40-35] from the

spring assembly.
Figure 20-40-36
1
2
3
N-18920
Removal of the plastic plug:
N-18919A Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
Inspect the adapter (Item 1), collar (Item 2), spring (Item tap drill
3) and washer (Item 4) [Figure 20-40-36].
Turn a 6-32 tap (Item 1) [Figure 20-40-38] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS.


(Cont'd) O-Ring
Figure 20-40-39
2
Plastic
1 Plug
0.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
N-18961 20-40-41].
Figure 20-40-42
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-39].
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 1
the lift spool before the control valve is
replaced.
Figure 20-40-40
N-18967
Clamp the collar (Item 1) [Figure 20-40-42] in a vise.
N-18963
Install the plastic plug and O-ring in the spool [Figure 20-
40-40].


(Cont'd)
Figure 20-40-43
1
N-19004
1 3
2 Install the spring tool (Item 1) [Figure 20-40-45] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-46
Apply grease on all the detent component surfaces before

assembly [Figure 20-40-43].
Install the spring (Item 1) and detent balls (Item 2) into the 2
adapter (Item 3) [Figure 20-40-43] and compress with the
detent pliers (Item 1) [Figure 20-40-44].
Figure 20-40-44
N-18917
Install the spool seal (Item 1) and back-up washer (Item 2)

[Figure 20-40-46].
1
N-18968
Install the detent adapter to the collar [Figure 20-40-44].
NOTE: The collar and the detent adapter are held

together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.


(Cont'd)
Figure 20-40-47
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-49].
N-19005
Figure 20-40-50
Install the spring assembly to the lift spool hand tight

[Figure 20-40-47].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
1
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m).
NOTE: The adapter must fit in the center of the washer

(Item 1) [Figure 20-40-47].
Figure 20-40-48 N-19008
Install the detent sleeve (Item 1) [Figure 20-40-50] to the

detent adapter.
CD-15051
Install the detent balls and spring [Figure 20-40-48].


(Cont'd)
1
Figure 20-40-51
1
S5924
Install the end cap (Item 1) [Figure 20-40-53].

1 2
S5926 Figure 20-40-54
Install the lift spool assembly in the spool bore [Figure 20-
40-51].
Install the detent bonnet (Item 1) [Figure 20-40-51].
Install the mounting screws (Item 2) [Figure 20-40-51].
Installation: Lubricate the screws and tighten to 90-100

in.-lb. (10-11,3 N•m) torque.
1
Figure 20-40-52
S5930
Install the spool seal (Item 1) [Figure 20-40-54] on the

linkage end of the valve.
1
2
S5925
Install the washer (Item 1) and snap ring (Item 2) [Figure

20-40-52].


(Cont'd)
Figure 20-40-55
2 2
1
3
S5932
Install the end cap / spool lock block (Item 1) [Figure 20-
40-57].
S5923
Install the lift and tilt spool rubber boots and mount plate
(Item 2) and install the four mounting screws (Item 3)
Install the O-ring (Item 1) and bushing (Item 2) [Figure [Figure 20-40-57].
20-40-55] on the lift spool.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Figure 20-40-56 N•m) torque.
Figure 20-40-58
1
2
S5931
S5933
Install the O-ring (Item 1) [Figure 20-40-56] on the control
valve.
Use an Ohm meter to measure the lock solenoid coils
resistance.
The correct resistance for the coil is 5.5 ± 0.28 Ohms.
Installation: Install the lift spool (Item 1) and tilt spool

(Item 2) [Figure 20-40-58] lock solenoids and tighten to
35-45 ft.-lb. (52-61 N•m) torque.

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 20-40-9.)
Figure 20-40-59
1
2
S5936
1 2 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-61].
S5934
Figure 20-40-62
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-59] from the tilt spool.
Figure 20-40-60
S5937
Remove the three bolts (Item 1) [Figure 20-40-62] from

the spool centering block and remove the spool centering
block.
S5935
Installation: Tighten the bolts to 90-100 in.-lb. (10-11,3
N•m) torque.

Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-63 1
N-18942
Put the linkage end of the spool in the vise [Figure 20-40-
S5938 65].
Install the spool tool (Item 1) [Figure 20-40-65] over the

Check and replace the O-ring (Item 1) [Figure 20-40-63] centering spring.
before replacing the spool centering block.
Figure 20-40-66
Figure 20-40-64
N-19014
S5939
Remove the bolt (Item 1) [Figure 20-40-66] holding the

Remove the tilt spool, centering spring, back-up washer centering spring to the spool.
and spool seal [Figure 20-40-64].
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
Installation: Always use a new spool seal. N•m) torque.
Remove spring tool from the spring assembly.

HYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Spool Removal And Installation
Tilt Spool Removal And Installation (Cont'd) The tool listed will be needed to do the following
procedure:
Figure 20-40-67
MEL 1278 - Detent Tool
1 MEL 1285 - Detent Spring Tool

2
3 Remove the end cap / spool lock block from the control
valve (See End Cap / Spool Lock Block Removal And
4
Figure 20-40-69
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 1
3) and washer (Item 4) [Figure 20-40-67].
Figure 20-40-68
2
1 S5941
Remove the spacer (Item 1) [Figure 20-40-69] from the

auxiliary spool.
Figure 20-40-70
S5940 N-18943
1
Remove the spool seal(s) (Item 1) and the back-up

washer (Item 2) [Figure 20-40-68].
Installation: Always use a new spool seal.
S5935

Auxiliary Spool Removal And Installation (Cont'd)
Figure 20-40-71
1
2
S5938
Check and replace the O-ring (Item 1) [Figure 20-40-73]

S5936 before replacing the spool centering block.
Figure 20-40-74
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-71].
Figure 20-40-72
1 S5942

lost when the detent sleeve is removed.
S5937
Remove the three bolts (Item 1) [Figure 20-40-72] from

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

N•m) torque.

Figure 20-40-75
3 2
1 1
S5945
2
Remove the auxiliary spool seal (Item 1) [Figure 20-40-

S5943 77] from the linkage end of the valve.
Figure 20-40-78
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-75].
Figure 20-40-76
1
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

S5944 40-78].
NOTE: Protect spool before clamping in vise.

Remove the auxiliary spool assembly and seal (Item 1)


1
Figure 20-40-79
1
3
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-81]

N-18915 from the spring assembly.
Figure 20-40-82
Install the spring tool (Item 1) [Figure 20-40-79] over the
centering spring.
1
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-79] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-79]

is white on all 700 series loaders.
Figure 20-40-80
N-19009
Remove spring tool (Item 1) [Figure 20-40-82] from the

spring assembly.
1
2
N-18916

lost when the detent adapter is removed.
Remove the detent adapter with an Alan wrench.
Remove the back-up washer (Item 1) and spool seal (Item

2) [Figure 20-40-80].

Figure 20-40-83
1
2
3
1
4
N-18920
Removal of the plastic plug:

N-18919A
Make a center point in the plug using a 1/16 inch drill.
Inspect the adapter (Item 1), collar (Item 2), spring (Item Drill a hole all the way through the plug using a 7/64 inch
3) and washer (Item 4) [Figure 20-40-83]. tap drill
Figure 20-40-84 Turn a 6-32 tap (Item 1) [Figure 20-40-85] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS.
Figure 20-40-86
2
1
N-18918
Remove the stud from the end of the spool [Figure 20-40-
84].
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-86].
NOTE: Check the O-ring for damage. The auxiliary

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

Figure 20-40-87
N-18967
Clamp the collar (Item 1) [Figure 20-40-89] in a vise.

N-18963
Figure 20-40-90
Install the plastic plug and O-ring in the spool [Figure 20-
40-87].
Figure 20-40-88 2
O-Ring
1 3
2
Plastic N-18958
Plug
0.60 inch
(15,2 mm) Apply grease on all the detent component surfaces before
assembly [Figure 20-40-90].
B-14712
Install the spring (Item 1) and detent balls (Item 2) into the
adapter (Item 3) [Figure 20-40-90] and compress with the
Install the stud and tighten until the other end of the stud detent pliers (Item 1) [Figure 20-40-91].
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-88].

Figure 20-40-91
2
1 N-18917
Install the spool seal (Item 1) and back-up washer (Item 2)

N-18968 [Figure 20-40-93].
Figure 20-40-94
Install the detent adapter to the collar [Figure 20-40-91].
NOTE: The collar and the detent adapter are held

together by spring pressure when assembled
to the auxiliary spool not the detent balls. Hold
the detent adapter and collar together to
prevent the detent balls and spring from falling
1
out.
Figure 20-40-92
N-19005
1
Install the spring assembly to the auxiliary spool hand

tight [Figure 20-40-94].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
N-19004
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m).
Install the spring tool (Item 1) [Figure 20-40-92] over the NOTE: The adapter must fit in the center of the washer
washer, spring, collar and detent adapter. (Item 1) [Figure 20-40-94].

Figure 20-40-95
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-97] to the

CD-15051 detent adapter.
Install the detent balls and spring [Figure 20-40-95].
Figure 20-40-96
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-96].

Solenoid Removal And Installation
Figure 20-40-98
1
1
S4186
Remove the solenoid stem (Item 1) [Figure 20-40-100].

S4185
Installation: Lubricate the O-rings and tighten the stem to
20-24 ft.-lb. (27-33 N•m) torque.
Remove the nut (Item 1) [Figure 20-40-98] from the
solenoid stem. Figure 20-40-101
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-98].

1 1 1
Figure 20-40-99
1
2 2
S4187
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-101] from the cartridge.
N-18693A
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing

Remove the O-rings (Item 1) [Figure 20-40-99] from both excessive wear.
ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-40-101] may be
Use an Ohm meter to measure the solenoid coil cleaned with solvent. If it is torn or worn it
resistance. needs to be replaced.
The correct resistance for the coil is 9.79 ± 0.29 Ohms. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-99] and

[Figure 20-40-101] and new back-up rings (Item 2)
[Figure 20-40-101] on the solenoid stem.

Lock Valve Removal And Installation

1
Figure 20-40-102 1
1 1
2
1
2 2 2
S4194

S4185 [Figure 20-40-104] from the lift lock valve, and replace
with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-102] is for the lift circuit.
Figure 20-40-103
S4193
Remove the lift lock valve (Item 1) [Figure 20-40-103]

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

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

Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105
S5946
Remove the tilt lock valve (Item 1) [Figure 20-40-107]

S4189 from the front of the control valve.
Installation: Lightly lubricate the lock valve O-rings and

Locate the tilt circuit lock valve (Item 1) [Figure 20-40- tighten to 20-24 ft.-lb. (27-33 N•m) torque.
105].
Figure 20-40-108
Figure 20-40-106
1
1
1 1
1
2 2 2
S4194
S4191

Remove the lift spool lock solenoid (Item 1) [Figure 20- [Figure 20-40-108] from the tilt lock valve, and replace
40-106]. with new.
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-106].
Installation: Lubricate the O-rings and tighten the spool

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

HYDRAULIC CONTROL VALVE (CONT'D)
Main Relief Valve Removal And Installation
Figure 20-40-109
S4191
Remove the main relief valve (Item 1) [Figure 20-40-109].
Figure 20-40-110
S4192
Remove the O-rings (Item 1) [Figure 20-40-110] from the

main relief valve.
Installation: Always use new O-rings. Tighten main relief

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

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.
The lift arm bypass control valve is manually operated by

pulling up on the Control 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 lower to the
transport position.
Testing
WARNING
Figure 20-50-1
1 W-2059-0598
Install jack stands under the rear corners of the loader.
Start the engine. Raise the lift arms and install an

approved lift arm support device (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
Raise the operator cab (See Raising on Page 10-30-1.)

S4225
Figure 20-50-2
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm bypass Control Knob until the lift arms
slowly lower. 1
The knob should return to its initial position.
S4225
Hold the Lift Arm bypass Control knob (Item 1) [Figure

20-50-2] and loosen the jam nut on the Lift Arm bypass
valve shaft.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-5
Figure 20-50-3
1
1 2
S4228
Remove the two mounting bolts / nuts (Item 1) [Figure 20-

S4226 50-5].
Installation: Tighten the mounting bolts to 180-200 in.-lb.

Remove the Lift Arm bypass Control knob (Item 1) and (21-23 N•m) torque.
the jam nut (Item 2) [Figure 20-50-3] from the Lift Arm
bypass valve shaft. Figure 20-50-6
Figure 20-50-4
2 3
1
S4229
S2910
Remove the lift arm bypass control valve (Item 1) [Figure
20-50-6].
Disconnect the base end lift tubeline (Item 1) [Figure 20-
50-4] from the Lift Arm bypass valve. Remove the rubber washer (Item 2) [Figure 20-50-6].
Disconnect the motor case drain hose (Item 2) [Figure

20-50-4].

LIFT ARM BYPASS CONTROL VALVE (CONT’D)
Figure 20-50-7
2 3
1
S4229
Remove the bypass valve (Item 1) from the valve block

(Item 3) [Figure 20-50-7]. Inspect the bypass valve for
damage and replace if necessary.
Installation: Tighten the valve to 33-37 ft.-lb. (45-50 N•m)

torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.

HYDRAULIC PUMP This procedure will require one operator in the cab and
one operator running the tester.
Description
Start the engine and run at low idle. Press the Front
The hydraulic gear pump is attached to the end of the Auxiliary button. Engage the front auxiliary with the trigger
hydrostatic pumps and is located on the right side of the on the right handle. Make sure the tester is connected
loader between the hydraulic control valve and the engine. correctly. If no flow is indicated on the tester, the hoses
are connected wrong. With the hoses connected correctly,
The hydraulic gear pump is a combination of gear pumps increase the engine speed to full RPM.
that provide hydraulic flow to several hydraulic systems.
Warm the fluid to 140°F (60°C) by turning the restrictor
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about a 1000
This supplies charge pressure to the hydrostatic pump. PSI (69 bar).
A seal kit is available to service the hydraulic pump. If any NOTE: DO NOT EXCEED 3300 PSI.
of the main components of the pump are damaged, the
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-60-1] on the
tester counterclockwise to obtain free flow, the flow should
Pump Test at Quick Couplers be approximately 16-17 GPM (60,6-64,5 L/min).
The tools listed will be needed to do the following Start turning the restrictor clockwise, causing more
procedure: restriction on the flow. The GPM should drop off slightly
until the pressure reaches approximately 2400 PSI (165
MEL10103 - Hydraulic Tester bar). At approximately 2400 PSI (165 bar) the flow should
MEL10106 - Hydraulic Test Kit start decreasing rapidly until the pressure reaches 2650-
2750 PSI (183-190 bar). At 2650-2750 PSI (183-190 bar)
Figure 20-60-1 the flow should be at 0 GPM (0 L/min). Turn the restrictor
(Item 2) [Figure 20-60-1] counterclockwise to free flow.
Shut the front auxiliary hydraulics off.
1
If flow and pressure specs are not obtained, go to Direct
Pump Testing. (See Direct Pump Test on Page 20-60-2.)
P-16903 S6029
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 3/4 inch (19 mm) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 50 GPM (189 L/min).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

the front auxiliary quick couplers.

HYDRAULIC PUMP (CONT’D) Figure 20-60-2
Direct Pump Test
The tools listed will be needed to do the following

procedure:
MEL1563 - Remote Start Tool

MEL10103 - Hydraulic Tester
1
WARNING
S4268
Put jackstands under the front axles and rear corners
Failure to use jackstands can allow the machine to fall Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
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.
Figure 20-60-3
Raise the lift arms and install an approved lift arm support
20-1.) 1
2
WARNING
S5999
W-2059-0598 Connect the INLET hose from the tester to the OUTLET
hose (Item 1) [Figure 20-60-2] and [Figure 20-60-3] of
Raise the operator cab (See Raising on Page 10-30-1.) the pump.
Connect the OUTLET hose (Item 2) [Figure 20-60-2] and

[Figure 20-60-3] from the tester to the tubeline on the
control valve.
Connect the remote start tool (See Remote Start
Procedure on Page 10-60-4.)

HYDRAULIC PUMP (CONT’D) flow (GPM). The high pressure flow must be at least 80%
of free flow.
Direct Pump Test (Cont’d)
%= HIGH PRESSURE FLOW (GPM)
X 100
FREE FLOW (GPM)
IMPORTANT A low percentage may indicate a failed pump.
*Refer to (See Hydraulic System on Page SPEC-10-3.) for

The hydraulic tester must be in the fully open position
system relief pressure and full RPM.
before you start the engine.
I-2024-0284
Direct Pump Test (Charge Section)
Figure 20-60-4 The tools listed will be needed to do the following

EXAMPLE: TESTER procedure:
CONNECTION
MEL1563 - Remote Start Tool
Reservoir MEL10103 - Hydraulic Tester
6661247 - Filter Assembly
17 KB 1212 - Elbow Fitting
15 KB 1212 - Straight Fitting
15 KB 0812 - Reducer Fitting
Hydraulic Pump
Out In Hydraulic Control
Valve
WARNING
1 Failure to use jackstands can allow the machine to fall
W-2017-0286
BH-196

Sample tester connection shown [Figure 20-60-4]. THE LOADER on Page 10-10-1.)
Start the engine and run at low idle RPM. Make sure the Raise the lift arms and install an approved lift arm support
tester is connected correctly. If no flow is indicated on the device (See LIFT ARM SUPPORT DEVICE on Page 10-
tester, the hoses are connected wrong. With the hoses 20-1.)
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F (60°C) by turning the restrictor

control (Item 1) [Figure 20-60-4] on the tester to about
1000 PSI (68,95 bar).
WARNING
DO NOT exceed system relief pressure. Open the the lift arms are secured by an approved lift arm
restrictor control and record the free flow (GPM) at full support device. Failure to use an approved lift arm
RPM*. support device can allow the lift arms or attachment
Push the maximum / variable flow switch (on the remote W-2059-0598
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

Direct Pump Test (Charge Section) (Cont’d)
NOTE: The fluid from the charge pump must be filtered

after it passes through the Hydraulic Tester, to
1
prevent any contamination to the Hydrostatic
Pumps.

3
Connect the remote start tool (See Remote Start 2
Procedure on Page 10-60-4.)
P-39248
Figure 20-60-5
3 4
P-39250
Assemble the filter assembly (Item 1), elbow fitting (Item

2), straight fitting (Item 3) and the reducer fitting (Item 4)
[Figure 20-60-5].
Figure 20-60-6
1
1
P-39247
Determine the proper direction of oil flow through the filter

housing (Item 1) [Figure 20-60-6] and [Figure 20-60-7].

Install the fitting (15KB 1212-Straight Fitting) (Item 2)

[Figure 20-60-7] in the filter housing inlet.
Install the fitting (15KB 0812-Reducer Fitting) (Item 3)

[Figure 20-60-7] in the filter housing outlet.
Figure 20-60-8
S4269
Disconnect the OUTLET hose (Item 1) [Figure 20-60-8]

from the charge pump.

HYDRAULIC PUMP (CONT’D) Figure 20-60-
154
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-60-9
P-39255A
Be sure all connections are tight and that the hoses are
S4270
not touching any moving parts before starting the loader
[Figure 20-60-10].
Connect the inlet hose from the hydraulic tester to the Start the engine and run at low idle RPM. Make sure the
outlet fitting (Item 1) [Figure 20-60-9] of the charge pump. tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
Connect the outlet fitting on the hydraulic filter to the hose connected correctly, increase the engine speed to full
that was removed from the charge pump. RPM*.
Connect the outlet hose on the hydraulic tester to the inlet Warm the fluid to 140°F. (60°C.) by turning the restrictor
fitting on the hydraulic filter assembly. control (Item 1) [Figure 20-60-10] on the tester to about
1000 PSI (68,95 bar). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.
Turn the restrictor down to system operating pressure. DO

NOT EXCEED SYSTEM RELIEF PRESSURE. Refer to
Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%= HIGH PRESSURE FLOW (GPM)
X 100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to (See Hydraulic System on Page SPEC-10-3.) for

system relief pressure and full RPM.
**Refer to the Hydraulic Schematics for pump flow and

RPM.

HYDRAULIC PUMP (CONT’D) Figure 20-60-
155
Removal And Installation 1
1
S4205
IMPORTANT
Remove the hydraulic reservoir bracket by removing the
When repairing hydrostatic and hydraulic systems, two screws (Item 1) [Figure 20-60-11].
parts clean. Always use caps and plugs on hoses, Figure 20-60-12
damage the system.
I-2003-0888

Raise the lift arms and install an approved lift arm support 1
20-1.)

S4206
Remove the hydraulic reservoir (See Removal And

Disconnect the two outlet tubelines from the hydraulic
pump by loosening the nuts (Item 1) [Figure 20-60-12].

Removal And Installation (Cont’d) 11”
Figure 20-60-13 2.5”

1-1/2” I.S. Dia.
2-1/2” O.S. Dia.
2.5”
1-1/2” Square Tubing 1/4” (4)

1 1/4” Wall Thickness Thick Gusset
1”
16”
2”
1”
9”
1” 45°
S4207
Disconnect the inlet tubeline (Item 1) [Figure 20-60-13]

between the engine and the pump assembly from the 4”
hydraulic pump. 1”
0.5”
1”
Figure 20-60-14
0.375”
Use two 3/8”x1” Bolts for Drilled and Tapered Holes S5906
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
dimensions shown in [Figure 20-60-15] to make the
engine removal tool. (See Engine Removal And
Installation on Page 70-10-9.)
Figure 20-60-16
1 1
S4744
Remove the four engine mounts (Item 1) [Figure 20-60-

14].
Installation: Tighten the engine mount bolts to 70 ft.-lb.

(95 N•m) torque.
S2903
Install the chain on the engine as shown in [Figure 20-60-

16].
NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
reach the correct lifting position.

Figure 20-60-17
1
S4207
Remove the hydraulic pump from the loader by removing

S2904 the two screws (Item 1) [Figure 20-60-19].

Lift the engine / hydrostatic pump assembly over a height
of approximately 1/5 in. (0,5 mm) [Figure 20-60-17].
Push the engine / hydrostatic pump assembly to the side

to make sure there is enough space to remove the
hydraulic pump from the assembly.
Figure 20-60-18
S4745
Put a wooden block between the engine mount socket

(Item 1) [Figure 20-60-18] pump assembly and the side
of the frame to make sure the engine / hydrostatic pump
assembly will stay in its place.

HYDRAULIC PUMP (CONT’D)
1. Bolt (8)
2. Washer
3. Shaft seal
4. Washer
5. Pump Flange Section
6. Plug
7. O-ring
8. Pre-Load Seal
9. Load Seal
10. Wear plate
11. Drive Gear
12. Key
13. Idler Gear
14. Hydraulic Pump Section
15. O-ring
16. Pump Center Section
17. O-ring
18. Drive Gear NOT AVAILABLE AT TIME
19. Idler Gear OF PRINTING
20. Pre-Load Seal
21. Load Seal
22. Wear plate
23. Charge Pump Section
24. O-ring
25. Pump End Section
S4746

Figure 20-60-20 1
1 3
1
S4209
Remove the pump flange section (Item 1) and the

S4208 hydraulic pump section (Item 2) from the pump center
section (Item 3) [Figure 20-60-21].
Mark the pump sections for correct assembly [Figure 20-
Remove both intermediate O-rings.
60-20].
Figure 20-60-22
Loosen the eight pump housing bolts (Item 1) [Figure 20-
60-20].
Installation: Tighten to 34 to 38 ft.-lb. (25 to 28 N•m)

torque.
1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly S4749
damage the system.
I-2003-0888
Remove the shaft seal (Item 1) [Figure 20-60-23] from
the pump flange section.


1
Figure 20-60-23
2
S4212
Figure 20-60-26
S6033
Remove the wear plate (Item 1) and the bushings (Item 2)

1
[Figure 20-60-23] from the pump end section and check
for wear. Replace if needed.
Figure 20-60-24
S4213
Remove the gear and axle (Item 1) [Figure 20-60-25] and

[Figure 20-60-26] from the pump center section.
Inspect the gear and axle (Item 1) [Figure 20-60-26].

Replace if needed.
S4748
Remove the load and preload seals (Item 1) [Figure 20-

60-23] from the wear plate.

Figure 20-60-27
1
S4216
Remove the bushings (Item 1) [Figure 20-60-29] from the

S4214 pump center section and check for wear. Replace if
needed.
Remove the pump center section (Item 1) [Figure 20-60- Figure 20-60-30
27] with drive gear and drive shaft by lifting it up.
Figure 20-60-28
1
1
S4217
3
Inspect the drive gear and drive shaft (Item 1) [Figure 20-
S4215
60-30] for wear. Replace if needed.
Remove the section seal (Item 1) [Figure 20-60-28] from

the pump center section.
Remove the pin (Item 2) from the drive shaft (Item 3)

[Figure 20-60-28] and remove the drive shaft by pulling it
out of the bushing.


1
Figure 20-60-31
S4219
Figure 20-60-34
S4218
Remove the wear plate (Item 1) [Figure 20-60-31] from 1

the pump lower section.
Figure 20-60-32
S4213
Remove the gear and axle (Item 1) [Figure 20-60-33] and

[Figure 20-60-34] from the pump lower section.
Inspect the gear and axle (Item 1) [Figure 20-60-34] for

S4748 wear. Replace if needed.
Remove the load and preload seals (Item 1) [Figure 20-

60-23] onto the wear plate.

Figure 20-60-35
1
S4223
Remove the section seal (Item 1) [Figure 20-60-37] from

S4221 the pump end section
Figure 20-60-38
Remove the drive gear (Item 1) [Figure 20-60-35] from
the charge pump section.
Inspect the drive gear for wear and replace if needed.
Figure 20-60-36
S4224
Remove the bushings and check for wear. Replace if

needed [Figure 20-60-38].
S4222 Hydraulic Pump Start Up
Ensure the hydraulic reservoir is filled to the correct level

Remove the charge pump section (Item 1) [Figure 20-60- before starting the engine. (See Checking And Adding
36] from the pump lower section by lifting it up Fluid on Page 10-120-1.)

HYDRAULIC / HYDROSTATIC FILTERS Hydraulic / Hydrostatic Filter Housing Removal And
Installation
Description
Drain the hydraulic fluid reservoir.
The hydraulic / hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic / Open the rear door of the loader.
hydrostatic systems are operating.
Figure 20-70-1
The hydraulic / hydrostatic filter system consists of one
hydraulic / hydrostatic filter, one fan / charge pressure
filter and two case drain filters.
The hydraulic / hydrostatic filter removes contaminants

after the oil cooler. 1
The charge pressure filter removes contaminants before

the oil enters the hydrostatic pump.
1
IMPORTANT S5973

Disconnect the sensor wires (Item 1) [Figure 20-70-1]
tubelines and ports to keep dirt out. Dirt can quickly from the hydraulic / hydrostatic filter.
damage the system.
I-2003-0888 Figure 20-70-2
1 2
S4105
Disconnect the tubeline (Item 1) and the hose (Item 2)

[Figure 20-70-2] from the hydraulic / hydrostatic filter.

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Hydraulic / Hydrostatic Filter Housing Removal And

Installation (Cont’d)
Figure 20-70-3
1
1
S2905
Remove the hydraulic / hydrostatic filter housing by

removing the two screws (Item 1) [Figure 20-70-3].

HYDRAULIC FLUID RESERVOIR Stop the engine.
Description Raise the operator cab (See Raising on Page 10-30-1.)
The hydraulic fluid reservoir is a storage container for the Figure 20-80-1
loaders hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
The hydraulic fluid reservoir is secured to the main frame

behind the operators cab.
1

Start the engine. Raise the lift arms and install an

approved lift arm support device (See LIFT ARM S4131
SUPPORT DEVICE on Page 10-20-1.)
Drain the hydraulic reservoir (Item 1) [Figure 20-80-1] by

means of a hose. Make sure the reservoir is as empty as
possible.
Figure 20-80-2
WARNING
support device. Failure to use an approved lift arm 1
W-2059-0598 S4132

hydraulic reservoir by loosening the strap.
IMPORTANT
damage the system.
I-2003-0888

HYDRAULIC FLUID RESERVOIR (CONT’D) Hydraulic Fluid Screen
Removal And Installation (Cont’d) Figure 20-80-5
Figure 20-80-3
1 1
S5916
S4133
Remove the fill cap (Item 1) [Figure 20-80-5] from the
hydraulic reservoir.
Disconnect the three hydraulic tubelines (Item 1) [Figure
20-80-3] from the hydraulic reservoir. Cap the tubelines. Figure 20-80-6
Figure 20-80-4
1
1
2
S5917
S4134
Remove the hydraulic fluid screen (Item 1) [Figure 20-80-
6] from the reservoir.
Remove the bracket (Item 1) by removing the two screws
(Item 2) [Figure 20-80-4]. Wash the screen in clean solvent and air dry, before
installing.
Installation: Tighten the screws to 15-20 ft.-lb. (20-27
N•m) torque.
Remove the hydraulic reservoir.

OIL COOLER Figure 20-90-1
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. The cooling fan forces air around the
passages cooling the oil. 1
The oil cooler is located underneath the rear grill.
S4134
IMPORTANT
Disconnect the two plugs (Item 1) [Figure 20-90-1].
Figure 20-90-2
damage the system.
I-2003-0888
2
Remove the rear grill (See Removal And Installation on

Page 50-60-1).
1 1
S4252
Disconnect the two hydraulic tubelines (Item 1) [Figure

20-90-2] from the oil cooler.
Remove the oil cooler (and frame) by removing the five

screws (Item 2) [Figure 20-90-2].

OIL COOLER (CONT’D)
Figure 20-90-3
1 2
3
S4253
Figure 20-90-4
S6032
Remove the ventilators from the oil cooler frame by

removing the eight screws (Item 1) [Figure 20-90-3].
Remove the nuts (Item 2) [Figure 20-90-3]from the two oil

cooler fittings.
Remove the oil cooler [Figure 20-90-4] from the frame by

removing the bolts (Item 3) [Figure 20-90-3].

BUCKET POSITION VALVE Figure 20-100-2
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 in the same relative position to the ground to
maximum lift height without using the tilt function.
1
The bucket position valve is located below the operator
cab below the left side of the control panel.
See Hydraulic Schematic for more circuit information.
Solenoid Removal And Installation S4171
Figure 20-100-1
Remove the solenoid stem (Item 1) [Figure 20-100-2]
from the bucket position valve.
1 Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 N•m)
torque.
2
Figure 20-100-3
S4294

1
Disconnect the wire harness connector (Item 1) [Figure
20-100-1] from the bucket position shutoff solenoid. 2
Remove the solenoid nut (Item 2) [Figure 20-100-1]. S5910
Installation: Tighten the solenoid nut to 60 in.-lb. (6,78 Inspect the solenoid stem and replace the O-rings (Item
N•m) torque. 1) and back-up washers (Item 2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT’D) Start the engine.
Solenoid Testing Raise the lift arms and install an approved lift arm support
Figure 20-100-4 20-1)
Stop the engine.
Raise the operator cab (See Raising on Page 10-30-1)
Figure 20-100-5
P9175
Use a test meter to measure coil resistance [Figure 20-

100-4]. Coil wires do not have polarity. Correct resistance
for the coil is 9.7 ohms ± 1 ohm @ 78° F (25,5° C).
S4294
Remove the solenoid (Item 1) [Figure 20-100-5] from the
hydraulic control valve by removing the nut.
Installation: Tighten the solenoid nut to 60 in.-lb. (6,78

N•m) torque.
WARNING
W-2059-0598

BUCKET POSITION VALVE (CONT’D) Figure 20-100-8
Figure 20-100-6
1
S4172
Remove the hydraulic tubeline (Item 1) by loosening the

S4268 nuts (Item 2) [Figure 20-100-8]. Cap the tubeline and the
fittings after disconnection.
Remove the left steering linkage by removing the bolts Figure 20-100-9
and nuts on both ends of the steering linkage [Figure 20-
100-6].
NOTE: Before disconnecting the hydraulic tubelines

from the bucket position valve, first mark the
tubelines and the fittings of the bucket
position valve to make sure the tubelines will
be put on the right fitting while reconnecting
the tubelines. 2 1
Figure 20-100-7
S4173
Disconnect the hydraulic tubeline (Item 1) by loosening

2 the nut (Item 2) [Figure 20-100-9]. Cap the tubline and
the fitting after disconnection.
2
S4171
Remove the hydraulic tubeline (Item 1) by loosening the

nuts (Item 2) [Figure 20-100-7]. Cap the fittings and
tubeline after disconnection.

Figure 20-100-10
1
1
S4176
Remove the bucket position valve with its support plate by

S4174 removing the two screws (Item 1) [Figure 20-100-12].
Figure 20-100-13
Disconnect the two hydraulic tubelines by loosening the
nuts (Item 1) [Figure 20-100-10]. Cap the tubelines and
the fittings after disconnection. 1
1
Figure 20-100-11
S4177
Remove the bucket position valve from its support plate by

S4175
Disconnect the hydraulic tubeline (Item 1) [Figure 20-

100-11] from the bucket position valve by loosening the
nut. After disconnection, cap the fitting and the tubeline.


3
Figure 20-100-14
2
1 1
S5913
Remove the tilt cylinder check valve (Item 1), spring (Item
S5911 2) and plug (Item 3) [Figure 20-100-16]. Check for wear,
check O-ring and replace as needed.
Remove the solenoid stem (Item 1) [Figure 20-100-14]. Figure 20-100-17
Assembly: Tighten the solenoid stem to 30-35 ft.-lb.

(40,8-47,6 N•m) torque.
Figure 20-100-15
2
1
1
S5914
Remove the plug (Item 1) and the flow control spool (Item
2) [Figure 20-100-17].
S5912
Check the flow control spool for wear, check the O-ring on
the plug and replace if needed.
Remove the plug and O-ring (Item 1) [Figure 20-100-15].
NOTE: Always install new O-rings before any parts are

installed into the valve. Check the parts for
wear or damage and replace as needed.

BUCKET POSITION VALVE (CONT’D)
Figure 20-100-18
S5915
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-18].
Check all parts and replace as needed. Install a new O-

ring on the plug before installing.

BOB-TACH (POWER) BLOCK Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1).
Description
The Power Bob-Tach block is an option that allows the device (See LIFT ARM SUPPORT DEVICE on Page 10-
operator to hydraulically control the Bob-Tach levers for 20-1).
mounting and dismounting the attachments.
The Power Bob-Tach block is operated by a switch on the
front console. Drain the hydraulic reservoir.
The Power Bob-Tach block is mounted on the front right Remove the steering linkages.
side of the machine.
Figure 20-110-1
WARNING
support device can allow the lift arms or attachment 1
W-2059-0598
S4390
Disconnect the Power Bob-Tach harness from the

solenoid connectors (Item 1) [Figure 20-110-1].
Figure 20-110-2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
S4391
Disconnect the hydraulic tubeline (Item 1) [Figure 20-

110-2] from the Power Bob-Tach block.

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-110-5
Figure 20-110-3
3 S4393
Disconnect the two hoses (Item 1) [Figure 20-110-3] and

1 S4398 (Item 2) [Figure 20-110-5] from the Power Bob-Tach
block.
Figure 20-110-4 Figure 20-110-6
1
3
S2853 1 S4398
Disconnect the hose (Item 1) [Figure 20-110-3] and Remove the four mounting bolts (Item 3) [Figure 20-110-
[Figure 20-110-4] from the Power Bob-Tach block. 6].
Installation: Tighten the mounting bolts to 25-28 ft.-lb.

(34-38 N•m) torque.
Remove the Power Bob-Tach block.

Figure 20-110-7
1
3
2
2 1 S5900
Remove the spring guide (Item 1), spring (Item 2) and the
S4399 spool (Item 3) [Figure 20-110-8].
Check the O-ring (Item 4) [Figure 20-110-8] on the plug

Clean the block (Item 1) [Figure 20-110-7] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct
assembly. Figure 20-110-9
Remove the plug (Item 2) [Figure 20-110-7].
Installation: Tighten the plug to 25-30 ft.-lb. (34-40,6

N•m) torque.
1
IMPORTANT
1
tubelines and ports to keep dirt out. Dirt can quickly S5901
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 20-110-9].
Installation: Tighten the plug to 12-14 ft.-lb. (16,3-19

N•m) torque.

Figure 20-110-10
1 3
S5903
Do not remove the plugs (Item 1) [Figure 20-110-12].

S2852
NOTE: Do not remove the plugs. If the plugs are
removed the internal pressure relieving spring
Remove the check valve (Item 1) [Figure 20-110-10]. setting will be altered.
Installation: Oil the check valve and O-rings and tighten Figure 20-110-13
the check valve to 20-25 ft.-lb. (27,1-34 N•m) torque.
Figure 20-110-11
1
2 1
P-48384
3
S5902 Remove the plug (Item 1) [Figure 20-110-13], inspect the
O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-110-13]
(Item 2) [Figure 20-110-11]. to 12-14 ft.-lb. (16,3-19 N•m) torque.
Check the O-rings and back up washers (Item 3) [Figure
20-110-11] on the check valve and piston assembly and
replace as needed.

Figure 20-110-14
1 1 2
2
S5904
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-110-16].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 1) located behind the plug ease of installation.
(Item 2) [Figure 20-110-14].
Figure 20-110-17
Installation: Tighten the orifice screw (Item 2) [Figure
20-110-14] to 6-8 ft.-lb. (8,1-10,8 N•m) torque.
Figure 20-110-15
1
1
2
P-48386
Remove the solenoid stem (Item 1) [Figure 20-110-17].

P-48127
Installation: Tighten the solenoid stem to 20-25 ft.-lb.
(27,1-34 N•m) torque.
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-110-15].
Remove the solenoid nut (Item 2) [Figure 20-110-15].
Installation: Tighten the solenoid valve stem nut to 15-45

in.-lb. (1,7-5,1 N•m) torque.

Figure 20-110-18
S5905
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 110-20].
Installation: Tighten the screened orifice plug to 11-12

Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9-16,3 N•m) torque.
110-18].
Figure 20-110-21
Figure 20-110-19
2
2
1
1
S4394
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-110-

Inspect the solenoid stem (Item 1), armature assembly 21] for damage and replace if needed. If the screened
(Item 2) and the spool (Item 3) [Figure 20-110-19] for orifice plug is blocked replace with a new plug.
damage.
Check the O-ring (Item 2) [Figure 20-110-21] and replace
NOTE: If the solenoid stem is damaged (Item 1) check if needed.
the armature assembly (Item 2) for damage.
The armature assembly and spool (Item 3)
[Figure 20-110-19] are non-serviceable parts. If
they are damaged, order a new power Bob-
Tach block assembly from Bobcat parts.

FRONT AUXILIARY HYDRAULIC COUPLERS
Description
The front auxiliary hydraulic couplers supply hydraulic

flow for various attachments.
The front auxiliary hydraulic couplers are located at the

front of the machine on the left side arm.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-120-1
1 2
S4044
Disconnect the auxiliary tubelines (Item 1) [Figure 20-

120-1] from the coupler frame.
Remove the mounting bolt (Item 2) [Figure 20-120-1].

HYDROSTATIC SYSTEM
CASE DRAIN FILTER ............................................................................. 30-60-1

Description ......................................................................................... 30-60-1
Disassembly And Assembly............................................................... 30-60-1
CHARGE PRESSURE ............................................................................ 30-30-1

Adjusting ............................................................................................ 30-30-3
HYDROSTATIC
Description ......................................................................................... 30-30-1
SYSTEM
Sender Removal And Installation ....................................................... 30-30-2
Testing ............................................................................................... 30-30-1
DRIVE BELT ........................................................................................... 30-50-1

Adjusting ............................................................................................ 30-50-1
Belt Removal And Installation ............................................................ 30-50-2
Description ......................................................................................... 30-50-1
Shield Removal And Installation ........................................................ 30-50-1
Tensioner Pulley Disassembly And Assembly .................................... 30-50-2
Tensioner Pulley Removal And Installation ........................................ 30-50-2
HYDROSTATIC MOTOR ............................................................................ 30-20-1

Description ......................................................................................... 30-20-1
Disassembly And Assembly ............................................................... 30-20-2
Removal And Installation ................................................................... 30-20-1
HYDROSTATIC PUMP ............................................................................... 30-40-1

Assembly ......................................................................................... 30-40-11
Description ......................................................................................... 30-40-1
Disassembly ...................................................................................... 30-40-6
Hydrostatic Pump Start Up ...............................................................30-40-15
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Replenishing / High Pressure Relief Valve Removal And Installation 30-40-1
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC 01)
UNLESS OTHERWISE SPECIFIED.

HYDROSTATIC SYSTEM INFORMATION
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.
IMPORTANT
damage the system.
I-2003-0888

HYDROSTATIC 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 the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side, in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves are not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump is damaged.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct 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.

HYDROSTATIC MOTOR Figure 30-20-1
Description
Remove the back wheel / tire assemblies by removing the
The hydrostatic motors are driven by high pressure from eight bolts (Item 1) [Figure 30-20-1].
the hydrostatic pumps.
Figure 30-20-2
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.
The hydrostatic motors do not have an internal brake.
S4372
WARNING
S4499
W-2059-0598
Remove the cover by removing the four bolts (Item 1)

WARNING [Figure 30-20-2].

explosion or fire.
W-2103-0508

HYDROSTATIC MOTOR Figure 30-20-1
20-1.)
Stop the engine.

HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 30-20-5
Figure 30-20-3
1
1
S4257
S4230
Remove the end cap (Item 1) from the hydrostatic motor

by removing the four bolts (Item 2) [Figure 30-20-5].
Disconnect the three hydraulic tubelines (Item 1) [Figure
30-20-3] from the hydrostatic motor. Installation: Tighten the bolts to 45-55 ft.-lb. (61-75 N•m).
Figure 30-20-4 Figure 30-20-6
1
S4231 S4258
Remove the hydrostatic motor from the loader by Remove the O-rings (Item 1) [Figure 30-20-6] from the
removing the four mounting bolts (Item 1) [Figure 30-20- end cap and check for wear. Replace if needed
4] and pulling it out of the loader.
Installation: Tighten the four hydrostatic motor mounting

bolts 90-100 ft.-lb. (122-136 N•m).

HYDROSTATIC MOTOR (CONT’D) Figure 30-20-9
Figure 30-20-7
2 S4495
Installation: The motor needs proper timing when

S4259 reassembling. The timing alignment should be as shown
above [Figure 30-20-9]. Wrong timing results in reverse
rotation of the motor.
Remove the valve (Item 1) and valve plate (Item 2)
[Figure 30-20-7] from the hydrostatic motor. Figure 30-20-10
Figure 30-20-8
2
1 1
2
S4261
S4260
Remove both inner and outer seals (Items 1 and 2) and
the two springs (Item 3) [Figure 30-20-10] from the cone.
Remove the valve (Item 1) and check the O-ring (Item 2)
[Figure 30-20-8] for wear. Replace if needed.


1
Figure 30-20-11
S4271
Remove the drive shaft (Item 1) [Figure 30-20-13] from

S4497 the hydrostatic motor.
Remove the gerotor section (Item 2) [Figure 30-20-13]

Installation: Install the inner and outer seals as shown in from the hydrostatic motor.
[Figure 30-20-9]. Apply grease on the inner and outer
seals. Figure 30-20-14
NOTE:
2
Figure 30-20-12 1
S4272
1
2 NOTE: Do not disassemble the gerotor section (Item
S4262 1) [Figure 30-20-14]
Installation: Align the drain hole (Item 2)[Figure 30-20-

Remove the balance ring (Item 1) from the valve (Item 2) 14] with other sections on hydrostatic motor.
[Figure 30-20-9]. Apply grease on all seals.

Figure 30-20-15
S4277
Installation: Use a hydraulic press to install the drive

S4274 shaft in the housing [Figure 30-20-17].
Figure 30-20-18
Remove the drive shaft (Item 1) [Figure 30-20-15] from
the hydrostatic motor by pulling it out.
1
Turn the hydrostatic motor upside down.
2
3
Figure 30-20-16
S4278
1
Remove the seal (Item 1) [Figure 30-20-18] from the
drive shaft and inspect for wear. Replace if needed.
2
S4275 Remove the snap ring (Item 2) [Figure 30-20-18] from the
drive shaft.
Remove the plate from the drive shaft by removing the Remove the upper bearing (Item 3) [Figure 30-20-18]
eight bolts (Item 1) [Figure 30-20-16]. from the drive shaft by pulling it back.
Remove the O-ring (Item 2) [Figure 30-20-16] and

inspect for wear. Replace if needed.
Installation: Pretighten the eight bolts to 50 ft.-lb. (6

N•m), then torque screws to 300 ft.-lb.(34 N•m).

Figure 30-20-19
2
S4280
Installation: Use a hydraulic press to install the two

S4279 bearings and the ring on the drive shaft [Figure 30-20-
20].
Remove the spacer (Item 1) [Figure 30-20-19] that is

situated between the two bearings.
Remove the lower bearing (Item 2) [Figure 30-20-19]

from the drive shaft by pulling it back.

CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic

WARNING
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.
W-2059-0598
Charge pressure is obtained from the standard section on
the hydraulic gear pump.
Figure 30-30-2
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary spool in the main
1
hydraulic control valve.
The charge pressure sender is located on the charge filter

housing mounted next to the blower housing. Charge
pressure alarm settings are pre-programmed into the
main controller and are based on loader type and options
installed.
3
2
Testing
Figure 30-30-1
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-30-2].
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to

the adapter fitting. Tighten all connections.
2
Raise the loader lift arms and install an approved lift arm
3 support device. (See LIFT ARM SUPPORT DEVICE on
1 Page 10-20-1.)
Place the loader on jackstands. (See LIFTING AND

P-43196A
BLOCKING THE LOADER on Page 10-10-1.)
The tools needed to check charge pressure, hydraulic Raise the operator cab. (See Raising on Page 10-30-1.)
hose (Item 1), Hydraulic gauge 1000 PSI (68,95 bar)
(Item 2) and adapter fitting (P/N 93F-5) (Item 3) [Figure
30-30-1].

CHARGE PRESSURE (CONT’D) Sender Removal And Installation
Testing (Cont’d) Figure 30-30-4
Figure 30-30-3
1
1
2
S5907
S5907
Disconnect the charge pressure sender connector (Item
1) [Figure 30-30-4] from the sender.
Remove the cap (Item 1) [Figure 30-30-3] from the fitting.
Remove the sender (Item 2) [Figure 30-30-4] from the
Install the hose that is attached to the pressure gauge, to adapter fitting.
the fitting, where the cap was removed.
Installation: Tighten the charge pressure sender to 7.4-
Tighten the hydraulic fittings. 8.1 ft.-lb. (10-11 N•m) torque.
Start the loader and warm the hydraulic fluid to 140° F

(60° C).
The charge pressure at high idle, with the fluid

temperature of 140° F (60° C) is 270 PSI (20 bar) with the
pump in neutral.

CHARGE PRESSURE (CONT’D)
Adjusting
IMPORTANT
damage the system.
I-2003-0888
Figure 30-30-5
S4376
The charge pressure valve is located inside the left hand

machine side hydrostatic pump (Item 1) [Figure 30-30-5].
See page 30-40-7 for disassembly of the charge inlet
relief valve.
The charge inlet relief valve can not be adjusted.

HYDROSTATIC PUMP Figure 30-40-2
Description
The hydrostatic pump is composed of two hydrostatic 1

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 2
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
S4152
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump contains the charge pressure relief. Remove the replenishing / high pressure relief valve (Item
The charge pressure relief is adjustable with shims. 1) [Figure 30-40-2] from the pump.
The hydrostatic pump is located in the center of the Assembly: Tighten the plug to 30-50 ft.-lb. (41-68 N•m)
mainframe mounted to the engine flywheel housing. torque.
Replenishing / High Pressure Relief Valve Removal Check for damage and replace as needed.
And Installation
Check O-ring (Item 2) [Figure 30-40-2] for damage and
Figure 30-40-1 replace as needed.
If the replenishing / high pressure relief valve must be

replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing / high

1 pressure relief valve is 4250 PSI (293 bar).
S4147
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-40-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two are located 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 30-40-4
IMPORTANT 2

1
damage the system.
I-2003-0888
S4142
Remove the engine / hydrostatic pump assembly from the

loader. (See Removal And Installation on Page 70-10-2.) Loosen the drive belt (Item 1) by pulling the tension wheel
(Item 2) [Figure 30-40-4] upwards with a handle.
Figure 30-40-3
Remove the drive belt by pulling it back from the pulleys.
Figure 30-40-5
1
S4109
1
Remove the cover on the left side of the engine by S4143

removing the two brackets (Item 1) [Figure 30-40-3].
Remove the nut and washer (Item 1) [Figure 30-40-5] by

screwing them loose.
Installation: Tighten to 175-200 ft.lb. (237-271 N•m)

torque.

Figure 30-40-6 1
2
2
2
1
1 1
S4146
1
Remove the black cover from the pump assembly by

S4144 removing the six screws (Item 1) and loosening the two
bolts (Item 2) [Figure 30-40-8].
Install the puller (Item 1) on the hydrostatic pump drive Figure 30-40-9
pulley. Remove the drive pulley (Item 2) [Figure 30-40-6]
from the pump shaft.
Installation: Install the key in the hydrostatic pump shaft

before installing the pump drive pulley.
1
Figure 30-40-7
1 S4147
1 Remove the hydraulic pump from the pump assembly by


S4145 torque.
Remove the three hydrostatic pump mounting bolts (Item

1) [Figure 30-40-7] from the pump and drive belt housing.
The pump assembly (one hydraulic and two hydrostatic) is
now loose from the drive belt housing.

torque.

HYDROSTATIC PUMP (CONT’D)
Figure 30-40-10
S4148
Separate the two hydrostatic pumps by removing the two

screws (Item 1) [Figure 30-40-10].

torque.
WARNING
explosion or fire.
W-2103-0508

HYDROSTATIC PUMP (CONT’D)
1. Bolt (2)
2. Washer
3. O-ring
4. Coupler
5. O-ring
6. Replenishing/High Pressure Relief Valve
7. Pin
8. Bearing
9. Valve Plate
10. Gasket
11. Block
12. Wear Plate
13. Swash plate
14. Tapered Roller Bearing
15. Plug
16. O-ring
17. Housing
18. O-ring
19. Bearing Race
20. Cover
21. Washer
22. Bolt (6)
23. Bearing
24. Crush Ring
25. Seal
26. Cover
27. Shaft (For Left Pump)
28. Key
29. Retainer Ring
30. Bearing Thrust
31. Bearing
32. Washer
33. Seal
34. Retainer Ring
35. Shaft (For Right Pump)
36. O-ring
37. Charge Pressure Relief Valve Housing
38. Piston
39. Spring
40. Washer
41. Retainer Ring
42. Pin
43. End Cap
S4747

Disassembly
1
Figure 30-40-11
1
S4151
1
Screw the two replenishing/high pressure valves (Item 1)
1 S4149 [Figure 30-40-13] out of the end cap.
NOTE: While removing the valves, oil can be spilled.

Remove the four bolts (Item 1) [Figure 30-40-11] from the
pump housing to separate the hydrostatic pump into left Figure 30-40-14
and right.
Figure 30-40-12
1
3
1
2 S4152
S4150 Remove the spring washer (Item 1) [Figure 30-40-14] to

disassemble the valve.
Remove the valve plate (Item 1) [Figure 30-40-12] and

gasket from the smallest hydrostatic pump part. Check
the valve plate for wear (both sides).
Check the valve plate locating pin (Item 2) [Figure 30-40-

12] for wear and replace if needed.
Check the needle bearing (Item 3) [Figure 30-40-12] for

wear and replace if needed.

Disassembly (Cont’d)
Figure 30-40-15
S4157
Remove the block and piston assembly (Item 1) [Figure

S4155 30-40-17] from the pump by pulling it back.
Figure 30-40-18
Remove the charge inlet relief valve (Item 1) [Figure 30-
40-15].
Figure 30-40-16
1
2
2
6 5 4 3 1
S4158
Pull the ring (Item 1) and pistons (Item 2) [Figure 30-40-

S4156 18] out of the cylinder block.
Check all the pistons for wear and replace if needed.

Remove the retaining ring (Item 1) [Figure 30-40-16].
NOTE: Remove the retaining ring very carefully

because of the expanding spring.
Successively pull the washer (Item 3), spring (Item 4) and

piston (Item 5) out of the valve housing (Item 2) [Figure
30-40-16].
Remove the O-ring (Item 6) [Figure 30-40-16].

Figure 30-40-19
1
2 7
5 6
1 3 4
8 S4160
S4159 Remove the retaining ring (Item 1) [Figure 30-40-20] from

the back of the pump to remove the pump shaft out of the
pump housing.
Pull the retaining ring (Item 1) out of the cylinder block
(Item 2) [Figure 30-40-19]. Figure 30-40-21
NOTE: Remove the retaining ring carefully because of

the expanding spring.
Pull the two washers (Items 3 and 4) and the spring (Item 1 2 3 4 5 4
5) [Figure 30-40-19] out of the cylinder block. 6
Remove the ball guide retainer (Item 6) [Figure 30-40-19]

from the cylinder block.
Check the ball guide retainer for wear and replace if

needed.
Pull the retainer (Item 7) out of the cylinder block and

S4161
remove the three pins (Item 8) [Figure 30-40-19].
Check the cylinder block for wear and replace if needed.

Remove the seal ring (Item 1) and the washer (Item 2)
Check the three pins to see if they are all the same length. [Figure 30-40-21] from the pump shaft.
Remove the retaining ring (Item 3) [Figure 30-40-21] from

the pump shaft.
Remove the two bearing thrusts (Items 4) and the bearing

(Item 5) from the pump shaft. Also remove the retaining
ring (Item 6) [Figure 30-40-21].

Figure 30-40-22
2
1 3
S4164
Remove the O-ring (Item 1), the crush ring (Item 2) and
S4162
the bearing race (Item 3) [Figure 30-40-24] from the
cover. Inspect them and replace if needed.
Remove the bearing (Item 1) [Figure 30-40-22] from the Figure 30-40-25
pump housing.
Figure 30-40-23
1
1
1
1
S4165
S4163
Remove the lower cover from the pump housing by
removing the three bolts (Item 1) [Figure 30-40-25].
Remove the cover from the pump housing by removing
the three bolts (Item 1) [Figure 30-40-23].

Figure 30-40-26
1
1
S4168
Remove the wear plate (Item 1) [Figure 30-40-28] from

S4166 the swash plate.
Slide the swash plate from side to side and remove the
lower tapered roller bearing (Item 1) [Figure 30-40-26]
from the swash plate shaft.
Figure 30-40-27
S4167
Tilt the swash plate (Item 1) [Figure 30-40-27] and

remove the swash plate with upper tapered roller bearing
from the pump housing.

Assembly
Figure 30-40-29
1
S4165
Install the lower cover on the pump housing and tighten

S4168 the bolts (Item 1) [Figure 30-40-31] to 29 ft.-lb. (39,3
N•m).
Install the wear plate (Item 1) [Figure 30-40-29] onto the Figure 30-40-32
swash plate.
Figure 30-40-30
2
1 3
S4164
S4166 Install the O-ring (Item 1), the crush ring (Item 2) and the
bearing race (Item 3) [Figure 30-40-32] on the cover.
Install the swash plate and the upper tapered roller

bearing into the pump housing [Figure 30-40-30].

Assembly (Cont’d)
Figure 30-40-33
1 2 3 4 5 4 6
1
1
1
S4161
Install the retaining ring (Item 1), the two metal rings (Item
S4163 4) and the bearing (Item 5) [Figure 30-40-35] onto the
pump shaft.
Install the cover on the pump housing and tighten the Install the retaining ring (Item 3) [Figure 30-40-35] onto
bolts (Item 1) [Figure 30-40-33] to 29 ft.-lb. (39,3 N•m). the pump shaft.
Figure 30-40-34 Install the big metal ring (Item 2) and the seal ring (Item 1)
[Figure 30-40-35] onto the pump shaft.
Figure 30-40-36
1
1
S4162
Install the bearing (Item 1) [Figure 30-40-34] into the

pump housing. S4160
Install the pump shaft into the pump housing and install
the retaining ring (Item 1) [Figure 30-40-36].

Assembly (Cont’d)
Figure 30-40-37
2 7
5 6
1 3 4
S4157
8
Install the rotating group into the pump as shown in

S4159 [Figure 30-40-39].
Figure 30-40-40
Install the two rings (Items 3 and 4) and the spring (Item
5) [Figure 30-40-37] into the cylinder block.
Install the retaining ring (Item 1) [Figure 30-40-37] into

the cylinder block.
2
Install the three pins (Item 8) into the cylinder block and 6 5 4 3 1
put the tension ring (Item 7) [Figure 30-40-37] in its place.
Install the ball guide retainer (Item 6) [Figure 30-40-37]

into the cylinder block.
Figure 30-40-38
S4156
Install the cylindric part (Item 5), the spring (Item 4), the
the ring (Item 3) and the retaining ring (Item 1) into the
valve housing (Item 2) [Figure 30-40-40].
S4158
Install the ring and pistons into the cylinder block [Figure
30-40-38].

Assembly (Cont’d)
Figure 30-40-41
S4152
Assemble the parts shown in [Figure 30-40-42] to

S4155 become the part shown in [Figure 30-40-43].
Figure 30-40-44
Screw the cylinder (Item 1) [Figure 30-40-41] into the end
cap after first installing the O-ring (Item 6) [Figure 30-40-
40]. 1
Figure 30-40-42
1
S4151
Install the two valves (Item 1) [Figure 30-40-44] into the

end cap and tighten to 95-105 ft.-lb. (128,8-142,4 N•m).
S4153

Assembly (Cont’d)
Figure 30-40-45 1
1 1
1 S4149
Assemble the two pump parts by means of the four bolts

S4150
(Item 1) [Figure 30-40-47].
Tighten the bolts to 19 ft.-lb. (25 N•m) torque.

Coat the backside of the valve plate (Item 1) [Figure 30-
40-45] with petroleum jelly to hold it in position and install Hydrostatic Pump Start Up
the valve plate onto the end cap.
Follow the hydraulic pump start up procedure (See
Figure 30-40-46 Hydraulic Pump Start Up on Page 20-60-14).
S6017
Install the two pins (Items 5) and gasket (Item 3) [Figure

30-40-46] onto the pump part.

DRIVE BELT Adjusting
The drive belt makes the mechanical connection from the

engine flywheel to the hydrostatic pump pulley.
The belt is a cord-reinforced rubber design. 1
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

the flywheel housing by metal clips. The shield is also in
place to protect the operator.
Shield Removal And Installation

S4232
Figure 30-50-1
The adjustment of the drive belt is done automatically by

means of a spring loaded tensioner pulley (Item 1)
[Figure 30-50-2].
1
S4232
Remove the two drive belt shield mounting clips (Item 1)

[Figure 30-50-1].
Remove the belt shield.

DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Belt Removal And Installation Remove the drive belt from the engine (See Belt Removal
And Installation on Page 30-50-2).
Figure 30-50-4
Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance
(See Removal And Installation on Page 60-20-1.) 1
Remove the belt shield (See Shield Removal And

Figure 30-50-3
S4233
1
Remove the tensioner pulley from the engine by removing

the screw (Item 1) [Figure 30-50-4].
Tensioner Pulley Disassembly And Assembly
S4233 Figure 30-50-5
Loosen the drive belt (Item 1) by pulling the tension wheel

(Item 2) [Figure 30-50-3] upwards with a socket wrench.
Remove the drive belt by pulling it back from the pulleys.
Install a new drive belt.

1
Reinstall the belt shield and connect the negative (-) cable
to the battery.
S4234
Remove the bolt (Item 1) [Figure 30-50-5] from the

tensioner pulley and remove the black cover.

CASE DRAIN FILTER Figure 30-60-3
Description
The case drain filter is an external filter assembly in the

case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See

Removing And Replacing Case Drain Filter on Page 10-
120-3.)
P-76218
Figure 30-60-1
1
P-76212
Remove the filter housing nut (Item 1) from the filter

housing (Item 2) [Figure 30-60-1].
Figure 30-60-2
P-76214
Remove the packing (Item 1) and O-ring (Item 2) [Figure

30-60-2] from the filter housing nut.

215 of 521
CASE DRAIN FILTER Figure 30-60-3
Remove the filter element and spring assembly (Item 1)

[Figure 30-60-3]
NOTE: Remember the orientation of the filter element

and spring assembly for correct assembly.
Figure 30-60-4
P-76216
The larger taper spring (Item 1) slides over the end of the
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-60-4] slides into the filter element.

215 of 521
216 of 521
DRIVE SYSTEM
BRAKE .................................................................................................. 40-10-1

Description ....................................................................................... 40-10-1
Disk Removal And Installation ......................................................... 40-10-1
CHAINCASE ......................................................................................... 40-30-1

Center Cover Removal And Installation ........................................... 40-30-2
Center Cover Removal And Installation ........................................... 40-30-2
Front Cover Removal And Installation ............................................. 40-30-1
DRIVE COMPONENTS ........................................................................ 40-20-1

Axle Seal Removal And Installation. ................................................ 40-20-2 DRIVE
Axle Sprocket And Bearings Removal And Installation .................... 40-20-4 SYSTEM
Chain Removal And Installation ....................................................... 40-20-8
Description ....................................................................................... 40-20-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.

BRAKE Disk Removal And Installation
Description Raise the lift arms and install an approved lift arm support
Figure 40-10-1 20-1.)
WARNING
1 W-2059-0598

S2849
Disconnect and remove the engine speed control (See

Removal And Installation on Page 70-20-1.)
The brake is used to hold the machine in place. The brake
is operated by a switch (Item 1) [Figure 40-10-1] located
Remove the control panel.
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. An electric solenoid is
getting power from a relay to pull the wedge away from the
Remove the traction lock assembly (See Removal And
discs. A signal from the main Bobcat controller holds the
wedge away from the discs.
Figure 40-10-2
The hold signal will be interrupted and the wedge will drop
if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake (See TRACTION

LOCK on Page 60-110-1.)
1
1 S0364
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.

BRAKE (CONT’D) Figure 40-10-4
Disk Removal And Installation (Cont’d)
Figure 40-10-3
3
P-54222
1 Snap ring pliers with 90° tips is necessary for removing

N-19105 the parking brake discs.
Remove the snap ring (Item 1) from the end of the

Inspect the traction lock guides (Item 1) [Figure 40-10-3] sprocket (Item 2) [Figure 40-10-4].
and the brake discs for damage or wear and replace if
necessary. Slide the disc (Item 3) [Figure 40-10-4] off the sprocket
and remove the disc.
Reverse the removal procedure to install the disc in the

loader.

DRIVE COMPONENTS
Description
S4265
The drive components consist of a 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) Figure 40-20-2
Axle Seal Removal And Installation
Figure 40-20-1
1
1
P-4159
2
Install the puller tool (Item 1) [Figure 40-20-2] on the axle
P-4157 hub.
A driver tool (Item 2) [Figure 40-20-2] can be used for

The tools listed are needed for the following procedure: centering the threaded rod of the puller.
Axle Hub Puller Tool

MEL1399 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)
WARNING
To loosen the axle hub mounting bolt (Item 1) [Figure 40-
20-1], use the following procedure. NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
Before lifting and blocking the loader, loosen the hub tapered fit on the axle end and can come off the axle
mounting bolt (Item 1) [Figure 40-20-1]. with great force and cause serious injury.
W-2186-0395
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
Use a wrench with the puller and remove the axle hub
the chaincase before lifting and blocking the
from the axle tube. A spacer and a power ram MEL 1242
loader. (See Axle Sprocket And Bearings
can be 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 725-800 ft.-

lb. (983-1085 N•m) torque.
Remove two of the wheel mounting studs (Item 2) [Figure

40-20-1].
Use a wheel mounting nut on both studs and remove the

two studs with a hammer.
Installation: Support the flange of the axle hub and install

the two studs with a hammer. A hydraulic press can also
be used to install the studs.

Axle Seal Removal And Installation (Cont’d)
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
P-4161 the 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:

1
MEL1242 - Power Ram
MEL1202B - Axle Bearing Service Set
2
NOTE: The procedure shown is for removing the front
axle, bearings and sprocket. This procedure
can also be used for the rear axle, bearings 1
and sprocket.
Use jackstands to support the rear of the loader. (The

loader wheels should remain on the ground.) S2912
Remove the 12 front cover mounting bolts (Item 1) and

the front cover (Item 2) [Figure 40-20-6] from the
WARNING chaincase (See Front Cover Removal And Installation on
Page 40-30-1.)
the lift arms are secured by an approved lift arm Figure 40-20-7
W-2059-0598
20-1.)

1
P-4147A
Loosen the axle sprocket mounting bolt (Item 1) [Figure

40-20-7].

Remove the fluid from the chaincase.
Remove the axle hub. (See Axle Seal Removal And

Remove the sprocket mounting bolt (Item 1) [Figure 40-

20-7].
Installation: Tighten the sprocket mounting bolt to 300-

330 ft.-lb. (407-447 N•m) torque.


(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 40-20-
Install the MEL1242 power ram (Item 1) [Figure 40-20-8] 10].
between the two sprockets.
Figure 40-20-11
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
P-4171
2 Be sure the bearing puller makes good contact with the

1 inner race of the bearing and press the bearing off the
mounting surface of the axle.
P-4162A
Be sure to hold on to the axle during removal as it will
slide freely along the axle shaft after removal from the
Remove the drive chain from the sprocket (Item 1) bearing mounting surface and until the bearing contacts
[Figure 40-20-9] and remove the sprocket from the the spline on the shaft.
chaincase.
Press the splined end of the axle free from the bearing
Remove the inner bearing (Item 2) [Figure 40-20-9] and [Figure 40-20-11].
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.


(Cont’d)
Figure 40-20-12
4
3
P-4175
2 When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated
P-4169 [Figure 40-20-13].
Figure 40-20-14
Installation: A piece of round tubing (Item 1) [Figure 40-
20-12] is needed to install the bearing on the axle shaft.
The tubing needs to measure approximately 0.500 inch

(12,7 mm) to 1.0 inch (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 inches
(53,3 mm) and the outside diameter should not be over
2.400 inches (60 mm).
A bearing puller (Item 2) [Figure 40-20-12] is also needed

to install the bearing on the axle.
Put the tubing (Item 1) on the bearing puller (Item 2)

[Figure 40-20-12].
P-4172
Put the bearing (Item 3) [Figure 40-20-12] on the tube as
shown.
Use the tools provided in the MEL1202B Axle Bearing
Put the spline end of the axle shaft (Item 4) [Figure 40- Service Set for bearing cup removal and installation. A
20-12] in the bearing and press the bearing onto the axle. slide hammer is also necessary for this procedure.
Be sure to hold on to the axle during installation, as it will Use the long rod and the bearing cup tool to remove the
slide freely along the axle shaft after the spline end has inner bearing cup [Figure 40-20-14].
passed through the bearing and until it reaches the
bearing mounting surface on the axle. Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].


(Cont’d) 1
2
Figure 40-20-15
P-4174A
2
1
Figure 40-20-18
P-4179
1
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-15] on the slide hammer.
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2) 2
[Figure 40-20-15] on the tool.
Figure 40-20-16 P-4164
Use the bearing cup installation tools (Item 1) 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 into the axle tube and
through the installation tool (Item 1) [Figure 40-20-17].
P-4180
Secure the tool to the threaded rod with a nut (Item 3)
[Figure 40-20-17].
Use the slide hammer and remove the bearing cup from
the axle tube [Figure 40-20-16]. Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
tool.

DRIVE COMPONENTS (CONT’D) Chain Removal And Installation

(Cont’d)
Secure the tool to the threaded rod with a nut [Figure 40-
20-18].
WARNING
Hold the inside nut with a wrench and tighten the outside the lift arms are secured by an approved lift arm
nut as shown in photo [Figure 40-20-18]. support device. Failure to use an approved lift arm
Tighten the nut until the bearing cup is seated. to fall and cause injury or death.
W-2059-0598
Figure 40-20-19
support device (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)

Raise the loader operator cab (See Raising on Page 10-

30-1.)
Drain the fluid from the chaincase.
Remove the engine speed control (See Removal And

P-4173

To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups. Remove the traction lock assembly (See Removal And
Put the bearing cup tool on the short rod.
Remove the center chaincase cover (See Center Cover
Put the bearing cup in the axle tube and put the tool into Removal And Installation on Page 40-30-2.)
the tube over the bearing cup [Figure 40-20-19].
Remove the front chaincase cover (See Front Cover
Hit the short rod with a hammer until the bearing cup is Removal And Installation on Page 40-30-1.)
seated inside the axle tube.
Remove the front axle and sprocket (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20-4.)

Chain Removal And Installation (Cont’d)
Figure 40-20-20
1 B-13504A
The tool listed is needed for the following procedure:

S0463
MEL1037 - Chain Link Tool
Remove the parking brake disc (Item 1) [Figure 40-20- Installation: If a new chain is installed, a connector link
20]. (See Disk Removal And Installation on Page 40-10- must be used to connect the chain together.
1.)
Use MEL1037 Chain Link Tool and #80 chain adapter.
Remove the six mounting bolts (Item 2) [Figure 40-20-20]
from inside the chaincase. Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Installation: Tighten the mounting bolts to 125-140 ft.-lb.
(170-190 N•m) torque. Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22].
Figure 40-20-21
Tighten the threaded rod of the chain link tool to 130 ft.-lb.
(176 N•m) torque.
1
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
P-54226
Tip the end of the sprocket 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 [Figure 40-20-21], so the 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.

CHAINCASE Figure 40-30-1
Description
Remove the 12 front chaincase cover mounting screws
The chaincase contains the drive components. (Item 1) [Figure 40-30-1].
Front Cover Removal And Installation Remove the front chaincase cover from the loader.
Raise the loader lift arms and install an approved lift arm Installation: Apply polyurethane sealant to mating
support device (See LIFT ARM SUPPORT DEVICE on surfaces. Polyurethane sealant should be applied to the
Page 10-20-1) screw threads to stop oil leakage.
S2912
WARNING
W-2059-0598

CHAINCASE (CONT’D) Figure 40-30-3
Center Cover Removal And Installation 3
1 2
WARNING
W-2059-0598
S4237
support device (See LIFT ARM SUPPORT DEVICE on
Disconnect the two electrical connectors (Item 1) and
Page 10-20-1)
remove the nut (Item 2) [Figure 40-30-3].
Remove the two solenoid coils (Item 3) [Figure 40-30-3]
from the solenoid stem.
Remove the remote control panel (See Removal and
Figure 40-30-4
Remove the hydraulic control valve (See Removal And
Figure 40-30-2 1
S4238
Remove the solenoid stem (Item 1) [Figure 40-30-4] from

S4236
the Bob-Tach block.
Disconnect the electrical connector (Item 1) [Figure 40-

30-2] from the traction lock solenoid.

Center Cover Removal And Installation (Cont’d)
Figure 40-30-5
2 S4241
Remove the center chaincase cover by removing the

S4239 chaincase cover mounting screws (Item 1) [Figure 40-30-
7].
Remove the side bracket (Item 1) by removing the screw Figure 40-30-8
(Item 2) [Figure 40-30-5].
Figure 40-30-6
3 1
1 2
3
2
2
S4242
S4240 Remove the traction lock assembly (Item 1) [Figure 40-

30-8] from the center chaincase cover.
Remove the side bracket (Item 1) by removing the screw Remove the traction lock solenoid by removing the two
(Item 2) [Figure 40-30-6]. screws (Item 2) [Figure 40-30-8].
Remove the traction lock guides (Item 3) [Figure 40-30-8]

from the center chaincase cover by removing the four
screws.
Thoroughly clean the polyurethane from the chaincase

cover, screws and traction lock guides and dry.

Center Cover Removal And Installation (Cont’d)
Figure 40-30-9
1
INCORRECT CORRECT
2
3
2
P11337
1
Installation: Install the traction wedge assembly (Item 1)
N-19106 N-19105 into the solenoid traction lock guides (Item 2) [Figure 40-
30-10]. Tighten the four bolts and check to make sure the
shaft assembly is moving freely in the guides.
Installation: Install the traction lock guides (Item 1)
[Figure 40-30-9] to the chaincase cover using the four Installation: Apply polyurethane sealant to mating
screws. Do not tighten at this time. surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage.

MAIN FRAME
BOB-TACH HAND LEVER ................................................................... 50-40-1

Description ...................................................................................... 50-40-1
Lever And Wedge Disassembly And Assembly .............................. 50-40-3
Pivot Pin Bushing And Seal Removal And Installation .................... 50-40-4
Removal And Installation ................................................................ 50-40-1
BOB-TACH (POWER OPTION) ........................................................... 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
CAB DOOR ........................................................................................ 50-130-1

Adjusting ....................................................................................... 50-130-3
MAIN
Aligning ......................................................................................... 50-130-2
FRAME
Checking Operation ...................................................................... 50-130-3
Description .................................................................................... 50-130-1
Removal And Installation .............................................................. 50-130-1
CONTROL HANDLE / LEVER ........................................................... 50-110-1

Boot Removal And Installation ...................................................... 50-110-1
Description .................................................................................... 50-110-1
Lever Removal And Installation..................................................... 50-110-1
CONTROL PANEL ............................................................................. 50-100-1

Description .................................................................................... 50-100-1
Linkage Neutral Adjusting ........................................................... 50-100-11
Linkage Removal And Installation ................................................. 50-100-6
Linkage Travel Adjusting ............................................................. 50-100-14
Pintle Arm Removal And Installation ............................................. 50-100-7
Pintle Arm Disassembly and Assembly ....................................... 50-100-10
Removal and Installation ............................................................... 50-100-2
Shaft Disassembly And Assembly ................................................ 50-100-5
Shaft Removal And Installation ..................................................... 50-100-5
CONTROL PEDALS AND LINKAGES ................................................. 50-90-1

Description ...................................................................................... 50-90-1
Linkage Removal And Installation ................................................... 50-90-2
Pedal (Adjusting) ............................................................................ 50-90-2
Pedal Removal And Installation ...................................................... 50-90-1
FUEL TANK ......................................................................................... 50-80-1

Fuel Fill Screen Removal And Installation....................................... 50-80-2
Fuel Level Sender Removal And Installation................................... 50-80-2
Fuel Pickup Screen ......................................................................... 50-80-3
LIFT ARMS .......................................................................................... 50-50-1


MAIN FRAME (CONT’D)
OPERATOR CAB ................................................................................. 50-20-1

Gas Cylinder Bracket Disassembly And Assembly ......................... 50-20-3
Gas Cylinder Removal And Installation ........................................... 50-20-1
OPERATOR SEAT ............................................................................... 50-30-1

Seat Belt Removal And Installation ................................................. 50-30-1
OPERATOR SEAT (SUSPENSION) .................................................... 50-31-1

Back Cushion Removal And Installation ......................................... 50-31-3
Lower Cushion Removal And Installation........................................ 50-31-3
Seat Belt Removal and Installation ................................................. 50-31-2
Shock Removal And Installation ..................................................... 50-31-4
Slide Rail Removal And Installation ................................................ 50-31-2
3-Point Seat Belt Removal And Installation..................................... 50-31-4
REAR DOOR ....................................................................................... 50-70-1

Latch Removal And Installation....................................................... 50-70-3
Striker (Adjusting) ........................................................................... 50-70-2
Striker Disassembly and Assembly ................................................. 50-70-2
Striker Removal and Installation ..................................................... 50-70-2
REAR GRILL ........................................................................................ 50-60-1

SEAT BAR ........................................................................................... 50-10-1

Compression Spring Disassembly And Assembly .......................... 50-10-4
Description ...................................................................................... 50-10-1
Disassembly And Assembly ............................................................ 50-10-3

MAIN FRAME (CONT’D)
WINDOW (FRONT DOOR) ................................................................ 50-123-1

Installation (Standard Window) ..................................................... 50-123-2
Removal (Standard Window) ........................................................ 50-123-1
Removal And Installation (Special Applications Window) ............. 50-123-3
WINDOW (REAR) .............................................................................. 50-120-1

Installation .................................................................................... 50-120-1
Removal ....................................................................................... 50-120-1
WINDOW (SIDE)................................................................................ 50-122-1

WINDOW (TOP)................................................................................. 50-121-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR
BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.

SEAT BAR Removal And Installation
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
The seat bar is located in the operator cab.
P-43383
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

from the cab harness.
Lower the seat bar.

SEAT BAR (CONT’D) Figure 50-10-5
Figure 50-10-3
N-18572
Remove the seat bar mounting nuts (Item 1) [Figure 50-

P10564 P10563 10-5] (both sides).
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m) torque.

Loosen the nut (both sides) at the front corners of the
operator cab [Figure 50-10-3]. Lower the operator cab (See Lowering on Page 10-30-2.)
Remove the nuts and plates (both sides) [Figure 50-10- Figure 50-10-6
3].
Installation: Tighten the nuts to 40-50 ft.-lb. (54-68 N•m)

torque.
1
Figure 50-10-4
S4010
Remove the seat bar (Item 1) [Figure 50-10-6] from the

operator cab.
S4078 Reverse the above procedure to install the seat bar into
the operator cab.
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].


5
Figure 50-10-7 4 6
4 3
6
5
7
2 7
3
2 9
8 1
10 N-19340
1
N-19383
Figure 50-10-8
4
5 9 8
3 6
2 10
7
1
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] and [Figure 50-10-
8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Installation: Tighten the mounting bolt (Item 2) [Figure

50-10-7] and [Figure 50-10-8] to 50-70 in.-lb. (5,6-7,9
N•m) torque.

Figure 50-10-10
4
5
3 6
2
7
1
N-19220
Assemble the parts as shown for the right side of the

seat bar pivot assembly [Figure 50-10-9] and [Figure 50-
10- 10].
Seat Bar Mount (Item

1)Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item
4)Seat Bar (Item 5)
Keyed Plastic Bushing (Item
6)Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7)

[Figure50-10-9] and [Figure 50-10-10] to 50-70 in.-lb.
(5,6-7,9
N•m) torque.

SEAT BAR (CONT’D) NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
Compression Spring Disassembly And Assembly affected parts before the application of
LOCTITE #518.
Figure 50-10-11
Disassemble and assemble the seat bar compression
6 7 spring and parts as shown in Fig. [Figure 50-10-11].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
5
Pin (Item 6)
4 6
Bushing (Item 7)
3
2
1
N-19384
Figure 50-10-12
N-19222
Turn the bolt (Item 1) [Figure 50-10-11] and [Figure 50-

10-12] out of the clevis.
Assembly: Apply LOCTITE #518 adhesive to the bolt

threads. Adjust the compression spring by turning the bolt
in past the end of the clevis three turns.

OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING 1
Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or
death.
W-2113-0288
P1518 P1528
WARNING Remove the cab nut and holddown plate (Item 1) [Figure
50-20-2] (both sides).
the lift arms are secured by an approved lift arm Installation: Tighten the nut to 40-50 ft.-lb. (54-68 N•m)
support device. Failure to use an approved lift arm torque.
to fall and cause injury or death. Figure 50-20-3
W-2059-0598
1
Figure 50-20-1
N-20617D
P-54018
Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Remove the operator cab stop (Item 1) (both sides) Raise the operator cab. (See Raising on Page 10-30-1.) to
[Figure 50-20-1]. release the tension on the gas cylinder.

Gas Cylinder Removal And Installation (Cont’d)

Rotate the mounting bracket forward to relieve any
Figure 50-20-4 remaining tension on the gas cylinder(s) [Figure 50-20-
6].
SINGLE GAS CYLINDER
Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.
Installation: Tighten the screws to 100-130 in.-lb. (11,3-

14,7 N•m) torque.
2 1
N-20631
Figure 50-20-5
DUAL GAS CYLINDER
1 2
P-43354
Loosen the front screw (Item 1) and remove the rear

screw (Item 2) [Figure 50-20-4] and [Figure 50-20-5]
from the gas cylinder mounting bracket.
P-48587

OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-9
Figure 50-20-7
SINGLE GAS CYLINDER
2
1
1
P1008
P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.
DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.
Figure 50-20-10
1
P-68819
Remove the retaining pin(s) (Item 1) [Figure 50-20-7] and

[Figure 50-20-8] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7] and

P1006
[Figure 50-20-8] from the operator cab.
Reverse the above procedure to install the gas

Apply a small amount of Loctite® #242 on the threads of
cylinder(s).
the cylinder rod [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.

1
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 S0365
Figure 50-20-11
Disconnect the cab harness connector (Item 1) [Figure
50-20-12].
1
Installation: Tighten connector screw to 30-35 in.-lb.
(3,4-4 N•m) torque.
Lower the cab (See Lowering on Page 10-30-2.)
Figure 50-20-13
N-20617D
1 2
Remove the operator cab gas cylinder(s) (See Gas
Cylinder Removal And Installation on Page 50-20-1.)
Remove the heater unit from the cab (if equipped).
Use the hoist connected to the operator cab grab handles

to lower or (raise) the operator cab when the gas cylinders P-54021
are disconnected [Figure 50-20-11].

Remove the rear mounting bolts (Item 1) and nuts (Item 2)
[Figure 50-20-13] (both sides) from the operator cab.
Installation: Tighten the bolt and nut to 25-35 ft.-lb. (34-

47 N•m) torque.

OPERATOR CAB (CONT’D)
Figure 50-20-14
N-20627A S4299
Connect the slings (Items 1, 2, and 3) [Figure 50-20-14]

to a chain hoist.
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
1 1
N-20729A
N-20729
Raise the operator cab. (See Raising on Page 10-30-1.)
Raise the operator cab (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Items
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 20 ft.-lb. (27
N•m) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2 N-20655
Remove the two nuts (Items 1 and 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) to 54 ft.-lb. (73 N•m)

P10564 P10563 torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lb.
(46 N•m) torque.
Lower the cab and install one of the plates and nuts Repeat for other half of seat belt and guide.
[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 1
1
1 1
S4352
S4355
Raise the operator cab. (See Raising on Page 10-30-1.)
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 20 ft.-lb. (27

N•m) torque.
Figure 50-31-2
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) Figure 50-31-3
Figure 50-31-4
S4351
NOTE: Assure seat tethers are securely fastened to

the seatbelt studs (Item 1) [Figure 50-31-3]
and the seat rail studs (Item 2) [Figure 50-31-
4].
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].

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
2
1
1 1
S4352
S4351
Remove the operator seat (See Removal And Installation
on Page 50-31-1.)
Remove the operator seat (See Removal And Installation
on Page 50-31-1.) Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5]. Remove the seat belt.
Remove the slide rail (Item 2) [Figure 50-31-5] from the Installation: Tighten the mounting nuts to 58 to 62 ft.-lb.
bottom of the seat frame. (78,6 to 84 N•m) torque.
Reverse the removal procedure to install the operator seat

slide rail.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Removal And Installation Figure 50-31-9
Figure 50-31-7
1
N-18583
S4353
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-9] and tilt the seat back all the way forward.
Remove the retainer clips (Item 1) [Figure 50-31-7] and
lift the seat cushion. Figure 50-31-10
Figure 50-31-8
1 1
N-18578
S4354
Remove the two mounting screws (Item 1) [Figure 50-31-
10] from the seat back and remove the back.
Inspect the seat ride adjustment [Figure 50-31-8].
Reverse the removal procedure to install the operator seat.
seat.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Raise the operator cab (See Raising on Page 10-30-1.)
Figure 50-31-11 Remove the operator seat (See Removal And Installation
on Page 50-31-1.)
Figure 50-31-12
2
1
2
1
1
P-43118
3
Raise the operator cab (See Raising on Page 10-30-1.) P16285
Remove the operator seat (See “Removal And

Remove the mounting nut (Item 1) [Figure 50-31-12].
Installation” on page 1.)
Remove the end release buckle (Item 2) [Figure 50-31-
Remove the seat shock mounting bolts (Item 1) (Both
12].
ends) [Figure 50-31-11].
Installation: Be sure the tether strap (Item 3) [Figure 50-
Remove the seat shock (Item 2) [Figure 50-31-11].
31-12] is on the seat belt stud behind the end release
buckle.
Reverse the removal procedure to install the operator seat
shock.
Figure 50-31-13
P16284
Remove the mounting nut (Item 1) [Figure 50-31-13].
Remove the seat belt retractor (Item 2) [Figure 50-31-13].
Installation: Be sure the tether strap (Item 3) [Figure 50-

31-13] is on the seat belt stud behind the seat belt
retractor.

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-31-14
1 2
P16126
1
INSIDE OF CAB
P16128
OUTSIDE OF CAB Remove the shoulder harness retractor (Item 1) [Figure

P16131 50-31-15].
Installation: Line up the bolt (Item 1) [Figure 50-31-14]

Remove the mounting bolt (Item 1) [Figure 50-31-14]. with the mounting bracket (Item 2) [Figure 50-31-15] on
the inside of the cab.

BOB-TACH HAND LEVER Figure 50-40-2
Description
Remove the retainer nut (Item 1) and bolt (Item 2) [Figure
The Bob-Tach is the section of the loader lift arm that 50-40-2] from the pivot pin.
attachments mount to. The Bob-Tach uses two manually
operated, spring assisted, locking wedge and lever Installation: Tighten the retainer bolt to 25-28 ft.-lb. (34-
assemblies to secure the attachment to the Bob-tach. 38 N•m) torque.
The Bob-Tach is located on the front of the loader and is Remove the rod end pivot pin (Item 3) [Figure 50-40-2].
connected to the lift arms.
Remove the tilt cylinder rod end.
Figure 50-40-1
S4304
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks [Figure 50-40-1] approximately 3 inches thick
under each side of the Bob-Tach. Lower the Bob-Tach
onto the blocks.
S4309

BOB-TACH HAND LEVER (CONT’D) Figure 50-40-4
Figure 50-40-3
2
1
1 S4316
2 Remove the seal dust cup (Item 1) [Figure 50-40-4].

S4313
Remove the rubber seal (Item 2) [Figure 50-40-4].
NOTE: Removal procedure is shown for the right side. Remove the pivot pin (Item 3) [Figure 50-40-4] from the
Left side procedure is the same. Bob-Tach frame.
Remove the grease fitting (Item 1) [Figure 50-40-3] from Check for wear and damage. Replace the pivot pins as
the Bob-Tach frame for the pivot pin (Both sides). needed.
NOTE: The grease fitting (Item 1) [Figure 50-40-3] must Installation: Push the pivot pin (Item 3) [Figure 50-40-4]
be removed to prevent the pivot pin from being into the Bob-Tach frame. Position the end of the pin flush
locked in the Bob-Tach frame. with the end of the Bob-Tach bushing.
Loosen the bolt (Item 2) [Figure 50-40-3] at the Bob-Tach Reverse the removal procedure to install the Bob-Tach.
pivot pin.
Strike the head of the bolt (Item 2) [Figure 50-40-3] to

push the pivot pin into the Bob-Tach frame.
Remove the bolt (Item 2) [Figure 50-40-3] and use a

punch to push the pivot pin all the way into the Bob-Tach
frame.
Installation: A longer bolt will be needed to temporarily

reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
NOTE: Use tapered ream MEL 1233 to clean the

tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
Slowly back the loader away to remove the Bob-Tach

frame.

BOB-TACH HAND LEVER (CONT’D) Figure 50-40-7
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
S5991
1
Remove the Bob-Tach lever (Item 1) [Figure 50-40-7].
S5989
Figure 50-40-8
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.
1
Figure 50-40-6
S5992
Use a punch and hammer, remove the roll pin (Item 1)

[Figure 50-40-8] from the Bob-Tach wedge and spring,
2 1
bolt and clevis assembly.
S5990
Remove the lever mounting bolt and nut (Item 1) and

spring (Item 2) [Figure 50-40-6].

BOB-TACH HAND LEVER (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-40-11

(Cont’d)
Figure 50-40-9
1
2
S4316
1
S5993 Remove the Bob-Tach (See Removal And Installation on

Page 50-40-1).
Remove the spring, bolt and clevis assembly (Item 1) Remove the rubber seal (Item 1) [Figure 50-40-11].
[Figure 50-40-9].
Installation: Use a new seal when assembling.
Remove the wedge (Item 2) [Figure 50-40-9] from the
Bob-Tach frame. Figure 50-40-12
Always replace bent or broken wedges.
Figure 50-40-10
2
1 1
S5995
4
3
Remove the bushing (Item 1) [Figure 50-40-12] with a
S5994
slide hammer.
Installation: Install the bushing with a driver tool and

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) or
hammer.
clevis (Item 4) are damaged, put the assembly in the vise.
Loosen and remove the bolt (Item 1) [Figure 50-40-10]
with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Reverse the removal procedure to install the Bob-Tach

Lever and Wedge.

BOB-TACH (POWER OPTION) Figure 50-41-2
Description
The Bob-tach is the section of the loader lift arm that

attachments mount to. The Power Bob-tach option uses
two hydraulically operated, spring assisted, locking wedge
and lever assemblies to secure the attachment to the Bob-
tach.
1
The hydraulically operated Power Bob-tach has a
hydraulic cylinder that opens and closes both wedge and 3
lever assemblies by pressing a switch on the front
accessory panel. The switch activates the Power Bob- 2
tach block to allow flow into or out of the hydraulic cylinder 4
connected to the levers on the Bob-tach. S4309
The Power Bob-tach block is located under the cab, on the

front left side, below the Bucket Positioning Valve (if Remove the retainer bolt (Item 1) and nut (Item 2) [Figure
equipped). 50-41-2] from the tilt cylinder rod end pin.
The Bob-tach is located on the front of the loader Installation: Tighten the retainer bolt and nut to 25-28 ft.-
connected to the loader lift arms. lb. (34-38 N•m) torque.
Removal And Installation Remove the pivot pin (Item 3) [Figure 50-41-2] from the
tilt cylinder rod end.
Figure 50-41-1
Remove the tilt cylinder rod end (Item 4) [Figure 50-41-2]
from the Bob-Tach.
S5919
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.
Remove the hoses on the cylinder fittings (Item 1) [Figure

50-41-1].
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to secure
the clamp.

BOB-TACH (POWER OPTION) (CONT’D) Figure 50-41-4
Figure 50-41-3
2
1
1 S4316
2 Remove the dust cup (Item 1) [Figure 50-41-4] (Both

S4313 sides) when the Bob-Tach is free from the loader.
Remove the rubber seal (Item 2) [Figure 50-41-4] (Both

Remove the grease fitting (Item 1) [Figure 50-41-3] (Both sides).
sides). This allows grease to come out in the next step.
Not letting grease escape will prevent the pin from going Installation: Use a new seal when assembling.
into the Bob-Tach far enough to remove the Bob-Tach
from the lift arms. Remove the Bob-Tach pivot pin (Item 3) [Figure 50-41-4]
(Both sides).
Loosen the bolt (Item 2) [Figure 50-41-3] at the Bob-Tach
pivot pin. (Both sides) Check for wear and damage on the pins and the Bob-Tach
bushings. Replace as needed.
Strike the head of the bolt (Item 2) [Figure 50-41-3] to
push the pivot pin into the Bob-Tach frame. (Both sides) Reverse the removal procedure to install the Bob-Tach.
Remove the bolt. (Both sides)
Installation: A longer bolt will be needed to temporarily

reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
Use a punch to push the pivot pins all the way inside the
Bob-Tach frame.
Remove the Bob-Tach from the lift arms.

BOB-TACH (POWER OPTION) (CONT’D) Figure 50-41-7
Lever And Wedge Disassembly And Assembly
Remove the Power Bob-Tach cylinder (See Removal And

1
Figure 50-41-5
S5997
Remove the wedge (Item 1) [Figure 50-41-7].
1 Always replace bent or broken wedges.
S5919 Figure 50-41-8
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-41-5], spring and 2
wedge. 1
3
Figure 50-41-6
1
5
S5998
Remove the washer and bolt (Item 1) [Figure 50-41-8].

torque.
S5996
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the bottom
Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-41-8].
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].
Installation: Tighten the nut to 25-28 ft.-lb. (34-38 N•m)

torque.

BOB-TACH (POWER OPTION) (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
4
1
3 2 S4316
N-20625 Remove the Bob-Tach (See Removal And Installation on

Page 50-41-1.)
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) or Remove the rubber seal (Item 1) [Figure 50-41-11].
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise. Installation: Use a new seal when assembling.
Remove the bolt and replace the damaged parts as Figure 50-41-12
needed.
Figure 50-41-10
S5995
N-18563 Remove the bushing (Item 1) [Figure 50-41-12] with a

slide hammer.
Use a punch and hammer to drive the roll pin (Item 1) Installation: Install the bushing with a driver tool and
[Figure 50-41-10] flush with the face of the Bob-Tach. hammer.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge.

LIFT ARMS Figure 50-50-3
Figure 50-50-1
1
2
1
S5954
Remove the tubeline clamps (Item 1) [Figure 50-50-3]

S4297 under the lift arms.
Pull the tubelines (Item 2) [Figure 50-50-3] down.

Roll the Bob-Tach fully forward. Stop the engine.
Remove the Bob-Tach frame from the lift arms. (See

Install jackstands under the rear of the loader [Figure 50-

50-1].
Left Side
Figure 50-50-2
S4044
Remove the front auxiliary block mounting bolts (Item 1)

[Figure 50-50-2].

LIFT ARMS (CONT’D) Figure 50-50-6
Right Side
Figure 50-50-4
1
1
S5955
Remove the tubeline clamps (Item 1) [Figure 50-50-6]

1 under the lift arms.
S4325 Figure 50-50-7
Remove the mounting bolt (Item 1) [Figure 50-50-4] from

the tilt tubeline clamp.
Figure 50-50-5
1
2 S4312
1
1
Remove the lift arm support device mounting bolt (Item 1)
[Figure 50-50-7] spacer and nut.
S5982 Installation: Tighten the mounting bolt and nut to 25-28

ft.-lb. (34-38 N•m) torque.
Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.
Installation: Tighten the mounting bolt and nut to 25-28


Figure 50-50-8
1 2
1
S5986
Wrap one of the 7 ft. lifting straps around the lift arm
S5983 crossmember as shown [Figure 50-50-10].
Both loops of the lifting strap should be supported by the

Raise the operator cab (See Raising on Page 10-30-1.) chain hoist [Figure 50-50-10].
Remove the right side lift cylinder pivot pin (Item 1) Use a chain hoist and lifting strap to raise the lift arms
[Figure 50-50-8]. enough to remove the tilt cylinder base end pivot pin
[Figure 50-50-10].
NOTE: Put a piece of cardboard under the rod end of
the lift cylinders to protect the fender from Figure 50-50-11
scratches.
Remove the lift arm support device (Item 2) [Figure 50-

50-8].
Figure 50-50-9
1 S5985
Remove the two tilt cylinders (Item 1) from the lift arm
crossmember by removing the bolts and nuts (Item 2)
[Figure 50-50-11] and removing the pivot pins.
S5984
Remove the left side lift cylinder pivot pin (Item 1) [Figure
50-50-9].

Figure 50-50-12
1 3
1
S4323
2
Remove the upright pivot pin mounting bolt (Item 1) and
S5987 nut (Item 2) [Figure 50-50-14] (Both sides.)
Tighten the pivot pin mounting bolt and nut to 25-28 ft.-lb.
Put the middle of the second lifting strap (Item 1) [Figure (34-38 N•m) torque.
50-50-12] up into the lift arm as shown.
Remove the upright pivot pin (Item 3) [Figure 50-50-14].
Install the lift cylinder pivot pin (Item 2) [Figure 50-50-12] (Both sides.)
and secure the pin with the mounting bolt and nut.
Figure 50-50-15
Wrap both ends of the strap around the top of the lift arm
and down the back of the lift arm [Figure 50-50-12].
Figure 50-50-13
S5956
S5987
Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-15].
Continue to wrap the lifting strap around the lift arm a
second time [Figure 50-50-13].
Fasten both loops of the lifting strap to a second chain

attached to the chain hoist.
Use the wrapping procedure on the third strap which

would be installed on the right side lift arm.
Use the chain hoist and lower the lift arms so they rest on
the blocking.

LIFT ARMS (CONT’D)
Figure 50-50-16
S5953
Pull the lift arms away from the loader [Figure 50-50-16].
Lower the lift arms slowly and put on the floor.
Reverse the removal procedure to install the lift arms on

the loader.

REAR GRILL Figure 50-60-3
Figure 50-60-1
P-48130
Installation: Line up the tab (Item 1) on the grill with the

S4331 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grill.
Figure 50-60-2
S4082
Lift up on the rear grill (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grill away from the loader.

REAR DOOR Figure 50-70-3

1
Figure 50-70-1
P-43360
1 Remove the top and bottom door hinge mounting bolts

P-68817 (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) [Figure 50-70-3] in the top
50-70-1] from the engine harness. hinge as shown.
Remove both rear lights from the door (See Rear Installation: Tighten the mounting bolts and nuts to 25-28
Removal And Installation on Page 60-60-1.) ft.-lb. (34-38 N•m) torque.
Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.
Reverse the removal procedure to install the rear door.

2
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 (CONT’D) Striker (Adjusting)
Striker Removal and Installation
Figure 50-70-4
WARNING
1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1 1
P-31126
Remove the two striker mount bolts (Item 1) [Figure 50-

70-4].
Remove the striker assembly from the loader. 1
Striker Disassembly and Assembly

P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
2 2 50-70-6].
3
Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1
Close the rear door (This will align the striker assembly to
the correct position.)
Open the door.

P-31320
Installation: Tighten the mounting bolts (Item 1) [Figure

50-70-6] to 90-100 ft.-lb. (125-135 N•m) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Remove the rollers (Item 2) and the spacer (Item 3) from
the bost (Item 4) [Figure 50-70-5].
Check the parts for wear and replace as needed.

REAR DOOR (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
P-31128
1
P-31125
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.
Remove the bolt and nut (Item 2) [Figure 50-70-7] from

the latch.
Figure 50-70-8
P-31127
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

REAR DOOR (CONT’D) Figure 50-70-9
Remove the door handle (Item 1) [Figure 50-70-9] from

the rear door.

FUEL TANK Figure 50-80-3

4
Figure 50-80-1
1
2
3
3 5
S4243
Disconnect the fuel fill hose (Item 1) and the vent hose
P1616 (Item 2) [Figure 50-80-3] from the fuel tank.
Remove the fuel supply and return hoses (Item 3) [Figure

Remove the cover (Item 1) [Figure 50-80-1] which is 50-80-3].
installed over the fuel drain.
Disconnect the fuel sender connector (Item 4) [Figure 50-
Installation: Tighten the cover mounting bolts to 15-20 80-3] from the fuel tank.
Lift the fuel tank (Item 5) [Figure 50-80-3] and remove it
Figure 50-80-2 from the loader.
P1619A
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
Remove the engine / hydrostatic pump assembly from the

loader (See Engine Removal And Installation on Page 70-
10-9.).

FUEL TANK (CONT’D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-5
Raise the loader operator cab (See Raising on Page 10-

30-1.)
Figure 50-80-4
S5981
1
Disconnect the fuel fill hose (Item 1) [Figure 50-80-5]
2 from the fuel tank.
S5980
Figure 50-80-6
Disconnect the harness (Item 1) and loosen the fuel level

sender (Item 2) [Figure 50-80-4] with a wrench.
Pull the fuel level sender (Item 2) [Figure 50-80-4] out

and remove it from the fuel tank. Check the fuel level
sender for damage and replace if necessary.
Installation: Tighten the fuel level sender to 50-60 in.-lb.

(5,7-6,8 N•m) torque.
1
S5959
Remove the fuel inlet screen (Item 1) [Figure 50-80-6].

Clean and dry the screen. Check the screen for damage
and replace if necessary.

FUEL TANK (CONT’D)
Fuel Pickup Screen
Figure 50-80-7
1
S5981
Disconnect the fuel hose (Item 1) [Figure 50-80-7] from

the fitting.
Remove the fitting and grommet from the fuel tank.
Remove the fuel supply hose assembly from the fuel tank.
Remove the fuel supply screen from the hose and check
the screen for damage. Replace if needed.

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 operator’s feet.
Pedal Removal And Installation
WARNING S2907
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 Installation: Tighten the bolt and nut to 25-28 ft.-lb. (34-
to fall and cause injury or death. 38 N•m) torque.
W-2059-0598
Check the rubber bushing in the pedal for wear and
Raise the lift arms and install an approved lift arm support replace as needed.
20-1.) Figure 50-90-2
P-28909
Remove the two mounting bolts (Item 1) [Figure 50-90-2]

from the pedal mounting bracket.
Remove the pedal assembly from the loader.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-3 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily while
properly sitting in the loader seat.
Figure 50-90-5
S2907
Disconnect the linkage from the pedal by removing the

bolt and nut (Item 1) [Figure 50-90-3].
Figure 50-90-4
P-28909
1 Loosen the two mounting bolts (Item 1) [Figure 50-90-5]

from the pedal mounting bracket.
Figure 50-90-6
1 2
S2908
Disconnect the linkage from the hydraulic control valve by

removing the bolt and nut (Item 1) [Figure 50-90-4].
Remove the linkage.

S2907
Loosen the bolt (Item 2) [Figure 50-90-6] 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

(Item 2) [Figure 50-90-6] on the pedal assembly to
standard torque.

CONTROL PANEL
Description
Figure 50-100-1
S5947
The steering system [Figure 50-100-1] consists of The steering system returns the levers to their starting
independent steering levers the operator uses to provide position by means of the centering spring and the
steering input to the loader. returning force of the torsion bushings.
The steering levers are attached to pivoting bellcranks NOTE: Torsion bushings need to be replaced if torn or
that pivot on a steering shaft and plastic bushings. The rotating in the housing. Loosen torsion
bellcranks have grease fittings.
bushing bolts slightly before adjustments are
The forward travel is adjusted by drift adjustment bolts. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
The bellcranks are attached to steering linkage bars with been made first.
rubber torsion bushings pressed into the bellcranks.
Bellcranks mount to the control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set linkage travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a
rubber torsion bushing is pressed into the pintle arms.
Pintle arms are of a two-piece design that allow easy

adjustment of the neutral or “creep”.

CONTROL PANEL (CONT'D) Figure 50-100-2
Removal and Installation
S4225
WARNING Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
Never work on a machine with the lift arms up unless 20-1.)
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising on Page 10-30-1.)
to fall and cause injury or death. Remove the engine speed control. (See Removal And
W-2059-0598 Installation on Page 70-20-1.)
Loosen the jam nut from the bypass control knob (Item 1)
[Figure 50-100-2].
WARNING Figure 50-100-3

Failure to use jackstands can allow the machine to fall 1
or move and cause injury or death. 2
W-2017-0286
3
S6040
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-3].

Removal and Installation (Cont'd)
Figure 50-100-4
1
1
1
S4381
Scribe a mark across the top of the steering linkage bars

S2862
which are connected to the steering shaft on the control
panel.
Disconnect the control harness connector (Item 1) Remove the four steering linkage mounting bolts (Item 1)
[Figure 50-100-4] from the control levers. [Figure 50-100-6].
Figure 50-100-5 Installation: Align the marks on the steering linkage bars.
Tighten the steering linkage mounting bolts to 35-40 ft.-lb.
(47,5-54,2 N•m) torque.
S2855
Remove the linkage (Item 1) [Figure 50-100-5] by

disconnecting it from the control valve and the shaft.

Removal and Installation (Cont'd)

Remove the control panel mounting bolts (Item 1) [Figure
Figure 50-100-7 50-100-9] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

15-20 ft.-lb. (20-27 N•m) torque.
Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
1 1
S2856
Figure 50-100-8
1
S2857
Remove the control panel mounting bolts (Item 1) [Figure

50-100-7] and [Figure 50-100-8] from both sides of the
control panel.
Installation: Tighten the control panel mounting bolts to

15-20 ft.-lb. (20-27 N•m) torque.
1
1
S4387 S2858

CONTROL PANEL (CONT'D) Shaft Disassembly And Assembly
Shaft Removal And Installation Figure 50-100-12
NOTE: The steering shaft can be removed without

removing the control panel from the loader.
1
Figure 50-100-10
2
2
P-4154
1 Disassemble the right and left steering bellcranks (Item

1) [Figure 50-100-12] from the cross shaft assembly.
S2855
Assembly: Install new nylon bushings (Item 2) [Figure
50-100-12] as needed when assembling the steering
Remove the linkage (Item 1) [Figure 50-100-10] by shaft. Be sure to apply grease on the cross shaft before
disconnecting it from the control valve and the shaft. installing the right and left bellcranks.
Remove the steering linkages (See Linkage Removal And NOTE: The bellcranks should pivot freely on the cross
Installation on Page 50-100-6.). shaft when assembled correctly.
Figure 50-100-11 Figure 50-100-13
1
1
1
S4227
S2857
Remove Control Handle Lever (See Lever Removal And To remove the steering shaft mounting bracket, remove
Installation on Page 50-100-1.) the three mounting bolts (Item 1) [Figure 50-100-13] from
the front of the control panel.
Remove the steering shaft pivot bolt (Item 1) [Figure 50-
100-11] from both sides of the control panel. Remove the steering shaft mounting bracket.
Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38 Installation: Tighten the mounting bolts to 15-20 ft.-lb.
N•m) torque. (20-27 N•m) torque.
Remove the steering shaft from the control panel.

CONTROL PANEL (CONT’D) Figure 50-100-14
Linkage Removal And Installation
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
S2855
Remove the steering linkage mounting bolt and nut (Item
WARNING 1) [Figure 50-100-14]. Do this for both steering linkages.
Installation: Tighten the steering linkage mounting bolts

Put jackstands under the front axles and rear corners to 35-40 ft.-lb. (47,5-54,2 N•m) torque.
Failure to use jackstands can allow the machine to fall Figure 50-100-15
W-2017-0286
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Lift and block the loader. (See LIFTING AND BLOCKING

Raise the operator cab (See Raising on Page 10-30-1.) 1
S2860
Remove the steering linkage mounting bolt (Item 1)

[Figure 50-100-15]. Do this for both steering linkages.
Installation: Tighten the steering linkage mounting bolts

to 35-40 ft.-lb. (47,5-54,2 N•m) torque.
Remove the steering linkages from the loader.
NOTE: After removal and installation of the linkage,

the linkage neutral adjustment procedure
must be performed.

Pintle Arm Removal And Installation

7
Figure 50-100-16 8
6
3 1 4
1
2
5
2
P-48630
2 The centering plate / centering spring assembly consists

P-48631
of the following parts [Figure 50-100-18]:
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-16]. 1 Bolt
2 Bushings
Remove the bolt / spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a NEW 4 Bushing Spacer
lock nut to 25-28 ft.-lb. (34-38 N•m) torque.
5 Spring
Figure 50-100-17 6 Lock Nut
7 Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-100-17] 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.

Pintle Arm Removal And Installation (Cont’d)
Figure 50-100-19
2
1
3
2 3
6
5
1
2 4
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) [Figure 50-100-20] and
rotate the cams 1/4 turn.
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-19]. 20] from the pintle.
If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
bolts (Item 2) [Figure 50-100-19]. Remove the centering N•m) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 35-40 ft.- 100-20].
lb. (47,5-54,2 N•m) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-20].
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.

Pintle Arm Removal And Installation (Cont’d)
Figure 50-100-21
2
2
3
4 1
3
P-48659
2
1 NOTE: When installing the pintle base (Item 1) onto

P-48624 the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure 50-
100-23].
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Installation: Install the pintle base (Item 1) onto the pump
Inspect the washers (Item 2), pintle arm (Item 3) and the shaft (Item 2) [Figure 50-100-23]. The top of the pintle
steering linkage bar (Item 4) [Figure 50-100-21] for base should be level with the top of the pump shaft.
damage and replace as needed. Tighten the bolt to 35-40 ft.-lb. (47,5-54,2 N•m) torque.
NOTE: The washers (Item 2) [Figure 50-100-21] are NOTE: After installing the linkage onto the
hardened, and should only be replaced hydrostatic pumps the linkage neutral
through Bobcat Parts. adjustment procedure must be performed.
Figure 50-100-22 Figure 50-100-24
1
1
P-54615 P-54625
Loosen the bolt (Item 1) and remove the pintle base (Item Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-22]. 2) [Figure 50-100-24] and inspect the pintle solid cams
for damage or excessive wear.
Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2

N•m) torque.

Pintle Arm Disassembly and Assembly
Figure 50-100-25
4 1 3
2
2
P-48619
3
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) [Figure 50-
100-26] to catch the torsion bushing.
Remove the base pintle (Item 1) [Figure 50-100-25] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure
50-100-26] 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 50-100-25]
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.
NOTE: Anti-sieze 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

procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

Remote Start Procedure on Page 10-60-4.) 1

Figure 50-100-27 S2855
3
Loosen the bolt / nut (Item 1) [Figure 50-100-28] only
until the tension is released from the torsion bushing.
Figure 50-100-29
2
1
1
P-48450 2
Tool that may assist in the neutral adjustment [Figure 50-

100-27].
To make this tool use a locking grip C-Clamp and grind P-54613
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-27] to a small rounded edge.
Loosen the nut (Item 1) only until the tension is released
A steering centering block (Item 3) [Figure 50-100-27] is from the torsion bushing (Item 2) [Figure 50-100-29].
also needed. The centering block can be placed as shown
and welded to the C-clamp if desired. NOTE: The bolt must be loose enough to allow the
torsion bushing (Item 2) [Figure 50-100-29] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

Linkage Neutral Adjusting (Cont’d)
Figure 50-100-30
2
2 P16121
Using the remote start tool, turn the key (Item 1) [Figure
S5974
50-100-32] to the run position.
Move the traction lock override switch (Item 2) [Figure 50-

Loosen the two bolts (Item 1) holding the right centering 100-32] so the traction function is unlocked. (The traction
block. Move the right hand centering block (Item 2) lock override switch light will be ON.) On a standard
[Figure 50-100-30] until both pintle cams contact the loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels/tracks
NOTE: The left centering block is not adjustable. By may begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-31 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-100-32] and start the engine and run at low idle.
Tighten bolts (Item 3) [Figure 50-100-31] to 35-40 ft.-lb.

(47,5-54,2 N•m).
1
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-30] and [Figure 50-
2 100-31].
S5975
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-27] 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 50-100-31]
around both centering blocks.
Lock the C-Clamp in place.

Linkage Neutral Adjusting (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-33
2 1
1
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
NOTE: This procedure is shown for neutral
adjustment on the left side of the loader. The
P-48632
procedure is the same for the right side neutral
adjustment.
Loosen the left pump pintle adjustment lock bolts (Item
1). (The right pump pintle adjustment lock bolts are (Item Turn the adjustment screw (Item 1) [Figure 50-100-34]
2) [Figure 50-100-33].) Loosen the bolts enough to allow counterclockwise until forward creep is seen.
free movement between the pintle arm and the pintle
base. Turn the adjustment screw (Item 1) [Figure 50-100-34]
counterclockwise to a point between forward and reverse
NOTE: If the bolts are too loose or too tight, the where there is zero creep.
neutral adjustment may be affected.
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) Linkage Travel Adjusting
Linkage Neutral Adjusting (Cont’d) NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
Figure 50-100-35 adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
2 1
2 1
WARNING
P-48632 W-2059-0598
Torque the left pump pintle adjustment lock bolts (Item 1) Raise the lift arms and install an approved lift arm support
[Figure 50-100-35] to 35-40 ft.-lb. (47,5-54,2 N•m). device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item 2)

[Figure 50-100-35] to 35-40 ft.-lb. (47,5-54,2 N•m).
Test both levers by moving them backward and forward

WARNING
and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels do not
come to a complete stop, repeat the adjustment or move and cause injury or death.
procedure again. W-2017-0286
Stop the engine.

Remove one pintle adjustment bolt (Item 1) [Figure 50- THE LOADER on Page 10-10-1.)
100-35] at a time and apply loctite 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the Raise the operator cab. (See Raising on Page 10-30-1.)
bolt to 35-40 ft.-lb. (47,5-54,2 N•m). Repeat for the three
remaining pintle adjustment lock bolts. Pre-load tension in the torsion bushings must be removed
before adjusting the steering linkage.
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 50-100-14.)

Linkage Travel Adjusting (Cont’d)
Figure 50-100-36
1
1
S2861
Remove access plug from the top of the control panel.

S2855
Turn the control lever drift adjustment bolts (Item 1)
[Figure 50-100-38] (one on each control lever) out until it
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt is flush with the bottom of the nut.
(Item 2). The bolt (Item 2) [Figure 50-100-36] must be
loosened enough to allow the torsion bushing to turn Figure 50-100-39
freely between the steering bellcrank and the linkage bar.
Figure 50-100-37
3 2
4
1
P-51173
P-54613 Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) [Figure
Loosen the nut (Item 1) only until the tension is released 50-100-39].
from the torsion bushing (Item 2) [Figure 50-100-37].
The bolt must be loose enough to allow the torsion

bushing (Item 2) [Figure 50-100-37] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel Adjusting (Cont’d)
Figure 50-100-40
2
2
1
P-51133
1 3 4
Before adjusting the linkage, check that the base pintle
P-51174 arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-41] and tighten to
35-40 ft.-lb. (48-54 N•m) torque. There should be no play
Move the right side steering lever forward and install a 15/ between the pintle arm and the square pump shaft.
16 inch (24 mm) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50- Also check that the cam mounting nuts or bolts (Item 4)
100-40]. [Figure 50-100-39] are tight, 35-40 ft.-lb. (48-54 N•m)
torque.
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel speed.
Remove the 3/8 inch (10 mm) thick spacer (Item 4)

[Figure 50-100-40].

Linkage Travel Adjusting (Cont'd)
Figure 50-100-42
P-51175
1
1
S4381
Remove the spacer (Item 1) [Figure 50-100-43].
Disconnect the remote start tool. (See Remote Start

Loosen the two bolts and nuts (Item 1) [Figure 50-100- Procedure on Page 10-60-4.)
42] on each steering linkage bar.
Figure 50-100-44
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
2
is rotated to the front as far as possible. Use a locking
plier, clamp the two linkage bars together.
Installation: Tighten the nuts and bolts to 35-40 ft.-lb.

(47,5-54,2 N•m) torque.
Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed. 1
Repeat the linkage travel adjustment procedure for the
right side linkage.
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) [Figure

50-100-44] to 35-40 ft.-lb. (47,5-54,2 N•m).

Linkage Travel Adjusting (Cont'd)
Figure 50-100-45
1
1
S2861
Push the control lever to full stroke and turn drift

S2855 adjustment bolt (Item 1) [Figure 50-100-46] in until it
touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Item 1) [Figure 50-100- Repeat steps on the other control lever.
45] to 35-40 ft.-lb. (47,5-54,2 N•m) torque at the steering
bell cranks. Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. (3048

mm) of “drift” in 100 ft. (30480 mm) of travel distance.
If the drift is excessive to the left, turn the right adjustment

bolt (Item 1) [Figure 50-100-46] 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.

Service Manual S100 Skid-Steer Loader: S/N A2G811001 & Above S/N A8ET11001 - A8ET19999

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EN

S/N A2G811001 & Above

6904926enGB (01-09) (B) Printed in Europe © Bobcat Company 2009

Instructions are necessary before operating or servicing machine. Read and

CORRECT CORRECT CORRECT

B-10731a B-15590 B-15591

WRONG WRONG WRONG

B-15592 B-15593 B-15599

B-15600 B-15601 B-6589

AIR CLEANER ........................................................ 70-01 HYDRAULIC / HYDROSTATIC SYSTEM ................10-01

ELECTRICAL SYSTEM INFORMATION ................. 60-01 SEAT BAR ................................................................50-01

SAFETY INSTRUCTIONS ................................................................. V

SERIAL NUMBER LOCATIONS ....................................................... IX

LOADER IDENTIFICATION .............................................................. XI

HYDRAULIC SYSTEM................................................................ 20-01

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

DRIVE SYSTEM ......................................................................... 40-01

ENGINE SERVICE...................................................................... 70-01 ENGINE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER

7 of 521 I S100 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

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.

8 of 521 II S100 Service Manual

9 of 521 III S100 Service Manual

10 of 521 IV S100 Service Manual

• The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

WARNING • The Skid-Steer Loader Safety Video is available from

11 of 521 V S100 Service Manual

The dealer and owner / operator review the recommended

Cutting or drilling concrete containing sand or rock

12 of 521 VI S100 Service Manual

Check hydraulic tubes, hoses and fittings for damage and

Flammable debris (leaves, straw, etc.) must be removed

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Check all electrical wiring and connections for damage.

13 of 521 VII S100 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

14 of 521 VIII S100 Service Manual

Always use the serial number of the loader when Figure 2

The engine serial number is located on top of the engine

Loader Serial Number

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

Explanation of loader Serial Number:

Module 1. - Model / Engine

1. The four digit Model / Engine Combination Module

2. The five digit Production Sequence Number identifies

15 of 521 IX S100 Service Manual

The delivery report must be filled out by the dealer and

16 of 521 X S100 Service Manual

17 of 521 XI S100 Service Manual