A770 6990245 enUS SM 08-15

Service Manual
A770 All-Wheel Steer Loader
S/N ATDW11001 & Above

S/N ATDY11001 & Above
Dealer Copy -- Not for Resale
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6990245enUS (08-15) (A) Printed in U.S.A. Bobcat Company 2015
iT4
1 of 1010
2 of 1010
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1694 NA1693

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

NA1674 NA1695 NA1680
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
NA1682 NA1683 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.
MSW39-0609
3 of 1010 1-1 A770 Service Manual


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


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15


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

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

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

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

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

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

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

the work lights.
FW SSL-1008 SM

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

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

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

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

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

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

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

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

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

SAFETY INSTRUCTIONS (CONTD)
The dealer and owner / operator review the

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

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

Dial 811 (USA Only)

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

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

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

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

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

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

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

FIRE PREVENTION (CONTD)
Welding And Grinding
Always clean the machine and attachment, disconnect

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

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

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

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

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

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P107182
1
The engine serial number (Item 1) [Figure 3] is located

on the side of the engine above the oil filter.

P100390E
The loader serial number plate (Item 1) [Figure 1] is

located on the outside of the loader frame.
Figure 2
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine

Combination NA3095
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 4
NA3106
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.

The delivery report must be reviewed and signed by the
owner or operator and the dealer.

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL and
OPERATORS
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
and SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
BUCKET [1]

STEP
BUCKET
STEPS
OPERATOR CAB
LIFT (ROPS and FOPS) [2]
CYLINDER LIFT ARM
REAR
GRILLE
LIFT ARM
BACK-UP SUPPORT DEVICE
ALARM
REAR
LIGHT
REAR
DOOR TAILLIGHT TIRES [3] NA5320
NA5321
[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS and FOPS - Roll-Over Protective Structure, per ISO 3471, and Falling-Object Protective Structure per ISO
3449, Level I. Level II is available.
[3] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.


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

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . 10-30-6
TRANSPORTING LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
REMOTE START TOOL KIT-MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-2
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
DIAGMASTER (SERVICE TOOL) KIT - 7024161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Diagmaster (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
DST-i LED Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
DST-i Operation Status And Display Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Diagmaster (Service Tool) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Crankcase Ventilation Filter . . . . . . . . . . . . . . . . . . . . . . 10-120-4
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-130-4
Removing And Replacing Steering Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-5
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-6
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-8
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1


LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-90977
Lift the front of the loader and put jackstands under the
B-7023B axle tubes [Figure 10-10-2].
NOTE: Make sure the jackstands do not touch the

tires. Make sure tires clear floor or any
obstacles.
WARNING

Figure 10-10-3
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operators
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Always park the loader on a level surface.

P-90978
P-85425
WARNING Lift the rear of the loader and install jackstands [Figure
10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
23 of 1010 10-10-1 A770 Service Manual


LIFT ARM SUPPORT DEVICE Installing
Description
DANGER
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-90328
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or AVOID DEATH
with missing parts can cause lift arms to drop Disconnecting or loosening any hydraulic
causing injury or death. tubeline, hose, fitting, component or a part failure
W-2572-0407 can cause lift arms to drop.
Keep out of this area when lift arms are raised
The lift arm support device is used to support the lift arms unless supported by an approved lift arm
while working on a machine with the lift arms up. support. Replace if damaged.
D-1009-0409

Remove attachment from the loader. (See Installing And
Removing The Attachment (Hand Lever Bob-Tach)) OR
(See Installing And Removing The Attachment (Power
Bob-Tach)) in the Operation And Maintenance Manual.
Figure 10-20-1
P-85463A P100009
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.

LIFT ARM SUPPORT DEVICE (CONTD) Removing
Installing (Contd)
Figure 10-20-2
DANGER
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
P-90567B
unless supported by an approved lift arm
Have a second person install the lift arm support device support. Replace if damaged.
over the rod of one of the lift cylinders [Figure 10-20-2]. D-1009-0409

The lift arm support device must be tight against the The operator must be in the operators seat, with the seat
cylinder rod. belt fastened and seat bar lowered, until the lift arm
support device is removed, and the lift arms are lowered
Figure 10-20-3 all the way.
Start the engine and raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
P100399 Return the lift arm support device to the storage position
and secure with clamping knobs.
Remove the jackstands.
P100398
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
of the lift arm support device must go past the end of the
cylinder (Inset) [Figure 10-20-3].

OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and

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

Never modify the cab. Replace the cab and hardware if
damaged. See your dealer for parts.
ROPS - Roll-Over Protective Structure per ISO 3471 and

FOPS - 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.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

OPERATOR CAB (CONTD) Figure 10-30-3
Raising
Always stop the engine before raising or lowering the

operator cab.
Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
Figure 10-30-1
P-90564A
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.

P-85463A
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
Hardware Installed Hardware Removed
P100235A P100236A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONTD)
Lowering WARNING
Always stop the engine before raising or lowering the
operator cab. PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
NOTE: Always use the grab handles to lower the when the cab is past the latch stop.
operator cab. W-2469-0803
Figure 10-30-4 Figure 10-30-5
Hardware Removed Hardware Installed

P100236A P100235A
P100953 P-90565A
Pull down on the bottom of the operator cab until stopped

by the latching mechanism [Figure 10-30-4]. Install the washers and nuts (both sides) [Figure 10-30-
5].
NOTE: The weight of the operator cab increases
when equipped with options and accessories, Tighten the nuts to 54 - 61 Nm (40 - 45 ft-lb) torque.
such as: cab door, heater, and air
conditioning. In these cases, the operator cab Remove the jackstands.
may need to be raised slightly from the latch
to be able to release the latch.
Support the operator cab and release the latching

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

Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
NA3085
[DOOR] will appear in the data display [Figure 10-30-8]

when the door is open, the key switch is turned to RUN,
1 the seat bar is lowered, and the PRESS TO OPERATE
LOADER button is pressed.
P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed that deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
P-90726J
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] is OFF when the door is closed, the key switch is
turned to RUN, the seat bar is lowered, and the PRESS
TO OPERATE LOADER button is pressed.
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] is ON when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

OPERATOR CAB (CONTD) Forestry Door And Window Kit
Special Applications Kit Figure 10-30-10
WARNING
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
NA1819
Figure 10-30-9
Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the
loader. Kit includes 19,1 mm (0.75 in) thick laminated
polycarbonate front door, polycarbonate side windows

and polycarbonate rear window [Figure 10-30-10].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Applications Kit to restrict
material from entering cab openings.
NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.50 in)
thick polycarbonate front door and polycarbonate rear
window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

installed for special applications to restrict material from
entering cab openings.
See your dealer for availability.
Special Applications Kit Inspection And Maintenance
Inspect for cracks or damage. Replace if required.

Pre-rinse with water to remove gritty materials.
Wash with a mild household detergent and warm
water.
Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
Do not use abrasive or highly alkaline cleaners.
Do not clean with metal blades or scrapers.

Forestry Door And Window Kit Inspection And

Maintenance
Inspect for cracks or damage. Replace if required.

Order part number 7171104 if door frame is damaged
and needs to be replaced.
Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
Pre-rinse with water to remove gritty materials.
Wash with a mild household detergent and warm
water.
Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
Do not use abrasive or highly alkaline cleaners.
Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-11

1
P100984
Inspect both emergency exit levers (Item 1) [Figure

10-30-11], linkages and hardware for loose or
damaged parts.
Repair or replace if necessary.

TRANSPORTING LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P107245A P107253
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
NOTE: Always disengage the auto idle feature when

loading or unloading the loader on a trailer.
Figure 10-40-1

P100400
Alternate Rear Tie-Down Alternate Front Tie-Down
1
P-85466
P107246A P-85599B
P100389
Use the following procedure to fasten the Bobcat loader

A loader with an empty bucket or no attachment must be to the transport vehicle to prevent the loader from moving
loaded backward onto the transport vehicle [Figure 10- during sudden stops, or when going up or down slopes
40-1]. [Figure 10-40-2].
The rear of the trailer must be blocked or supported (Item 1. Lower the bucket or attachment to the floor.
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up. 2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie-down

positions [Figure 10-40-2]. (Lift arms shown raised
for visual clarity.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.


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

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

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires will not turn.) There might be slight wear to
the tires when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)


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

are:
2
MEL1563 - Remote Start Tool 3
MEL1566 - Service Tool Harness Communicator 1
(Computer Interface)
Figure 10-60-1
1
P16117
The traction lock switch (Item 1) [Figure 10-60-2] is used

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

The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
P16114 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
The remote start tool (Item 1) [Figure 10-60-1] is when checking pressures and flow rate.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering NOTE: With the engine running; pushing and holding
linkage, and electrical diagnostics. the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-5
Remote Start Tool - MEL1563 (Contd) 1
Figure 10-60-3
3
1 2
P-90972
Loaders equipped with an attachment harness (Item 1)

P16114 must remove the tie strap (Item 2) and disconnect the
attachment harness from the loader harness (Item 3)
[Figure 10-60-5].
Remove the service tool harness (Item 1) from the cover
(Item 2) [Figure 10-60-3]. Connect the service tool harness to the ACD connector

and the loader harness connector.
Figure 10-60-4
NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool.
P-90973
Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.
Connect the service tool harness control to the loader

harness connector.

REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566
Figure 10-60-6
P16119
The service tool harness communicator (Item 1) is

required to connect remote start tool to the Service PC

(Item 2) [Figure 10-60-6].

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-8
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit 1
Figure 10-60-7
1
P-90973
Figure 10-60-9

P16115
The remote start tool (Item 1) [Figure 10-60-7] is

required when the operator cab is in the raised position
for service and the service technician needs to turn the 2
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.

P-90972
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Remove the cap (Item 1) [Figure 10-60-8].
Raise the operator cab (if required by the procedure).
OR
Open the rear door of the loader.
Remove the tie strap (Item 2) and disconnect the
attachment control harness (Item 1) [Figure 10-60-9] (If
equipped).

REMOTE START TOOL KIT-MEL1563 (CONTD)
Remote Start Procedure (Cont'd)

WARNING
Figure 10-60-10
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
1 otherwise disable the starter before working in
the engine area.
W-2457-1110
P-90974
Figure 10-60-12
Figure 10-60-11

2
1
1
P16116
P-90975
The remote start tool (Item 1) [Figure 10-60-12] has

Connect the remote start tool to the engine harness three rocker switches.
connector (Item 1) [Figure 10-60-10].
OR
Connect the remote start tool to the engine harness

connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-14
Figure 10-60-13
2
3 1
P-85311B
Push the couplers on the front auxiliary block toward the

P16118 block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-14].
The traction lock switch (Item 1) [Figure 10-60-13] is

used to turn traction lock ON or OFF. Push the switch to

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

10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when checking pressures and flow rate.
NOTE: With the engine running; pushing and holding

the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
WARNING
Use traction lock override switch for service work
with seat bar raised.
Traction lock is engaged when light is OFF.
Lift and block the loader. Check that wheels are
clear.
Traction lock is disengaged when light is ON.
See Service Manual for more instruction.
W-2785-0209

REMOTE START TOOL (SERVICE TOOL) KIT -
7217666
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool and
MEL1400B - BOSS Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7217666,

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

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

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7217666 (CONT'D)
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps

5 3
are:
Order from Bobcat Parts P/N: 7217666 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
1
7022042 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS Service Tool Harness
Figure 10-61-1 The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-2] has five buttons.
The STOP button (Item 2) [Figure 10-61-2] is used to

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

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader electrical system. The button will illuminate to
indicate the service tool is active.
1
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
button will illuminate indicating the traction lock is
The remote start tool (Item 1) [Figure 10-61-1] is disabled in which the wheels or tracks are able to turn.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering The auxiliary button (Item 6) [Figure 10-61-2] is used to
linkage, and electrical diagnostics. 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.

7217666 (CONT'D)
Loader Service Tool Harness - 6689747

1
Figure 10-61-3
2 3
P-90972
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must remove the tie
P-76678 strap (Item 2) and disconnect the attachment harness
from the loader harness (Item 3) [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
P-90973
Loaders without an attachment control harness, remove

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Contd)
Figure 10-61-6
3 2
1 P-76450
P-90976 The computer service tool harness (Item 1) [Figure 10-

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

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

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

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The key switch must be in the off position or

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

REMOTE START TOOL (SERVICE TOOL) KIT - Raise the operator cab (if required by the procedure).
7217666 (CONT'D)
Remote Start Procedure
Figure 10-61-9
WARNING
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine 1
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
Remove the operator panel key (key switch), lock P-90973
the keypad with a unique password (keyless) or

otherwise disable the starter before working in
Loaders without an attachment control harness, remove
the engine area.
W-2457-1110
the loader harness cap (Item 1) [Figure 10-61-9] and

connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
procedure: NOTE: When using a Remote Start Tool (Service tool)
harness on loaders not equipped with an
7217666: Remote Start Tool (Service Tool) Kit attachment control device, the Remote Start
Tool (Service Tool) harness attachment
Figure 10-61-8 control device connector must be capped.
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure

10-61-8] is required when the operator cab is in the
raised position for service and the service technician
needs to turn on the loader or start the engine. Example:
adjusting the steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.

72176666 (CONT'D)
Figure 10-61-10
2 3
1
1
P-90976
NOTE: The Remote Start Tool (Service Tool)

connection harness has two connectors (Item
P-90974 1) and (Item 3). The main connector (Item 1)
[Figure 10-61-11] is always used for
connection to the loader harness.
For loaders with an attachment control harness, the
attachment harness (Item 1) must be disconnected from

The second connector (Item 3) [Figure 10-61-
the loader harness (Item 2) [Figure 10-61-10]. 11] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
When the remote start procedure is completed, replace connector has a cap attached to it to prevent
the loader connector cap (Item 1) [Figure 10-61-10] or damage or corrosion when not in use.
reconnect the attachment control harness to the loader
harness. 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 key switch must be in the off position or

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

7217666 (CONT'D)
Figure 10-61-12
2
1 2
5 3
6 4
P-76441
1
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
P-76439 pressed and the loader is communicating with the service
tool.
The Remote Start Tool (Service Tool) (Item 1) [Figure The computer icon with the right facing arrows (Item 2)
10-61-12] has five buttons.

[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
The STOP button (Item 2) [Figure 10-61-12] is used to and from the computer.
stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine. NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
The RUN button (Item 3) [Figure 10-61-12] is used to the RUN button on the remote start tool. Then
turn the Remote Start Tool (Service Tool) on and press the auxiliary (AUX) hydraulics button on
activates the loader electrical system. The button will the remote start tool and move the AUXILIARY
illuminate to indicate the service tool is active. Hydraulic Switch to the right and left several
times.
The START button (Item 4) [Figure 10-61-12] is used to
start the loader engine. Figure 10-61-14
The traction lock button (Item 5) [Figure 10-61-12] is

used to turn traction lock ON or OFF. Push the button and
the button will illuminate indicating the traction lock is
disabled in which the wheels or tracks are able to turn.
The auxiliary button (Item 6) [Figure 10-61-12] 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.
P-85311B
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-61-14].


DIAGMASTER (SERVICE TOOL) KIT - 7024161 Figure 10-70-2
Diagmaster (Service Tool)
The tools listed will be needed to do the following

procedure:
Order from Bobcat Parts P/N: 7024161 - Diagmaster

(Service Tool) Kit
Figure 10-70-1
3 1 5
4 4
2
3 P107546
2 The Diagmaster (Service Tool) (DST-i) has five LEDs

[Figure 10-70-2].
The Power LED (Item 1) [Figure 10-70-2] indicates when

power is supplied from machine cable or USB cable.
1

The Machine communication LED (Item 2) [Figure 10-
P107539 70-2] indicates when communication is in progress.
The PC Communication (Bluetooth) LED (Item 3) [Figure

The diagmaster (service tool) (Item 1) [Figure 10-70-1] 10-70-2] indicates Bluetooth communication status
used with the Service PC is required when the service (Bluetooth is optional).
technician is checking the fuel systems, diesel particulate
filter (DPF) and engine electrical diagnostics. The PC Communication (USB) LED (Item 4) [Figure 10-
70-2] indicates stand-by for communication or
Kit Includes: communication in progress.
Diagmaster (Service Tool) (DST-i): (Item 1) The Error Detection LED (Item 5) [Figure 10-70-2]
7024272 - Vehicle Cable: (Item 2) indicates an error has occurred.
7024271 - USB Cable: (Item 3)
Diagmaster Diagnostic Software: (Item 4) See the following table for additional LED indicator
[Figure 10-70-1] information. (See DST-i LED Table on Page 10-70-2.)

DIAGMASTER (SERVICE TOOL) KIT - 7024161
(CONTD)
DST-i LED Table
ITEM TYPE OF LED COLOR LED STATUS DETAILS

1 Power Indicator Green Light OFF Power OFF
Light ON Power is supplied from machine cable or USB
cable
2 Machine Communication Green Light OFF Stand-by for communication
Indicator Light Flashing Communication in progress
(synchronized with
communication)
3 PC Communication Blue Reserved Bluetooth communication (Bluetooth is
(Bluetooth) Indicator optional)
4 PC Communication (USB) Green Light OFF USB cable has not connected to PC or USB
Indicator driver has not installed to PC
Light ON Stand-by for communication
Light Flashing Stand-by for establishment of communication
Light Flashing Communication in progress
(synchronized with

communication)
5 Error Detection Indicator Red Light OFF Normal Conditions
Light Flashing Error occurs
DST-i Operation Status And Display Specification
LIGHT OPERATION DURING NORMAL CONDITIONS

Diagmaster Status LED Status
Power Machine USB Error
Power OFF Off Off Off Off
Power ON On Off Off Off
USB stand-by status On Off Flashing Off
USB cable has not connected to PC or USB driver has On Off Off Off
not installed to PC
Diagmaster mode (USB) Stand-by for communication On Off On Off
Machine stand-by for communication but no USB On Off On Off
communication
Machine communication disconnected On Off On Off
Machine / USB communication in progress On Flashing Flashing Off
(Synchronized (Synchronized
with with
communication) communication)
LIGHT OPERATION DURING ABNORMAL OPERATION
Diagmaster Status LED Status
Power Machine USB Error
System Error On Flashing Flashing Flashing
On Off Off Flashing

(CONTD)
Diagmaster (Service Tool) Procedure
Open rear door

1
NOTE: Install Diagmaster diagnostic software on the
Service PC before making any connections.

Make all connections with the machine key in
the OFF position.

To monitor, diagnose or enter information the
Service PC must be connected to the
Diagmaster (Service Tool).
P107540
Figure 10-70-3
Remove the electrical connection (Item 1) [Figure 10-70-
5] from the engine harness connector.
2 Figure 10-70-6

4 5
3 1
1
P107544
Figure 10-70-4
P107541
2
1
Connect the vehicle cable connector to the engine
5
harness connector (Item 1) [Figure 10-70-6].
NOTE: Determine that the PC has diagmaster

communication interface driver installed
4 before connecting the DST-i to the PC.
P107542
Connect the vehicle cable (Item 1) to the designated

connection (Item 2) and connect the USB cable (Item 3)
to the usb connection (Item 4) on the DST-i (Item 5)
[Figure 10-70-3] [Figure 10-70-4].

(CONTD)
Diagmaster (Service Tool) Procedure (Contd)
Figure 10-70-7
1 P107548
The next screen is the opening screen for the diagmaster.

Select menu (Item 1) [Figure 10-70-7].
P107543
Figure 10-70-10
Connect the USB cable (Item 1) to the Service PC (Item

2) [Figure 10-70-7] USB connection.
Figure 10-70-8
1
P107602
Select start diagnosis (Item 1) then select new diagnosis

(Item 2) [Figure 10-70-10] from the start menu.
P107547
Upon login the Splash Screen will display [Figure 10-

70-7].

(CONTD)
Diagmaster (Service Tool) Procedure (Contd)
Figure 10-70-11
P107602
2 To resume a previously saved diagnosis select restart

diagnosis (Item 1) [Figure 10-70-13].
P107587
Figure 10-70-14
Follow the instructions (Item 1) then select the check icon

(Item 2) [Figure 10-70-11]. 1

Figure 10-70-12
2
P107588
2 Select a project from the list (Item 1) and click restart

diagnosis icon (Item 2) [Figure 10-70-14] to load project.
P107599
Diagmaster will gather project information (Item 1) and

addition information can be entered into the blank boxes
(Item 2) [Figure 10-70-12].


SERVICE SCHEDULE
Maintenance Intervals
WARNING
Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early
failures.
Instructions are necessary before operating or
The service schedule is a guide for correct maintenance
of the Bobcat loader.
W-2003-0807
Every 10 Hours (Before Starting The Loader)
Engine Oil - Check level and add as needed.

Engine Air Filters and Air System - Check display panel. Service only when required. Check for leaks and damaged
components.
Engine Cooling System - Clean debris from radiator, fuel cooler, hydraulic fluid cooler, air conditioning condenser (if

equipped), and rear grille. Check coolant level COLD and add premixed coolant as needed.
Fuel Filter - Check display panel. Remove the trapped water when required.
Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges, Steering Cylinders - Lubricate with
multipurpose lithium based grease.
Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks - Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
Bobcat Interlock Control Systems (BICS) - Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
Front Horn / Back-up Alarm - Check for proper function.
Tires - Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the
tire.
Operator Cab - Check the fastening bolts, washers, and nuts. Check the condition of the cab.
Indicators and Lights - Check for correct operation of all indicators and lights.
Wheel Nuts - Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts
and tighten to correct torque.
Safety Signs and Safety Treads - Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
Hydraulic Fluid - Check fluid level and add as needed.
Heater and Air Conditioning Filters (If Equipped) - Clean or replace filters as needed.
Every 50 Hours
Hydraulic Hoses and Tubelines - Check for damage and leaks. Repair or replace as needed.
Final Drive Transmission (Chaincase) - Check fluid level and add as needed.
Parking Brake and Joysticks - Check for correct operation. Repair or adjust as needed.
Wheel Nuts - Check for loose wheel nuts and tighten to correct torque.
Engine / Hydrostatic Drive Belt - Perform at first 50 hours, then as scheduled. Check for wear or damage. Check
idler arm stop.
Engine Oil and Filter - Perform at first 50 hours, then as scheduled. Replace oil and filter.

SERVICE SCHEDULE (CONTD)
Maintenance Intervals (Contd)
Every 100 Hours

Battery - Check cables, connections, and electrolyte level; add distilled water as needed.
Engine Oil and Filter - Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours Or Every 12 Months

Engine / Hydrostatic Drive Belt - Check for wear or damage. Check idler arm stop.
Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed.
Bobcat Interlock Control System (BICS) - Check the function of the lift arm bypass control.
Steering King Pins - Lubricate with multipurpose lithium based grease.

Fuel Filter - Replace filter element.
Steering Valve Inline Filter, Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap - Replace the charge
filter, the steering filter, and the reservoir breather cap.
Engine Oil and Filter - Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Heater Coil and Air Conditioning Evaporator - (If Equipped) - Clean the heater coil and air conditioning. Clean the
plenum drains.

Hydraulic / Hydrostatic Filter - Replace the hydraulic / hydrostatic filter.
Hydraulic Reservoir - Replace the fluid.
Final Drive Transmission (Chaincase) - Replace the fluid.
Wheel Bearing / Outer Splines - Repack wheel bearings, grease internal splines in hub yoke.
Engine Valves - Adjust the engine valve clearance.
Every 1500 Hours

Fuel Injectors - Check for proper operation.
Exhaust Gas Recirculation (EGR) Cooler - Test the EGR cooler for leaks.
Crankcase Ventilation Filter - Replace the crankcase ventilation filter.
Positive Crankcase Ventilation (PCV) Valve - Check the PCV valve for free movement.
Every 3000 Hours

Turbocharger - Check the turbocharger for leaks. Tighten bolts, nuts, and clamps or replace gaskets, clamps, and
hoses as needed. Check the wheel clearance. Replace turbocharger if the wheel touches the housing.
Diesel Particulate Filter (DPF) - Disassemble, clean, and reassemble the DPF.
Exhaust Gas Recirculation (EGR) System - Perform an EGR actuation test. Clean the gas and coolant passages.
Supply Pump - Check for proper operation and calibrate.
Mass Air Flow Sensor - Check for proper function.
Every 24 Months
Coolant - Replace the coolant.

ENGINE AIR CLEANER Figure 10-90-3
Replacing Filter Elements
Figure 10-90-1
1
3
P107189
NA3178
Remove the outer filter (Item 1) [Figure 10-90-3] and

Change the air filter elements only when necessary. The discard.
service indicator (Item 1) will FLASH. Press the
Information button (Item 3) until the display screen shows NOTE: Make sure the filter housing is free of dirt and
the service codes. Service code [M0117] (Air Filter debris. Verify that sealing surfaces are clean.
Plugged) will show in the display screen (Item 2) [Figure DO NOT use compressed air.

10-90-1] when air filter change is necessary.
Install new outer filter. Push in until the filter contacts the
Replace the inner filter every third time the outer filter is base of the housing. Install the cover and secure the
replaced or as indicated. latches [Figure 10-90-2].
Outer Filter Install the rear grille.
Stop the engine and remove the rear grille. (See

Removing on Page 50-60-1.)
Figure 10-90-2
1
P107187A
Open the latches (Item 2) and remove the cover (Item 1)

[Figure 10-90-2].

ENGINE AIR CLEANER (CONTD) Figure 10-90-5
Replacing Filter Elements (Contd)
Inner Filter
Replace the inner filter only under the following

conditions:
Replace the inner filter every third time the outer filter
2
is replaced.
After the outer filter has been replaced, start the

engine and operate at full rpm. If service code
[M0117] (Air Filter Plugged) is still displayed in the 1
data display, replace the inner filter.
P107187A

Removing on Page 50-60-1.) Install the cover (Item 1) and secure the latches (Item 2)
[Figure 10-90-5].
Remove the cover [Figure 10-90-2] and the outer filter
[Figure 10-90-3]. Install the rear grille.
Figure 10-90-4

1
P107188
Remove the inner filter (Item 1) [Figure 10-90-4].
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new inner filter. Push in until the filter contacts the
base of the housing.
Install the outer filter [Figure 10-90-3].

ENGINE COOLING SYSTEM Cleaning
Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-80-1.)
Maintenance Platform Stop the engine and remove the rear grille. (See
Figure 10-100-1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
1 Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-0907
P107193 Loaders With Air Conditioning

Figure 10-100-2
A maintenance platform (Item 1) [Figure 10-100-1] is
available from your dealer to facilitate access when
cleaning the engine cooling system.
1
2 2
P107095C
Use low air pressure or water pressure to clean the top of

the air conditioning condenser (Item 1) [Figure 10-100-
2].
The area between the air conditioning condenser and the

hydraulic fluid cooler will require occasional cleaning.
Remove the bolts (Item 2) and the brackets (Item 3)
[Figure 10-100-2].

ENGINE COOLING SYSTEM (CONTD) All Loaders
Cleaning (Contd) Unhook the two rubber straps (Item 2) [Figure 10-100-4].
Loaders With Air Conditioning (Contd) Figure 10-100-5
Figure 10-100-3
1
4
1
2 3
P107195
P107095B
Raise the hydraulic fluid cooler (Item 1) until the support
bar (Item 2) drops into position to support the hydraulic

NOTE: Be careful when raising and lowering the air fluid cooler. Use low air pressure or water pressure to
conditioning condenser so that the air clean the top of the radiator (Item 3) [Figure 10-100-5].
conditioning condenser does not fall on the
hydraulic fluid cooler and damage the fins. Use low air pressure or water pressure to clean the fuel
cooler (Item 4) [Figure 10-100-5].
Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the Raise the support bar (Item 2) [Figure 10-100-5] slightly
hydraulic fluid cooler (Item 2) [Figure 10-100-3]. and lower the hydraulic fluid cooler.
Lower the air conditioning condenser (Item 1) [Figure 10- Fasten the two rubber straps [Figure 10-100-4].
100-3]. Install the brackets and the bolts [Figure 10-100-
2]. Check the cooling system for leaks.
Loaders Without Air Conditioning Install the rear grille.
Figure 10-100-4
P107194
Use low air pressure or water pressure to clean the top of

the hydraulic fluid cooler (Item 1) [Figure 10-100-4].

ENGINE COOLING SYSTEM (CONTD)
Checking And Adding Coolant

IMPORTANT
Check the engine coolant level every day before starting
the engine for the work shift. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Removing on Page 50-60-1.) Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-100-6 damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
1
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Add premixed coolant, 47% water and 53% propylene

2 glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-100-6].

P107196 Install the coolant fill cap [Figure 10-100-6].
NOTE: The coolant fill cap must be tightened until the

Coolant must be between the top and bottom level
cap clicks.
markers (Item 2) [Figure 10-100-6] when the engine is
cold.
Install the rear grille.
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Remove the coolant fill cap (Item 1) [Figure 10-100-6] to

add coolant.
The correct mixture of coolant to provide a -37C (-34F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.

ENGINE COOLING SYSTEM (CONTD) Attach a hose to the coolant drain petcock (Item 1)
[Figure 10-100-8] located to the left of the oil filter
Removing And Replacing Coolant assembly. Open the petcock and drain the coolant into a
container. Close the petcock and remove the hose.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.) Recycle or dispose of used coolant in an environmentally
safe manner.
Stop the engine. Open the rear door and remove the rear
grille. (See Removing on Page 50-60-1.) Close the rear door.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-5.)
WARNING
The correct mixture of coolant to provide a -37C (-34F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
AVOID INJURY
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
Do not remove engine coolant cap when the engine
of water.
is hot. You can be seriously burned.
W-2607-0804
Figure 10-100-7
IMPORTANT
AVOID ENGINE DAMAGE

1 Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

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

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

P107196 concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Remove the coolant fill cap (Item 1) [Figure 10-100-7].
Add premixed coolant, 47% water and 53% propylene
Figure 10-100-8
glycol to the coolant tank until the coolant level reaches
the lower level marker on the tank (Item 2) [Figure 10-
100-7].
Install the coolant fill cap [Figure 10-100-7].
NOTE: The coolant fill cap must be tightened until the

cap clicks.
Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
1
Check the coolant level when cool. Add coolant as
P107197 needed. (See Checking And Adding Coolant on Page 10-
100-3.)

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade Number
2-D or Grade Number 1-D. Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline that
should prevent fuel gelling during cold temperatures: Biodiesel blend fuel is an excellent medium for
microbial growth and contamination that can cause
TEMPERATURE GRADE 2-D GRADE 1-D corrosion and plugging of fuel system components.
Above -9C (+15F) 100% 0% Use of biodiesel blend fuel may result in premature
Down to -29C (-20F) 50% 50% failure of fuel system components, such as: plugged
Below -29C (-20F) 0% 100% fuel filters and deteriorated fuel lines.
Shorter maintenance intervals may be required, such

Ultra low sulfur diesel fuel must be used in this machine.
as: cleaning the fuel system and replacing fuel filters
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur
and fuel lines.
maximum.
Using biodiesel blended fuels containing more than
NOTE: Biodiesel blend fuel may also be used in this
five percent biodiesel can affect engine life and cause
machine. Biodiesel blend fuel must contain
deterioration of hoses, tubelines, injectors, injector
no more than five percent biodiesel mixed
pump, and seals.

with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly
Apply the following guidelines if biodiesel blend fuel is
marketed as B5 blended diesel fuel. B5
used:
blended diesel fuel must meet ASTM D975 (US
Standard) or EN590 (EU Standard)
Ensure the fuel tank is as full as possible at all times
specifications.
to prevent moisture from collecting in the fuel tank.
Ensure that the fuel tank cap is securely tightened.
Biodiesel blend fuel can damage painted surfaces,

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

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

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

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

stability and should not be stored for more
than 3 months.

FUEL SYSTEM (CONTD) Figure 10-110-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Stop the engine and open the rear door.

NA1684
Figure 10-110-1
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 10-110-2].
Install and tighten the fuel cap (Item 1) [Figure 10-110-

1 1].
Close the rear door.
WARNING
P107190
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the fill cap (Item 1) [Figure 10-110-1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONTD) Replacing Element
Fuel Filter See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.)
Removing Water
interval. (See SERVICE SCHEDULE on Page 10-80-1.) Figure 10-110-4
Figure 10-110-3 3
2
P109401
1

Disconnect electrical connector (Item 2) [Figure 10-110-
P109401A
4].
Loosen the fuel filter head (Item 3) from the fuel filter
Loosen the drain (Item 1) [Figure 10-110-3] at the element (Item 1) [Figure 10-110-4]. Do NOT remove the
bottom of the filter to remove trapped water from the filter. hoses from the fuel filter head.
Securely tighten the drain. Loosen clamps (Item 4) [Figure 10-110-4].
Remove fuel filter element (Item 1) from the fuel filter

head (Item 3) [Figure 10-110-4].
WARNING
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
Put clean oil on the two new fuel filter element O-rings,
sparks or lighted tobacco away from fuel and oil.
install element, and tighten to 13,5 Nm (10 ft-lb) torque.
explosion or fire.
W-2103-0508
Install fuel filter assembly into clamps and tighten.
Connect electrical connector [Figure 10-110-4].
Close the rear door. Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-110-4.)

FUEL SYSTEM (CONTD) Removing Air From The Fuel System
Fuel Filter (Contd) After replacing the filter element or if the fuel tank has run
out of fuel, the air must be removed from the fuel system
Replacing Element (Contd) before starting the engine.
WARNING WARNING
AVOID INJURY OR DEATH AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, Diesel fuel or hydraulic fluid under pressure can
sparks or lighted tobacco away from fuel and oil. penetrate skin or eyes, causing serious injury or
Failure to use care around combustibles can cause death. Fluid leaks under pressure may not be visible.
explosion or fire. Use a piece of cardboard or wood to find leaks. Do
W-2103-0508 not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
Close the rear door. from a physician familiar with this injury.
W-2072-0807
Start the engine and allow to operate for one minute.
Figure 10-110-5
WARNING

1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
from a physician familiar with this injury. P109402
W-2072-0807
Open the air vent plug (Item 1) [Figure 10-110-5] on the

Stop the engine and check for leaks at the filter. fuel filter assembly three full turns.
Enter the operator cab and turn the key switch to RUN.
The electric fuel pump will fill the filter assembly with fuel.
Have a second person notify you when fuel flows from
the vent with no air bubbles.
Turn the key switch to STOP and close the air vent plug.
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-120-2

ENGINE OIL
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
engine for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-120-1
1 2
P107192
TEMPERATURE RANGE ANTICIPATED BEFORE

Park the machine on level ground. Stop the engine. Open NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
the rear door and remove the dipstick (Item 1) [Figure CLASSIFICATION CJ-4 OR BETTER)
10-120-1]. [1] Synthetic Oil - Use recommendation from Synthetic
Oil Manufacturer.
Keep the oil level between the marks on the dipstick. Do
not overfill. Use good quality engine oil that meets API Service
Classification of CJ-4 or better [Figure 10-120-2].
Remove the oil fill cap (Item 2) [Figure 10-120-1] to add
engine oil.
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONTD) Later Models
Removing And Replacing Oil And Filter Figure 10-120-4

Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
P109762A
Open the rear door.
Earlier Models
Figure 10-120-3 1 2
P109086B
P-90497B The oil drain hose is located behind a cover under the
right rear corner of the loader (Inset) [Figure 10-120-4].
1 Remove the cover mounting bolts (Item 1) and remove

the cover (Item 2) [Figure 10-120-4].
Figure 10-120-5
2
3
P-90499A
The oil drain hose is located behind a cover under the

right rear corner of the loader (Inset) [Figure 10-120-3].
Remove two cover mounting bolts (Item 1) [Figure 10-

120-3].
Loosen one cover mounting bolt (Item 2) and slide the 2

1
cover (Item 3) [Figure 10-120-3] to the rear of the loader
to remove.
P109089
Remove the oil drain hose (Item 1) from the storage

location and route through the opening (Item 2) [Figure
10-120-5].

ENGINE LUBRICATION SYSTEM (CONTD) Figure 10-120-7
Removing And Replacing Oil And Filter (Contd)
All Models 2
Figure 10-120-6
P107192
Remove the oil filter (Item 2) [Figure 10-120-7], and

1 clean the filter housing surface.
P-90498A
Use genuine Bobcat filter only.
Put clean oil on the new filter gasket, install the new filter,

Remove the oil drain cap (Item 1) [Figure 10-120-6] from and hand tighten.
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe Remove the oil fill cap (Item 3) [Figure 10-120-7].
manner.
Put oil in the engine and replace the fill cap. For the
Install and tighten the oil drain cap [Figure 10-120-6]. correct quantity, (See Capacities on Page SPEC-10-5.)
Do not overfill.
Install the cover and the cover mounting bolts [Figure 10-
120-3]. Tighten all bolts. Start the engine and allow to operate for several minutes.
Stop the engine and check for leaks at the filter.
(Earlier Models) - Install the cover and the cover
mounting bolts [Figure 10-120-3]. Tighten all bolts. Remove the dipstick (Item 1) [Figure 10-120-7] and
check the oil level.
OR
Add oil as needed if oil level is not at the top mark on the
(Later Models) - Remove the oil drain hose from the dipstick. Install the dipstick and close the rear door.
opening and return to storage location [Figure 10-120-
5]. Install the cover and the cover mounting bolts [Figure
10-120-4]. Tighten all bolts.
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONTD) Figure 10-120-10
Removing And Replacing Crankcase Ventilation

Filter

Figure 10-120-8
P107480
Press on the positive crankcase ventilation (PCV) valve

and verify that it moves smoothly [Figure 10-120-10].
(Filter housing shown removed for visual clarity.) Replace
the filter housing if the PCV valve does not move
smoothly.

Install new filter element ensuring that element is fully
P107180
seated in the housing.
Figure 10-120-11
Push down while turning counterclockwise to remove the
filter cap (Item 1) [Figure 10-120-8].
Figure 10-120-9
1
P107239
Remove the O-ring (Item 1) [Figure 10-120-11] and

P107240
discard.
Install new O-ring and lubricate with clean oil.

Remove the filter element (Item 1) [Figure 10-120-9] and
discard. Install the filter cap.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-130-3

HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG)
before starting the work shift. AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms, and
put the attachment flat on the ground or tilt the Bob-Tach
fully back if no attachment is installed.
Stop the engine.
Figure 10-130-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid
(Unlike biodegradable fluids that are vegetable based,

Bobcat biodegradable fluid is formulated to prevent
oxidation and thermal breakdown at operating
P100391 temperatures.)
Use only recommended fluid in the hydraulic system

Check the fluid level in the sight gauge (Item 1) [Figure [Figure 10-130-3]. (See HYDRAULIC / HYDROSTATIC
10-130-1]. Keep the fluid level within the operating range. FLUID SPECIFICATIONS on Page SPEC-50-1.)
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 10-130-2
WARNING
1 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P100055
Remove the fill cap (Item 1) [Figure 10-130-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-130-1].
Install the fill cap [Figure 10-130-2] and install the rear
grille.

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Figure 10-130-5
Removing And Replacing Hydraulic Fluid

Replace the fluid if contaminated or after major repair. 1
Always replace the hydraulic / hydrostatic filter, the

steering filter, and the hydraulic charge filter whenever
2
the hydraulic fluid is replaced. (See Removing And
Replacing Hydraulic / Hydrostatic Filter on Page 10-130-
4.), (See Removing And Replacing Steering Filter on
Page 10-130-5.), and (See Removing And Replacing
Hydraulic Charge Filter on Page 10-130-6.)
P107195

Removing on Page 50-60-1.) Raise the hydraulic fluid cooler (Item 1) until the support
bar (Item 2) [Figure 10-130-5] drops into position to
Figure 10-130-4 support the hydraulic fluid cooler. This procedure will aid
in draining the hydraulic fluid.
Figure 10-130-6

1
1
P100055
P100007
Remove the right side access cover bolts (Item 1)

[Figure 10-130-6] and remove the access cover. (Lift
arms shown raised for visual clarity.)
P107194
Remove the hydraulic fill cap (Item 1) and unhook the two
rubber straps (Item 2) [Figure 10-130-4].

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Figure 10-130-8
Removing And Replacing Hydraulic Fluid (Contd)
NOTE: The hose used to drain the hydraulic reservoir

is located under the fan motor on earlier
models and behind the fan motor on later
models.
1
Figure 10-130-7
Earlier Model Later Model
P-90506
Remove and clean the hydraulic fill screen (Item 1)

1 [Figure 10-130-8]. Use low air pressure to dry the
2 screen.
2
P109760A P115442A Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range
Remove the clamp (Item 1). Pinch off the hose (Item 2)

of the sight gauge. (See Capacities on Page SPEC-10-
[Figure 10-130-7] near the fitting and disconnect hose
5.) and (See Checking And Adding Fluid on Page 10-
from the fitting. Route the hose out the side of the loader
130-1.)
and drain the fluid into a container.
Install the hydraulic fill cap.
Connect the hose to the fitting when the fluid stops
draining. Install the clamp.
Recycle or dispose of used fluid in an environmentally
Start the engine and operate the loader hydraulic
safe manner.
controls.
WARNING WARNING
explosion or fire.
W-2103-0508 Use a piece of cardboard or wood to find leaks. Do
Install the side access cover and bolts [Figure 10-130-6]. from a physician familiar with this injury.
W-2072-0807
Raise the support bar supporting the hydraulic fluid
cooler and lower the hydraulic fluid cooler. Fasten the two
Stop the engine and check for leaks.
rubber straps [Figure 10-130-4].
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-130-1.)

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Install new filter element ensuring that element is fully
seated in the housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter Install the filter cap and tighten to 25 Nm (18 ft-lb)
torque.

WARNING
Clean the top of the filter housing. AVOID INJURY OR DEATH
Figure 10-130-9 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508

controls.

1
WARNING
P100047
Remove the filter cap (Item 1) [Figure 10-130-9]. death. Fluid leaks under pressure may not be visible.
Figure 10-130-10 not use your bare hand. Wear safety goggles. If fluid
from a physician familiar with this injury.
W-2072-0807
1

2
P100044 P100046
Remove the filter element (Item 1) [Figure 10-130-10]

and discard.

discard.
Install new O-ring and lubricate with clean oil.

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD)
Removing And Replacing Steering Filter WARNING

interval. (See SERVICE SCHEDULE on Page 10-80-1.) AVOID INJURY OR DEATH
Stop the engine and raise the operator cab. (See Raising penetrate skin or eyes, causing serious injury or
on Page 10-30-2.) death. Fluid leaks under pressure may not be visible.
The steering filter is located above the rear axle and not use your bare hand. Wear safety goggles. If fluid
slightly to the right of the center of the loader. enters skin or eyes, get immediate medical attention
Figure 10-130-11 W-2072-0807

2
1

3
P100397
Disconnect the hydraulic connections (Item 3) from the

steering filter (Item 2) [Figure 10-130-11].
Remove clamp bolt (Item 1) [Figure 10-130-11], clamp

and steering filter. Discard steering filter.
Install new steering filter using clamp and clamp bolt.
Tighten hydraulic connections.
WARNING
explosion or fire.
W-2103-0508
Lower the operator cab. (See Lowering on Page 10-30-

3.)

controls.

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Earlier Models
Removing And Replacing Hydraulic Charge Filter Figure 10-130-14

Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 10-130-12
1
P115440
2
Put a suitable container below the filter housing and
remove the filter housing (Item 1) [Figure 10-130-14]
using a socket wrench.
1
Figure 10-130-15

P100275
Unhook the four rubber straps (Item 1) and remove the

lower fan duct (Item 2) [Figure 10-130-12].
NOTE: Identification of the hydraulic charge filter

used on your machine is necessary to
perform the correct replacement procedure. 1
Figure 10-130-13
Earlier Model Later Model
P115440A
Remove the filter element (Item 1) [Figure 10-130-15]

and discard.
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.
Put clean oil on the seal of the new filter element. Install
P109622B P115441A the element on the filter base [Figure 10-130-15].
Earlier models use a separate filter housing and filter
Install and tighten the filter housing to 65 - 70 Nm (48 -
element. Later models use a spin-on filter [Figure 10-
52 ft-lb) torque [Figure 10-130-14].
130-13].

HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) All Models
Removing And Replacing Hydraulic Charge Filter Recycle or dispose of used fluid in an environmentally
(Contd) safe manner.
Later Models
Figure 10-130-16 WARNING

explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-130-12].
NOTE: Failure to install the lower fan duct correctly

may result in decreased cooling.
P115441 Lower the operator cab. (See Lowering on Page 10-30-

3.)

Put a suitable container below the filter, remove the filter
(Item 1) [Figure 10-130-16], and clean the filter base. Start the engine and operate the loader hydraulic
controls.
Put clean oil on the new filter gasket, install the new filter,
and tighten the filter to 37 45 Nm (27 33 ft-lb) torque.
WARNING
W-2072-0807


HYDRAULIC / HYDROSTATIC SYSTEM (CONTD)
Replacing Reservoir Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-80-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-

60-1.)
Figure 10-130-17

P100055
Remove the breather cap (Item 1) [Figure 10-130-17]

and discard.
Install new breather cap.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Fluid
Checking And Adding Fluid See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.) Park the loader on a level surface and stop the engine.
The chaincase contains the final drive sprockets and Remove the check plug (Item 1) [Figure 10-140-1] from
chains, and uses the same type fluid as the hydraulic / the front of the chaincase housing.
hydrostatic system. (See Hydraulic / Hydrostatic Fluid
Chart on Page 10-130-1.) Figure 10-140-2
Park the loader on a level surface and stop the engine.
Figure 10-140-1

P107281
Pump the fluid out of the chaincase [Figure 10-140-2].

(Lift arms shown raised for visual clarity.) Recycle or
P107956
dispose of used fluid in an environmentally safe manner.
Remove the check plug (Item 1) [Figure 10-140-1] from Add fluid through the check plug hole until the fluid flows
the front of the chaincase housing. (Lift arms shown from the hole. (See Capacities on Page SPEC-10-5.)
raised for visual clarity.)
Install and tighten the plug [Figure 10-140-1].
If fluid can be reached with the tip of your finger through
the hole, the fluid level is correct.
If the level is low, add fluid through the check plug hole
until fluid flows from the hole. WARNING
Install and tighten the plug [Figure 10-140-1]. AVOID INJURY OR DEATH
WARNING explosion or fire.
W-2103-0508

explosion or fire.
W-2103-0508


BOB-TACH (HAND LEVER) Figure 10-150-2
Inspection And Maintenance

1
Figure 10-150-1
Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
The wedges (Item 1) [Figure 10-150-2] must extend

through the holes in the attachment mounting frame.
P-85513A
The spring loaded wedges (Item 1) must contact the

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-150-1]. frame (Item 2) [Figure 10-150-2].

The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-150-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-150-3

The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA3114
Inspect the mounting frame on the attachment and Bob-

Tach, linkages, and wedges for excessive wear or
damage [Figure 10-150-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your dealer for repair or

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

Page 10-80-1.) and (See LUBRICATING THE LOADER
on Page 10-160-1.)


BOB-TACH (POWER) Figure 10-151-2
This machine may be equipped with a Power Bob-Tach.

1
Figure 10-151-1 2
1 Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
2 The wedges (Item 1) [Figure 10-151-2] must extend

through the holes in the attachment mounting frame.
NA3158 The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-151-2].

Push and hold the BOB-TACH WEDGES UP switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH WEDGES DOWN switch (Item 2) [Figure [Figure 10-151-2], the attachment will be loose and can
10-151-1] until the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely. Figure 10-151-3
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA3114
Inspect the mounting frame on the attachment and Bob-

Tach, linkages, and wedges for excessive wear or
damage [Figure 10-151-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your dealer for repair or

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

Page 10-80-1.) and (See LUBRICATING THE LOADER
on Page 10-160-1.)


LUBRICATING THE LOADER Figure 10-160-2
Lubrication Locations

1
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a good quality lithium based multipurpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. (See Installing And

Removing The Attachment (Hand Lever Bob-Tach)) OR P-90543A
(See Installing And Removing The Attachment (Power
Bob-Tach) in the Operation And Maintenance Manual.
1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-160-2].
Stop the engine.
Figure 10-160-3
Figure 10-160-1

2
4 2
8
9 10
11
3 5
6
12 13 P-90542A
7
P107399D
2. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-160-3].

The grease fitting locations [Figure 10-160-1] are
described in more detail in the following figures.
Lubricate the following:

LUBRICATING THE LOADER (CONTD) Figure 10-160-6
Lubrication Locations (Contd)
Figure 10-160-4
5
3
P100393
5. Rear Control Link (Both Sides) (2) [Figure 10-160-6].

P-90572A
Figure 10-160-7
3. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

160-4].

Figure 10-160-5
P-90544A
6. Front Control Link (Both Sides) (2) [Figure 10-160-7].
P-90666
4. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

160-5].

Figure 10-160-8
7
P-85720
9. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-31308A
160-10].
Figure 10-160-11
7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-160-8].

Figure 10-160-9
8
10
P-85719
P-85484
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-160-
11].
8. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

160-9].

Figure 10-160-12
13
11
P100394
13. Steering King Pin (Each Wheel) (4) [Figure 10-160-

P-85570A
14].
11. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10-

160-12]. (If equipped with Power Bob-Tach.)

Figure 10-160-13
12
P100394
12. Steering Cylinder (Each Wheel) (4) [Figure 10-160-

13].
The steering king pins do not require lubrication as often

as the other grease fittings and have a different
lubrication schedule. (See SERVICE SCHEDULE on
Page 10-80-1.)

TIRE MAINTENANCE The same size tires must be used on each side of the
loader. If different sizes are used, each tire will turn at a
Wheel Nuts different rate and cause excessive wear. The tread bars
of all the tires must face the same direction.
Figure 10-170-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating
the loader.
Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and 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.

P-85479A
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
See your SERVICE SCHEDULE for the correct interval to
check the wheel nuts [Figure 10-170-1]. (See SERVICE Avoid excessive pressure which can rupture the tire and

SCHEDULE on Page 10-80-1.) cause serious injury or death.
When installing wheel nuts, tighten to 217 Nm (160 During inflation of the tire, check the tire pressure
ft-lb) torque. frequently to avoid over inflation.
When checking wheel nut torque, set the torque

wrench to 190 Nm (140 ft-lb) to prevent
overtightening. WARNING
Rotating
Check the tires regularly for wear, damage and pressure. Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
Figure 10-170-2 explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010
NA1023A
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 10-170-2].


PIVOT PINS
Figure 10-180-1
P-90667
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure

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

- 40 ft-lb) torque.


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

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

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

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

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

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

condition.


STOPPING THE ENGINE AND LEAVING THE LOADER (Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
Procedure personnel.
Stop the loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Fully lower the lift arms and put the attachment flat on the Deluxe Instrumentation Panel allows
ground. operation of the loader without using a
password. (See Password Lockout Feature on
Figure 10-200-1 Page 60-200-2.) or (See Password Lockout
Feature on Page 60-201-1.)
Figure 10-200-3

P107184 P-85737A P-85735A
Set the engine speed control to the low idle position Exit the loader using grab handles, safety tread, and
[Figure 10-200-1]. steps (maintaining a three-point contact) [Figure 10-200-
3].
Engage the parking brake.
Figure 10-200-2
WARNING
1 1
Before you leave the operators seat:
Lower the lift arms and put the attachment flat on
the ground.
Stop the engine.
Raise the seat bar.
Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
P-90688A P-90214C
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) [Figure The seat bar system must deactivate these functions
10-200-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.


EMERGENCY EXIT
The front opening on the operator cab and rear window provide exits.
Rear Window Identification
Figure 10-210-1 There are two different procedures for removing the rear
window from your machine:
Latches Rubber Cord
1. This window is equipped with latches [Figure 10-210-
1].
2 2. This window is equipped with a rubber cord and tag

[Figure 10-210-1].
1
NOTE: Use these procedures to remove the rear
P-85309B P-64994D
window only under emergency conditions.
Damage to machine may occur.
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-210-2 Figure 10-210-4

1
P-85309A P-64994C
Turn both latches (Item 1) [Figure 10-210-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-210-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-210-3 Figure 10-210-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 10-210- Exit through the rear of the operator cab [Figure 10-210-
3]. 5].

EMERGENCY EXIT (CONTD) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine. See
Figure 10-210-6 your dealer for availability.
Figure 10-210-8
1
P-90669A
P13982
The rear window can be removed from outside the loader
using a T40 TORX Drive tool. Turn both screws (Item 1)

[Figure 10-210-6] counterclockwise until the latches Pull both handles (Item 1) [Figure 10-210-8] up and out
disengage from the window frame. Pull the top of the to remove the rear window.
window away from the cab and lift up to remove.
Front Door
OR
This machine may be equipped with a front door.
Figure 10-210-7
NOTE: Use this procedure to remove the front door
only under emergency conditions. Damage to
1 machine may occur.
Figure 10-210-9
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools. See
your dealer for availability. P-90725
Turn both knobs (Item 1) [Figure 10-210-7] Turn both latches (Item 1) [Figure 10-210-9] down until
counterclockwise until the latches disengage from the they disengage from the door frame.
window frame. Pull the top of the window away from the
cab and lift up to remove.
Push the door out of the operator cab door frame and exit
through the opening.

EMERGENCY EXIT (CONTD) Figure 10-210-12
Front Door (Contd)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-210-10
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-210-12] on the door. (Bottom
hinge shown.)
2
Figure 10-210-13

P-85781A 1
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 10-210-10]. 2
Figure 10-210-11
2
3
P-90686A
Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
1 against door and rotate latch (Item 1) [Figure 10-210-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity.)
P-85588A P-85589A
Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
Rotate and pull the clip (Item 1) out of the gas spring the clip into the hole in the gas spring socket. Rotate the
socket. Pull the gas spring socket (Item 3) straight off the clip to lock into position [Figure 10-210-11].
ball stud fitting (Item 2) [Figure 10-210-11].
Connect electrical connector and washer fluid hose
Remove the door hinges from the loader. [Figure 10-210-10].


SEAT BELT 1. Check the webbing. If the system is equipped with a
retractor, pull the webbing completely out and inspect
Inspection And Maintenance the full length of the webbing. Look for cuts, wear,
fraying, dirt, and stiffness.
2. Check the buckle and latch for correct operation.

WARNING Make sure latch plate is not excessively worn or
deformed and buckle is not damaged or casing
broken.
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in 3. Check the retractor web storage device (if equipped)
serious injury or death. by extending webbing to determine if it looks correct,
W-2466-0703
and that it spools out and retracts webbing correctly.
Check the seat belt daily for correct function. 4. Check webbing in areas exposed to ultraviolet (UV)
rays from the sun, or extreme dust or dirt. If the
Inspect the seat belt system thoroughly at least once original color of the webbing in these areas is
each year, or more often if the machine is exposed to extremely faded and / or the webbing is packed with
severe environmental conditions or applications. dirt, the webbing strength may have deteriorated.
Any seat belt system that shows cuts, fraying, extreme or 5. Check the hardware on both sides of the seat.
unusual wear, significant discolorations due to ultraviolet Hardware should be tight. Hardware must not be
UV exposure, dusty / dirty conditions, abrasion to the missing, rusted, corroded, or damaged.
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware, or any other obvious See your dealer for seat belt system replacement parts
problem should be replaced immediately. for your machine.
Figure 10-220-1
2 4
NA3113
The items below are referenced in [Figure 10-220-1].


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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification 44,5 mm (1.75 in) Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Parts Identification 50,8 mm (2.0 in) Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Parts Identification (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-9
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
CYLINDER (STEERING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal And Installation (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-3
Removal And Installation (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-11
MAIN RELIEF VALVE (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3

MAIN RELIEF VALVE (LATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-2
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-5
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-6
HYDRAULIC CONTROL VALVE (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-40-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-40-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-40-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-14

Port Relief Valve Removal And Installation (Auxiliary) . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-21
Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lift Arm Bypass Orifice Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29

HYDRAULIC CONTROL VALVE (LATE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24

Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Direct Pump Test (Steering Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-13
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-14

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Direct Pump Test (Steering Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-16
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-17
HYDRAULIC / HYDROSTATIC FILTERS (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . 20-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
HYDRAULIC FLUID RESERVOIR (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
HYDRAULIC FLUID RESERVOIR (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-2
OIL COOLER (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
OIL COOLER (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
BOB-TACH (POWER) BLOCK (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly (FFI/FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2

Disassembly And Assembly (FFH/FH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4


HYDRAULIC/HYDROSTATIC SCHEMATIC
AWS WITH NO OPTIONS
A770 (S/N ATDW11001 ATDW11599)
Printable Version Click Here
(PRINTED JUNE 2012)

V-1495legend
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 40 HYDRAULIC BRAKE SPRING APPLIED
Capacity at sight gauge . 9,8 L (2.6 U.S. gal) PRESSURE RELEASE (SAPR)
System Capacity . . . . . . 37,9 L (10.0 U.S. gal) 21 PULL BUTTON ACTIVATED 41 PILOT ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE 2 Speed
2 SIGHT GAUGE ARM BY-PASS
42 FIXED CAPACITY DISPLACEMENT
3 DIFFERENTIAL PRESSURE SWITCH: 22 SENSOR HYD. TEMPERATURE BIDIRECTIONAL HYDROSTATIC
103 kPa (1,03 bar) (15 psi) MOTOR 2 Speed
23 ANTICAVITATION VALVE
Normally Closed 43 FILTER - BRAKE
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE
44 SOLENOID ACTIVATED DIRECECTIONAL
(Fan Speed Regulator): 10797-12300 kPa CONTROL VALVE BRAKE
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) CHECK VALVE
45
25 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 517 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 46 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE 2 Speed Shift
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT 47 SOLENOID ACTIVATED DIRECTIONAL
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR Dealer Copy -- Not CONTROL
for ResaleVALVE 2 Speed Make-up
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER)
8 48 HYDRAULIC PUMP . . . . . . . Gear Type
RELIEF/ANTICAVITATION VALVE -
28 SENSOR CHARGE PRESSURE 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
PORT: 27579 kPa (276 bar) (4000 psi)
9 Fan Filter 49 CHARGE PUMP . . . . . . . Gear Type
RELIEF/ANTICAVITATION VALVE -
VARIABLE CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 29
27579 kPa (276 bar) (4000 psi) BIDIRECTIONAL HYDROSTATIC PUMP 50 STEERING PUMP . . . . . . . Gear Type
51,1 L/min (13.5 U.S. gpm) at High Engine Idle
10 SOLENOID ACTIVATED DIRECTIONAL 30 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 1862 kPa (18,6 bar)
PRESSURE: 36500 kPa (365 bar) (5294 psi)
11 (270 psi) Spring
LOAD CHECK VALVE
31 RELIEF VALVE - CHARGE INLET: 52 RELIEF VALVE: 13790 kPa (138 bar) (2000 psi)
12 LIFT CYLINDER SPOOL - MADE TO 2654 kPa (26,5 bar) (385 psi) at High
RESTRICT FLOW DURING BOOM Engine Idle With 60 C (140 F) Fluid 53 SOLENOID ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP CONTROL VALVE - TWO COIL - STEERING
32 SERVO PISTON Swash Plate
13 ANTICAVITATION VALVE 54 FILTER STEERING VALVE
33 SOLENOID ACTIVATED DIRECTIONAL
14 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE FORWARD/REVERSE 55 FILL PORT Factory Hydraulic Oil
BLEED-OFF VALVE 34 FILTER
15 PILOTED ACTIVATED DIRECTIONAL
35 CHECK VALVE COLD WEATHER BY-PASS
CONTROL VALVE - TILT CONTROL With 345 kPa (3,45 bar) (50 psi) Spring
CONTROL VALVE - LIFT CONTROL 36 RESTRICTION 1,7 mm (0.067 in)
17 SOLENOID ACTIVATED DIRECTIONAL 37 CHECK VALVE - With 1379 kPa (13,8 bar)
CONTROL VALVE - BICS CONTROL (200 psi) Spring
18 FILTER - BICS CONTROL VALVE 38 DRIVE MOTOR SHUTTLE VALVE
(SCREEN) FIXED CAPACITY DISPLACEMENT
39 NOTE: Unless otherwise specified, springs have
19 CHECK VALVE - With 100 kPa 1,0 bar BIDIRECTIONAL HYDROSTATIC MOTOR
(14.5 psi) Spring NO significant pressure value.
Printed in U.S.A. V-1495legend (5-30-12)
111 of 1010
INTEGRATED COUPLER BLOCK
TWO SPEED DRIVE MOTOR
Male
L
37
36 14
Male
38
Female
X HYDRAULIC CONTROL VALVE
41
W
9
42 39
10
40 10
Z
Auxiliary Spool
A B 55
8
11
R BICS CONTROL VALVE TILT CYLINDERS
HYDROSTATIC PUMP 29 T
33
X1
Tilt Spool
32
8
X2 15
30
11
2-SPEED & SAPR
BRAKE VALVE 16 LIFT CYLINDERS
B A D
MA
MB
34 13
A B
T
43 43 MG
31 30
Lift Spool
G 8
A B
P
MB
B1 34 12 18
45 46
MA
11 20
44 47 17 ? STEERING VALVE
45 53
IN 53
? 7 18
2
51
30 30 6 ? ?
X2 34
19
32
X1 ? 1
21
OIL COOLER
34 ? ?
35 33 STEERING
CYLINDERS (4) 51
? ?
T
HYDRAULIC FILTER
HYDRAULIC RESERVOIR
29 4 (VENTED)
R 2 1
48
5
3 ? ?
53 53
50 52
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
49
54
27
25
28
B 40 A
26 23
Z
P DR
24 WORKING CIRCUIT
42 39 CHARGE
PRESSURE
W
DRAIN / RETURN
41
DRAIN/RETURN MANIFOLD
X
22
AWS WITH NO OPTIONS
A770 (S/N ATDW11001 - ATDW11599)
38
37 36 Printable Version Click Here
L
(PRINTED JUNE 2012)
112 of 1010
7194316 (B)
PRINTED IN U.S.A.
AWS WITH ALL OPTIONS
A770 (S/N ATDW11001 ATDW11599)
(PRINTED JUNE 2012)

V-1497legend
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 40 HYDRAULIC BRAKE SPRING APPLIED 60 PILOT ACTIVATED DIRECTIONAL
Capacity at sight gauge . 9,8 L (2.6 U.S. gal) PRESSURE RELEASE (SAPR) CONTROL VALVE - HYDRAULIC
System Capacity . . . . . . 37,9 L (10.0 U.S. gal) 21 PULL BUTTON ACTIVATED 41 POWERED BOB-TACH
PILOT ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE 2 Speed 61 FILTER - BOB-TACH VALVE
2 SIGHT GAUGE ARM BY-PASS RESTRICTION - 2,08 mm (0.08 in)
42 FIXED CAPACITY DISPLACEMENT 62
3 DIFFERENTIAL PRESSURE SWITCH: 22 SENSOR HYD. TEMPERATURE BIDIRECTIONAL HYDROSTATIC
103 kPa (1,03 bar) (15 psi) 63 SOLENOID ACTIVATED DIRECTIONAL
23 ANTICAVITATION VALVE MOTOR 2 Speed CONTROL VALVE (TWO COIL)
Normally Closed 43 FILTER - BRAKE 64
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE RELIEF VALVE: 8274 kPa (83 bar) (1200 psi)
44 SOLENOID ACTIVATED DIRECECTIONAL
(Fan Speed Regulator): 10797-12300 kPa CONTROL VALVE BRAKE 65 CHECK VALVE - With 552 kPa (5,5 bar)
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi) (80 psi) Spring
VALVE: 172 kPa (1,7 bar) (25 psi) CHECK VALVE
45 66 SHUTTLE VALVE
25 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 517 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 46 SOLENOID ACTIVATED DIRECTIONAL 67 RELIEF VALVE: 13790 kPa (137 bar) (2000 psi)
CONTROL VALVE 2 Speed Shift
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT 47 SOLENOID ACTIVATED DIRECTIONAL 68 CHECK VALVE - With 2068 kPa (20,7 bar) (300
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR Dealer Copy -- Not CONTROL
for ResaleVALVE 2 Speed Make-up psi) Spring And With 0,33 mm (0.013 in) Orifice
at Front Quick Couplers 69 RESTRICTION - 0,51 mm (0.020 in)
27 FILTER - HYDRAULIC (CANISTER) 48 HYDRAULIC PUMP . . . . . . . Gear Type
8 RELIEF/ANTICAVITATION VALVE - RESTRICTION - 0,51 mm (0.020 in)
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 70
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR CHARGE PRESSURE
9 Fan Filter 49 CHARGE PUMP . . . . . . . Gear Type 71 PILOT ACTIVATED DIRECTIONAL
RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - REAR AUXILIARY
VARIABLE CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 29 72 RELIEF VALVE: 122753 kPa (228 bar) (3300 psi)
27579 kPa (276 bar) (4000 psi) BIDIRECTIONAL HYDROSTATIC PUMP 50 STEERING PUMP . . . . . . . Gear Type
51,1 L/min (13.5 U.S. gpm) at High Engine Idle 73 SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 30 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - TWO COIL
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 1862 kPa (18,6 bar)
PRESSURE: 36500 kPa (365 bar) (5294 psi) 74 RESTRICTOR - 0,8 mm (0.031 in)
11 (270 psi) Spring
LOAD CHECK VALVE 75 LOAD SHUTTLE VALVE - BLEED OFF
31 RELIEF VALVE - CHARGE INLET: 52 RELIEF VALVE: 13790 kPa (138 bar) (2000 psi)
12 LIFT CYLINDER SPOOL - MADE TO 2654 kPa (26,5 bar) (385 psi) at High 76 SOLENOID ACTIVATED DIRECTIONAL
RESTRICT FLOW DURING BOOM Engine Idle With 60 C (140 F) Fluid 53 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - Female
DOWN BUT NOT DURING BOOM UP CONTROL VALVE - TWO COIL - STEERING
32 SERVO PISTON Swash Plate 77 SOLENOID ACTIVATED DIRECTIONAL
13 ANTICAVITATION VALVE 54 FILTER STEERING VALVE CONTROL VALVE - Male
33 SOLENOID ACTIVATED DIRECTIONAL 78 HIGH FLOW HYDRAULIC PUMP Gear Type
FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE FORWARD/REVERSE 55 SOLENOID ACTIVATED DIRECTIONAL
14 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
CONTROL VALVE - BUCKET POSITION
BLEED-OFF VALVE 34 FILTER 79 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
VALVE (ON/OFF)
35 CHECK VALVE COLD WEATHER BY-PASS 56 FLOW DIVIDER ADJUSTMENT VALVE 80 DUMP VALVE ON / OFF
CONTROL VALVE - TILT CONTROL With 345 kPa (3,45 bar) (50 psi) Spring
16 PILOTED ACTIVATED DIRECTIONAL 57 PILOTED ACTIVATED DIRECTIONAL 81 CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi)
36 RESTRICTION 1,7 mm (0.067 in) CONTROL VALVE - FLOW CONTROL Spring
CONTROL VALVE - LIFT CONTROL
SPOOL 82 RIDE CONTROL VALVE
17 SOLENOID ACTIVATED DIRECTIONAL 37 CHECK VALVE - With 1379 kPa (13,8 bar)
58 CHECK VALVE - BUCKET POSITION 83 HIGH PRESSURE CHAMBER
CONTROL VALVE - BICS CONTROL (200 psi) Spring
VALVE
18 FILTER - BICS CONTROL VALVE 38 DRIVE MOTOR SHUTTLE VALVE
59 PILOTED ACTIVATED DIRECTIONAL 84 LOW PRESSURE CHAMBER
(SCREEN) FIXED CAPACITY DISPLACEMENT
39 CONTROL VALVE - UNLOADING 85 FILL PORT Factory Hydraulic Fill
19 CHECK VALVE - With 100 kPa 1,0 bar BIDIRECTIONAL HYDROSTATIC MOTOR SPOOL
(14.5 psi) Spring NOTE: Unless otherwise specified, springs have
Printed in U.S.A. NO significant pressure value. V-1497legend (5-30-12)
113 of 1010
INTEGRATED COUPLER BLOCK
Male
L
37
36 14
Male
38
81
LIFT CYLINDERS
Female
RIDE CONTROL (OPTIONAL)

X HYDRAULIC CONTROL VALVE
84 83
41
W
9 BUCKET POSITIONING
42 39 VALVE (OPTIONAL)
10 E1 E2 A1 A2
FEMALE MALE
40 REAR HYDRAULIC 10 E3
COUPLERS
82
Z
Auxiliary Spool
? ? 55
A B 85 B
75
56
77 ? 57
8
76 11
73 58
R ? ?
BICS CONTROL VALVE
D2
33 74
X1
Tilt Spool
58
59
32 C2
8
X2 15 C1 D1
72
30
11
ANTI-CAVITATION VALVE
2-SPEED & SAPR REAR AUXILIARY

BRAKE VALVE VALVE (OPTIONAL) 16
B A D
MA
MB
34 P in P out T 13
A B 71 TILT CYLINDERS
T
43 43 MG
31 30
Dealer Copy -- Not for Resale Lift Spool
G 8
A B BOBTACH CYLINDER (OPTIONAL)
P
MB
B1 34 12 18
45 46
MA
11 20
44 47 17 ?
45 65 53 STEERING VALVE
IN
2
53
? 7 18 51
30 30 64 66 68 6 ? ?
X2 34
19
63
32
X1 ? 1
21
67 OIL COOLER
34 ? ?
35 33 STEERING
70 CYLINDERS (4) 51
HYDRAULIC FILTER ? ?
T HYDRAULIC RESERVOIR
29 D 62 69 4 (VENTED)
R 2 1
48
49 61
POWER BOBTACH 5
VALVE (OPTIONAL) 60 3 ? ?
53 53
78 52
79 80 VARIABLE SPEED HYDRAULIC
?
54
27
25
50
28
B 40 A
26 23
Z
P DR
24 WORKING CIRCUIT
42 39 CHARGE
PRESSURE
W
DRAIN / RETURN
41
DRAIN / RETURN MANIFOLD
X
22
A770 (S/N ATDW11001 - ATDW11599)
38
37 36 Printable Version Click Here
L
(PRINTED JUNE 2012)
114 of 1010
7194316 (B)
PRINTED IN U.S.A.
(PRINTED AUGUST 2015)
V-1496legend
LEGEND
1 RESERVOIR: 14 FRONT AUXILIARY MANUAL PRESSURE 29 VARIABLE CAPACITY DISPLACEMENT 43 FILTER - BRAKE
Capacity at sight gauge . 9,8 L (2.6 U.S. gal) BLEED-OFF VALVE BIDIRECTIONAL HYDROSTATIC PUMP SOLENOID ACTIVATED DIRECECTIONAL
44
System Capacity . . . . . . 37,9 L (10.0 U.S. gal) 15 PILOTED ACTIVATED DIRECTIONAL 30 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE BRAKE
2 SIGHT GAUGE CONTROL VALVE - TILT CONTROL PRESSURE: 36500 kPa (365 bar) (5294 psi) 45 NOT USED ON THIS MODEL
16 PILOTED ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 RELIEF VALVE - CHARGE INLET: 46
CONTROL VALVE - LIFT CONTROL 34129 kPa (34,1 bar) (495 psi) at High CONTROL VALVE 2 Speed Shift
103 kPa (1,03 bar) (15 psi)
17 SOLENOID ACTIVATED DIRECTIONAL Engine Idle With 60 C (140 F) Fluid 47 NOT USED ON THIS MODEL
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - BICS CONTROL 32 SERVO PISTON Swash Plate
18 FILTER - BICS CONTROL VALVE 48 HYDRAULIC PUMP . . . . . . . Gear Type
5 SPRING LOADED FILTER BY-PASS 33 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) CONTROL VALVE FORWARD/REVERSE 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
VALVE: 172 kPa (1,7 bar) (25 psi) 19 CHECK VALVE - With 100 kPa 1,0 bar
34 FILTER 49 CHARGE PUMP . . . . . . . Gear Type
6 DIAGNOSTIC COUPLER (14.5 psi) Spring 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 35 CHECK VALVE COLD WEATHER BY-PASS 50 STEERING PUMP . . . . . . . Gear Type
7 RELIEF VALVE - MAIN: With 345 kPa (3,45 bar) (50 psi) Spring
51,1 L/min (13.5 U.S. gpm) at High Engine Idle
23787 - 24476 kPa (238 - 245 bar) 21 PULL BUTTON ACTIVATED Dealer Copy -- Not for Resale
36 RESTRICTION 1,7 mm (0.067 in) 51 CHECK VALVE - With 1862 kPa (18,6 bar)
(3450 - 3550 psi) at Front Quick Couplers DIRECTIONAL CONTROL VALVE - LIFT
(270 psi) Spring
ARM BY-PASS 37 CHECK VALVE - With 1379 kPa (13,8 bar)
RELIEF VALVE MAIN (OPTIONAL): (200 psi) Spring 52 RELIEF VALVE: 13790 kPa (138 bar) (2000 psi)
27234 27924 kPa (272 - 279 bar) 22 SENSOR HYD. TEMPERATURE 38 DRIVE MOTOR SHUTTLE VALVE 53 SOLENOID ACTIVATED DIRECTIONAL
(3950 - 4050 psi) at Diagnostic Coupler 6 CONTROL VALVE - TWO COIL - STEERING
23 ANTICAVITATION VALVE 39 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 54 FILTER STEERING VALVE
7A RELIEF VALVE AUXILIARY (OPTIONAL): 24 PROPORTIONAL RELIEF VALVE
23787 24476 kPa (238 - 245 bar) (Fan Speed Regulator): 10797-12300 kPa 40 HYDRAULIC BRAKE SPRING APPLIED
55 FILL PORT Factory Hydraulic Oil
(3450 - 3550 psi) at Diagnostic Coupler 6 (108 - 123 bar) (1566 - 1784 psi) PRESSURE RELEASE (SAPR)
41 PILOT ACTIVATED DIRECTIONAL
8 25 SPRING LOADED FILTER BY-PASS VALVE:
RELIEF/ANTICAVITATION VALVE - CONTROL VALVE 2 Speed
517 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
PORT: 27579 kPa (276 bar) (4000 psi) 42 FIXED CAPACITY DISPLACEMENT
26 FIXED CAPACITY DISPLACEMENT
9 BIDIRECTIONAL HYDROSTATIC
RELIEF/ANTICAVITATION VALVE - HYDRAULIC MOTOR MOTOR 2 Speed
PORT (OPTIONAL): 27579 kPa
27 FILTER - HYDRAULIC (CANISTER)
(276 bar) (4000 psi)
SOLENOID ACTIVATED DIRECTIONAL 28 SENSOR CHARGE PRESSURE
10
CONTROL VALVE - AUXILIARY Fan Filter
11 LOAD CHECK VALVE
12 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP
NOTE: Unless otherwise specified, springs have

NO significant pressure value.
Printed in U.S.A. V-1496legend (8-17-15)
115 of 1010
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
Male
TWO SPEED DRIVE MOTOR 36
37
L
Female
38
OUT
HYDRAULIC CONTROL VALVE (SPOOL VALVE)
9
X
41 10
39 42
10
Auxiliary Spool
Z
55
A B
40
7A
8 11 BOBCAT INTERLOCK CONTROL SYSTEM

R (BICS)
33 8
X1
32 Tilt Spool
15
X2
30 13 TILT CYLINDERS
11
2-SPEED & SAPR

BRAKE VALVE
MA
MB
34 8 16
B A
A B
43 T MG
31 30 Dealer Copy -- Not for Resale

Lift Spool
A B
P LIFT CYLINDERS
MB 12 20
B1 A1 MA 34 11 18
46 17
44 43
53 STEERING VALVE
IN
18
53
7 51
30 6
30
X2 34 19 21 2
32
X1 1
34
35 33 STEERING
CYLINDERS (4) 51
HYDRAULIC FILTER
T
OIL COOLER HYDRAULIC RESERVOIR
29 4 (VENTED)
R 2 1
48
5
3
53 53
49 52
VARIABLE SPEED HYDRAULIC
50 54
27
25
28
B 40 A
26 23
Z
P DR
24 WORKING CIRCUIT
39 CHARGE
42 PRESSURE
DRAIN / RETURN

X
41
22
AWS WITH NO OPTIONS
A770 (S/N ATDW11600 AND ABOVE)
38
(S/N ATDY11001 AND ABOVE)
37 36
L (PRINTED AUGUST 2015)

116 of 1010 7194316 (B)
PRINTED IN U.S.A.

V-1498legend
LEGEND
1 RESERVOIR: 17 SOLENOID ACTIVATED DIRECTIONAL 38 DRIVE MOTOR SHUTTLE VALVE 60 PILOT ACTIVATED DIRECTIONAL
Capacity at sight gauge . 9,8 L (2.6 U.S. gal) CONTROL VALVE - BICS CONTROL CONTROL VALVE - HYDRAULIC
39 FIXED CAPACITY DISPLACEMENT POWERED BOB-TACH
System Capacity . . . . . . 37,9 L (10.0 U.S. gal) 18 FILTER - BICS CONTROL VALVE BIDIRECTIONAL HYDROSTATIC MOTOR 61 FILTER - BOB-TACH VALVE
2 SIGHT GAUGE (SCREEN) 40 HYDRAULIC BRAKE SPRING APPLIED
19 CHECK VALVE - With 100 kPa 1,0 bar 62 RESTRICTION - 2,08 mm (0.08 in)
3 DIFFERENTIAL PRESSURE SWITCH: PRESSURE RELEASE (SAPR)
(14.5 psi) Spring 41 PILOT ACTIVATED DIRECTIONAL 63 SOLENOID ACTIVATED DIRECTIONAL
103 kPa (1,03 bar) (15 psi) 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
CONTROL VALVE 2 Speed CONTROL VALVE (TWO COIL)
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) 21 PULL BUTTON ACTIVATED 42 FIXED CAPACITY DISPLACEMENT 64 RELIEF VALVE: 8274 kPa (83 bar) (1200 psi)
DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC CHECK VALVE - With 552 kPa (5,5 bar)
65
5 SPRING LOADED FILTER BY-PASS ARM BY-PASS MOTOR 2 Speed (80 psi) Spring
VALVE: 172 kPa (1,7 bar) (25 psi) 22 SENSOR HYD. TEMPERATURE 43 FILTER - BRAKE 66 SHUTTLE VALVE
6 DIAGNOSTIC COUPLER 44 SOLENOID ACTIVATED DIRECECTIONAL 67 RELIEF VALVE: 13790 kPa (137 bar) (2000 psi)
CONTROL VALVE BRAKE
7 RELIEF VALVE - MAIN: 68 CHECK VALVE - With 2068 kPa (20,7 bar) (300
24 PROPORTIONAL RELIEF VALVE NOT USED FOR THIS MODEL
45 psi) Spring And With 0,33 mm (0.013 in) Orifice
23787 - 24476 kPa (238 - 245 bar) (Fan Speed Regulator): 10797-12300 kPa
(3450 - 3550 psi) at Front Quick Couplers (108 - 123 bar) (1566 - 1784 psi) 46 SOLENOID ACTIVATED DIRECTIONAL 69 RESTRICTION - 0,51 mm (0.020 in)
Dealer Copy -- Not CONTROL
for ResaleVALVE 2 Speed Shift RESTRICTION - 0,51 mm (0.020 in)
SPRING LOADED FILTER BY-PASS VALVE: 70
RELIEF VALVE MAIN (OPTIONAL): 25 47 NOT USED FOR THIS MODEL
27234 27924 kPa (272 - 279 bar) 517 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 71 PILOT ACTIVATED DIRECTIONAL
(3950 - 4050 psi) at Diagnostic Coupler 6 26 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - REAR AUXILIARY
48 HYDRAULIC PUMP . . . . . . . Gear Type 72 RELIEF VALVE: 122753 kPa (228 bar) (3300 psi)
7A RELIEF VALVE AUXILIARY (OPTIONAL): HYDRAULIC MOTOR 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
23787 24476 kPa (238 - 245 bar) 73 SOLENOID ACTIVATED DIRECTIONAL
27 FILTER - HYDRAULIC (CANISTER) 49 CHARGE PUMP . . . . . . . Gear Type
(3450 - 3550 psi) at Diagnostic Coupler 6 CONTROL VALVE - TWO COIL
51,1 L/min (13.5 U.S. gpm) at High Engine Idle 74 RESTRICTOR - 0,8 mm (0.031 in)
8 RELIEF/ANTICAVITATION VALVE - 28 SENSOR CHARGE PRESSURE
Fan Filter 50 STEERING PUMP . . . . . . . Gear Type 75 LOAD SHUTTLE VALVE - BLEED OFF
PORT: 27579 kPa (276 bar) (4000 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
29 VARIABLE CAPACITY DISPLACEMENT 76 SOLENOID ACTIVATED DIRECTIONAL
9 RELIEF/ANTICAVITATION VALVE - 51 CHECK VALVE - With 1862 kPa (18,6 bar) CONTROL VALVE - Female
BIDIRECTIONAL HYDROSTATIC PUMP
PORT (OPTIONAL): 27579 kPa (270 psi) Spring 77 SOLENOID ACTIVATED DIRECTIONAL
(276 bar) (4000 psi) 30 RELIEF/REPLENISHING VALVE - HIGH 52 RELIEF VALVE: 13790 kPa (138 bar) (2000 psi) CONTROL VALVE - Male
10 SOLENOID ACTIVATED DIRECTIONAL PRESSURE: 36500 kPa (365 bar) (5294 psi) 78 HIGH FLOW HYDRAULIC PUMP Gear Type
CONTROL VALVE - AUXILIARY 31 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - TWO COIL - STEERING 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
11 LOAD CHECK VALVE 34129 kPa (34,1 bar) (495 psi) at High 79 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
54 FILTER STEERING VALVE
LIFT CYLINDER SPOOL - MADE TO Engine Idle With 60 C (140 F) Fluid 80 DUMP VALVE ON / OFF
RESTRICT FLOW DURING BOOM 32 SERVO PISTON Swash Plate 55
CONTROL VALVE - BUCKET POSITION 81 CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi)
DOWN BUT NOT DURING BOOM UP Spring
33 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
13 ANTICAVITATION VALVE CONTROL VALVE FORWARD/REVERSE 82 RIDE CONTROL VALVE
56 FLOW DIVIDER ADJUSTMENT VALVE
14 FRONT AUXILIARY MANUAL PRESSURE 34 FILTER 83 HIGH PRESSURE CHAMBER
BLEED-OFF VALVE 35 CHECK VALVE COLD WEATHER BY-PASS CONTROL VALVE - FLOW CONTROL
84 LOW PRESSURE CHAMBER
15 PILOTED ACTIVATED DIRECTIONAL With 345 kPa (3,45 bar) (50 psi) Spring SPOOL
CONTROL VALVE - TILT CONTROL 36 RESTRICTION 1,7 mm (0.067 in) 58 CHECK VALVE - BUCKET POSITION 85 FILL PORT Factory Hydraulic Oil
16 PILOTED ACTIVATED DIRECTIONAL VALVE
37 CHECK VALVE - With 1379 kPa (13,8 bar) NOTE: Unless otherwise specified, springs have
CONTROL VALVE - LIFT CONTROL 59 PILOTED ACTIVATED DIRECTIONAL NO significant pressure value.
(200 psi) Spring
CONTROL VALVE - UNLOADING
Printed in U.S.A. SPOOL V-1498legend (8-17-15)
117 of 1010
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
Male
TWO SPEED DRIVE MOTOR 36
81 RIDE CONTROL
37 (OPTIONAL)
L
Female
38
OUT
HYDRAULIC CONTROL VALVE (SPOOL VALVE) 84

83 LIFT CYLINDERS
82
9
X
41 10 BUCKET POSITIONING
39 42 VALVE (OPTIONAL)
10
MALE E1 E2 A1 A2
FEMALE
Auxiliary Spool E3
REAR HYDRAULIC
Z COUPLERS 85
55
A B
40 B
75
56
77 7A 57
76 8 11
73
BOBCAT INTERLOCK CONTROL SYSTEM 58
R (BICS)
D2
33 74 8
X1
58
59
32 Tilt Spool
15 C2
X2 C1 D1
72
30 13
11
2-SPEED & SAPR REAR AUXILIARY

BRAKE VALVE VALVE (OPTIONAL)
MA
MB
34 P in P out T 8 16
B A
A B 71
43 T TILT CYLINDERS
MG
31 30
Lift Spool
P
A B BOBTACH CYLINDER (OPTIONAL)
MB 12 20
B1 A1 MA 34 11 18
46 17
44 43
65 53 STEERING VALVE
IN
18
53
7 51
30 64 66 68 6
30
X2 34 19 21 2
63
32
X1 1
34 67
35 33 STEERING
70 CYLINDERS (4) 51
HYDRAULIC FILTER
T
OIL COOLER HYDRAULIC RESERVOIR
29 D 62 69 4 (VENTED)
R 2 1
48
61
POWER BOBTACH 5
VALVE (OPTIONAL) 60 3
53 53
78 52
79 80 VARIABLE SPEED HYDRAULIC
49
54
27
25
50
28
B 40 A
26 23
Z
P DR
24 WORKING CIRCUIT
39 CHARGE
42 PRESSURE
DRAIN / RETURN

X
41
22
38
(S/N ATDY11001 AND ABOVE)
37 36
L (PRINTED AUGUST 2015)

118 of 1010
7194316 (E)
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

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

noise.

HYDRAULIC SYSTEM INFORMATION (CONTD)
Glossary Of Hydraulic / Hydrostatic Symbols (Contd)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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

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


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

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

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

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

(See DIAGNOSTIC SERVICE CODES on Page 60-100-
1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
Slow hydraulic system action. 1, 2, 4, 6
Hydraulic action is not smooth. 1, 3, 4, 5
Lift arms go up slowly at full engine rpm 1, 2, 3, 4, 5, 6, 7, 8
The lift arms come down with the joystick in neutral position 3, 8, 9, 10
Lift Arm Bypass Control valve stuck 10
Lift Arm Bypass Control valve stem bent or broken 11

KEY TO CORRECT CAUSE
1. The fluid level is not correct.

2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.)
6. Exceeding the loaders rated operating capacity.
7. Internal leak in the lift cylinder(s).
8. External leak from the cylinder(s).
9. Damaged lift spool.
10. Rotate shaft.
11. Replace Lift Arm Bypass Control valve assembly.


CYLINDER (LIFT) Figure 20-20-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
WARNING
AVOID INJURY OR DEATH 1
Use a piece of cardboard or wood to find leaks. Do P101721
from a physician familiar with this injury. Install a cap (Item 1) [Figure 20-20-2] on the hose and
W-2072-0807 tighten.
Engage the parking brake. Lower the seat bar. Start the
Figure 20-20-1 engine and press the PTOL button.

Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2], remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
P101720
Test only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] from the base end of the
cylinder.

CYLINDER (LIFT) (CONT'D)
Removal And Installation

WARNING
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
W-2017-0286
2
1
IMPORTANT 2

When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P100298
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

container to collect the hydraulic oil as the lift arms are
raised.
Recycle or dispose of used fluid in an environmentally

1 safe manner.
WARNING
P101720 AVOID INJURY OR DEATH
Mark and disconnect the two hydraulic hoses (Item 1) death. Fluid leaks under pressure may not be visible.
[Figure 20-20-3]. Use a piece of cardboard or wood to find leaks. Do
W-2072-0807

Removal And Installation (Contd)

DANGER
Figure 20-20-5
P-90328
AVOID DEATH
1 Disconnecting or loosening any hydraulic
P101724
support. Replace if damaged.
D-1009-0409
Remove the bolt and nut (Item 1) [Figure 20-20-5] from
the pin on the rod end of the cylinder.

Installation: Tighten the bolt and nut to 48 - 54 Nm (35 -
40 ft-lb) torque. WARNING
Figure 20-20-6
W-2059-0598
1
Figure 20-20-7
P101723
1
Remove the pin (Item 1) [Figure 20-20-6] from the rod
end of the cylinder.
NOTE: The center of the pin is threaded to allow the

use of a suitable puller for pin removal.
P-90605
Install a sling (Item 1) [Figure 20-20-7] in the middle of

the Bob-Tach.
Using a chain hoist raise the lift arms and install an

approved lift arm support device on the cylinder that is
connected to the lift arm.

CYLINDER (LIFT) (CONT'D) Figure 20-20-10
Figure 20-20-8
1
1 2
2
P101722
NOTE: The center of the pin is threaded. Remove the

P-90823
grease fitting (Item 1) [Figure 20-20-10] and
use a suitable puller to remove the pin.
Install a bolt (Item 1) through the eyelet of the cylinder Installation: Tighten the grease fitting to 20 Nm (15 ft-
and install a strap (Item 2) [Figure 20-20-8] to secure the lb) torque.

cylinder.
Remove the pin (Item 2) [Figure 20-20-10] from the base
Open the rear door. end of the cylinder.
NOTE: When removing the left side cylinder the Figure 20-20-11
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
Figure 20-20-9
P-90823
Using a chain hoist remove the cylinder (Item 1) [Figure

1 20-20-11] from the loader.
P-90834

the pin on the base end of the cylinder.
Installation: Tighten the bolt and nut to 48 - 54 Nm (35 -

40 ft-lb) torque.

Parts Identification 44,5 mm (1.75 in) Rod Diameter
1. Plug
2. O-ring
3. Tubeline
4. Tube
5. Clamp
6. Nut
7. Seal
8. Piston
9. Spacer
10. Wear Ring 1
2
11. Head
12. Seal
13. Wiper
14. Rod
15. Grease Fitting 4
1
2
5

3
6
2
7
8
10
7
2
11
12
13
14
15
NA6139S

Parts Identification 50,8 mm (2.0 in) Rod Diameter
1. Plug
2. O-ring
3. Tubeline
4. Tube
5. Clamp
6. Nut
7. Seal
8. Piston
9. Wear Ring
10. Head
11. Seal 1
12. Wiper 2
13. Rod
14. Grease Fitting
4
1
2
5

3
6
1
7
8
9
7
1
10
11
12
13
14
NA10254S

Disassembly
2
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-12 P-48038
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-14].
NOTE: If the fiber surface (Item 3) [Figure 20-20-14]

1 on the piston becomes damaged, the
complete piston must be replaced.

Figure 20-20-15
2
1
1
P-81032
Insert the adjustable gland nut wrench into the holes

(Item 1) [Figure 20-20-12] to loosen the head.
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
Figure 20-20-13
P101716
Remove the seal (Item 1) and the O-ring (Item 2) [Figure

20-20-15].
1
4
2
P100758
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
(if equipped) and head (Item 4) [Figure 20-20-13].

Disassembly (Contd)
Figure 20-20-16
4 2 1
P-81036
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-16].

Remove the wear ring (Item 4) [Figure 20-20-16].
Figure 20-20-17
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

17].

Assembly
3
Clean all parts in solvent and dry with compressed air. 1
Inspect the cylinder parts for wear or damage. Replace 2

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

installation.
Use the following tools to assemble the cylinder:

P-48038
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor Install the O-ring (Item 1) and seal (Item 2) on the piston
MEL1075 - Adjustable Gland Nut Wrench (Item 3) [Figure 20-20-19].
Figure 20-20-20
Figure 20-20-18

N-22358
P-7424
Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-18]. approximately three minutes [Figure 20-20-20].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Contd)
Figure 20-20-21
P-7425
Install the rod seal in the head [Figure 20-20-23].

P-7427
Figure 20-20-24
Install the rod seal on the rod seal tool [Figure 20-20-21].

NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-20-22
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
20-24] toward the outside of the head.
Figure 20-20-25
N20613
1
Rotate the handles to collapse the rod seal [Figure 20-
20-22].
N-22356
Install the wear ring (Item 1) [Figure 20-20-25].

Assembly (Contd)
Figure 20-20-26
1
2
81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

P101716 20-28].
Tighten the plug to 50 Nm (37 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-20-26].
Put the base end of the cylinder in a vise.

Install the seal (Item 2) [Figure 20-20-26].
Figure 20-20-29
Figure 20-20-27
4
1
3 P-81032
P100758
Tighten the head (Item 1) [Figure 20-20-29] to 373 Nm

Install the head (Item 1), spacer (Item 2) (if equipped) (275 ft-lb) torque.
and the piston (Item 3) [Figure 20-20-27] on the rod.
Grease the piston where the nut contacts the piston. Do

not get grease on the threads.
Provide an adequate support for the cylinder before

tightening.
NOTE: Clean and dry the rod threads. Install a NEW

NUT with pre-applied Loctite.
Install the nut (Item 4) [Figure 20-20-27].
Tighten the nut to 1491 Nm (1100 ft-lb) torque.


CYLINDER (TILT) Figure 20-21-2
Testing
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar.
1
2
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a P100721
physician familiar with this injury is not received
immediately.
W-2145-0290 Install a cap (Item 1) [Figure 20-21-2] on the hydraulic
hose and tighten.
Figure 20-21-1 Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.

Operate the control that rolls the Bob-Tach back.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-21-2] remove the cylinder for repair.
1
Repeat procedure to test the other cylinder.
P-85553
Test only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-21-1] from the rod end of the
cylinder.

CYLINDER (TILT) (CONT'D) Figure 20-21-5
Remove the attachment from the Bob-Tach. Roll the Bob-

Tach forward
2
Figure 20-21-3
1
1
P-85562
1
Remove the hoses (Item 1) [Figure 20-21-5] from the

cylinder.
Remove the base end pivot bolt and washer (Item 2)

[Figure 20-21-6].

P-85554 Figure 20-21-6

the rod end pivot pin.
Installation: Tighten the nut to 48 - 54 Nm (35 - 40 ft-lb) 1

torque.
Figure 20-21-4
P-85648
Remove the nut and washer (Item 1) [Figure 20-21-6]

from the base end pivot pin.
Installation: Tighten the nut to 258 - 264 Nm (190 - 195

ft-lb) torque.
P-85649
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

CYLINDER (TILT) (CONT'D) Base End Pivot Pin Removal And Installation
Removal And Installation (Cont'd) Remove the cylinder from the cylinder base end pivot pin.
(See Removal And Installation on Page 20-21-2.)
Figure 20-21-7
Figure 20-21-8
1
P-85564
P-85565
Slide the cylinder off the base pin and remove the
cylinder [Figure 20-21-7]. Using a 22,2 mm (0.875 in) drift, drive the taper pin (Item

1) [Figure 20-21-8] from the wheel side of the loader out
of the lift arm.
Figure 20-21-9
P-85567
Inspect the pin and replace as needed [Figure 20-21-9].

CYLINDER (TILT) (CONT'D)
Parts Identification (Early Models)
1. Grease Fitting
2. Plug
3. O-ring
4. Tube
5. Clamp
6. Nut 1
7. Seal
8. Piston
9. Tubeline
10. Head
11. Shaft Seal 4
2
12. Wiper
13. Rod
14. Bushing
3
6
5 7
9 8

3
2
10
11
12
13
14
NA6205S

Parts Identification (Later Models)
1. Grease Fitting
2. Plug
3. O-ring
4. Clamp
5. Tube
6. Nut
7. Seal 1
8. Piston
9. Collar 5
10. Tubeline
11. Head 2 3
12. Rod Seal
13. Wiper
14. Rod
15. Bushing 6
7
4 8

10 3 9
2
7
3
11
12
13
14
15
NA8210S

CYLINDER (TILT) (CONT'D) Remove the head and the rod assembly from the
Disassembly
Figure 20-21-12
3 Early Models
MEL1074 - O-ring Seal Hook 2
MEL1075-2 - Offset Pins 1
Figure 20-21-10
P-48071
1 Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
2

Figure 20-21-13
Later Models
4
2
P-85651B
Remove the bushing (Item 1) [Figure 20-21-10].
An identifying mark (Item 2) [Figure 20-21-10] on the rod 3 1

end indicates a later model cylinder.
Figure 20-21-11
P109554
Remove the nut (Item 1), piston (Item 2), collar (Item 3)
and head (Item 4) [Figure 20-21-13].
1
P-81032
Insert the adjustable gland nut wrench into the holes


Disassembly (Contd)
2
Figure 20-21-14
1
Early Models
P101716
3
2
Remove the seal (Item 1) and the O-ring (Item 2) [Figure
P-48073 20-21-16].
Figure 20-21-17
3

Figure 20-21-15
4 2 1
Later Models
P-81036
1
Remove the wiper seal (Item 1) and rod seal (Item 2)
P109555 from the inside of the head (Item 3) [Figure 20-21-17].
Remove the wear ring (Item 4) [Figure 20-21-17].

Remove the seal (Item 1) [Figure 20-21-15].

Disassembly (Contd)
Figure 20-21-18
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-21-

18].

Assembly Early Models
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace 1

any damaged parts.

installation. 3
2
P-48073
Figure 20-21-21
Figure 20-21-19
Later Models

1
P109555
P-7424
Install the seal (Item 1) on the piston (Item 3) [Figure 20-

Install the new seal on the tool and slowly stretch it until it 21-20].
fits the piston [Figure 20-21-19].

on the piston.

Assembly (Contd)
Figure 20-21-22
N20613

N-22358 21-24].
Figure 20-21-25
correct size. Leave the piston in the compressor for

approximately three minutes [Figure 20-21-22].
Figure 20-21-23
P-7425
P-7427


Assembly (Contd)
1
Figure 20-21-26 2
P101716
1

N-22359
Install the seal (Item 2) [Figure 20-21-28].
Install the wiper seal with the wiper (Item 1) [Figure 20- Figure 20-21-29

Early Models 1
Figure 20-21-27
2
3
1
P-48071
N-22356 Install the head (Item 1) and the piston (Item 2) [Figure
20-21-29] on the rod.
Install the wear ring (Item 1) [Figure 20-21-27]. Grease the piston where the nut contacts the piston. Do

tightening.


Assembly (Contd)
Figure 20-21-30
Later Models 1
3
1
4 P-81032
2

P109554 (275 ft-lb) torque.
Figure 20-21-33
Install the head, (Item 1) collar (Item 2) and the piston
(Item 3) [Figure 20-21-30] on the rod.



1
Figure 20-21-31
P-85650
Install the bushing (Item 1) [Figure 20-21-33]. Make sure

the bushing is aligned with the grease channel in the
cylinder.
81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

21-31].
Tighten the plug to 50 Nm (37 ft-lb) torque.

CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING
1
P-85570
W-2072-0807
Remove the hose (Item 1) [Figure 20-22-2] from the

base end port.

sparks or lighted tobacco away from fuel and oil. 1 2
explosion or fire.
W-2103-0508
Remove the attachment.
Figure 20-22-1
P-85568
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
engine.
Push and hold the BOB-TACH WEDGES UP Switch

(Front Accessory Panel).
P-85570 If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3] remove the cylinder for repair.
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

22-1].
Push and hold BOB-TACH WEDGES UP switch until

levers are in the unlocked position (Wedges fully raised).

CYLINDER (BOB-TACH) (CONTD) Figure 20-22-5
WARNING
penetrate skin or eyes, causing serious injury or 1
1
enters skin or eyes, get immediate medical attention P-85569
W-2072-0807
Remove the bolts and washers (Item 1) [Figure 20-22-5].
Remove the cylinder from the lever pivots.
WARNING Installation: Tighten the bolts to 48 - 54 Nm (35 - 40 ft-

lb) torque.

explosion or fire.
W-2103-0508
Figure 20-22-4
P-85570
Remove the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Install plugs in the hoses and cap on fittings.
Installation: Tighten the hoses to 29,8 - 32,5 Nm (22 -

24 ft-lb) torque.

CYLINDER (BOB-TACH) (CONTD)
Parts Identification
1. Grease Fitting
2. Tube
3. Nut
4. Seal 1
5. O-ring
6. Piston
7. Spacer
8. Back-up ring
9. Head
10. Rod Seal 2
11. Wiper
12. Rod
3
4
5
6
7

4
5
10
11
5 12
8
NA2603S

Disassembly 3
2 1
Figure 20-22-6 P-16295

Figure 20-22-9
1

5
2
1
P122371
4
3
Insert the adjustable gland nut wrench into the holes to
loosen the head (Item 1) [Figure 20-22-6].
Remove the head and the rod assembly from the N-20611
Figure 20-22-7 Remove the wiper seal (Item 1), rod seal (Item 2), back-
up ring (Item 3), O-ring (Item 4) and O-ring (Item 5)
2 [Figure 20-22-9] from the head.
4 3
1
P-16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-22-7].

Assembly
3 1
Inspect the cylinder parts for wear or damage. Replace

any damaged parts.

installation.

P16295
Figure 20-22-12
Figure 20-22-10

N-22358
P-7424

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-22-10]. approximately three minutes [Figure 20-22-12].

on the piston.

Assembly (Contd)
Figure 20-22-13
P-7425

P-7427
Figure 20-22-16

Figure 20-22-14
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
N20613

22-14].

Assembly (Contd)
Figure 20-22-17
1 1
2
P122371
3

Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-22-17].
Figure 20-22-18
3
1 2 4
P-81064
Install the head (Item 1), spacer (Item 2) and the piston
(Item 3) [Figure 20-22-18] on the rod.


tightening.



CYLINDER (STEERING) Figure 20-23-3
Testing
Lift and block the loader. (See Procedure on Page 10-10- 1

1.)
Figure 20-23-1
P-28215
Remove the bolt (Item 1) [Figure 20-23-3] from the

cylinder rod cover.
Remove the cover from the loader.

P-68472
Figure 20-23-4

Move the joystick to retract the cylinder that is to be
tested. The direction that you will need to move the
joystick will vary depending the cylinder that is needed to
2
be retracted [Figure 20-23-1].
1
Remove the wheel and tire assembly of the cylinder that
needs testing. (See Mounting on Page 10-160-1.)
Figure 20-23-2
P-28216
Remove the bolt [Figure 20-23-4] (Item 1) from the

steering cylinder pin.
1
Remove the steering cylinder pin (Item 2) [Figure 20-23-
4].
Remove the cylinder rod from the hub and swing the hub
P-24924 away from the cylinder.
Remove the two bolts (Item 1) [Figure 20-23-2] from

wheel position sensor / steering cylinder cover.
Remove the wheel position sensor / steering cylinder

cover from the loader.

CYLINDER (STEERING) (CONTD)
Testing (Contd)
WARNING
Figure 20-23-5
1 Diesel fuel or hydraulic fluid under pressure can
2 death. Fluid leaks under pressure may not be visible.
W-2072-0807
P-68445
Remove the rod (Item 1) and base (Item 2) [Figure 20-

23-5] hoses from the steering cylinder block.

NOTE: When testing the cylinder for leakage make
sure you have the proper rod and base hoses
for the cylinder you want to be testing. The
base end hoses for each cylinder are the ports
closest to the rear of the loader.
Cap the rod and base fittings on the steering block.
Install a port a power with a 20684 kPa (207 bar) (3000

psi) gauge onto the rod end hose.
Pump up the port a power until the cylinder retracts fully.
NOTE: The cylinder will have about an inch of stroke

before it reaches the fully retracted position.
Fluid will also come out of the base end hose
until the cylinder is fully retracted.
After the cylinder is retracted pump the port a power until

the pressure is between 12410 - 13100 kPa (124 - 131
bar) (1800 - 1900 psi) then lock the port a power.
NOTE: Do not exceed 13790 kPa (138 bar) (2000 psi)

on the port a power pressure gauge. This may
cause damage to the seals.
If fluid begins to leak from the base end hose and the
pressure gauge on the port a power starts to drop, the
cylinder must be repaired.

CYLINDER (STEERING) (CONTD) Figure 20-23-8
Removal And Installation (Front)

1.)
Remove the wheel and tire assembly. (See Mounting on

Page 10-160-1.)
Figure 20-23-6
P-28215
1
1 Remove the bolt (Item 1) [Figure 20-23-8] from the
cylinder rod cover.
Remove the cover from the loader.
Figure 20-23-9

P-26077
Remove the four bolts (Item 1) [Figure 20-23-6] from the

hydrostatic motor cover.
1
Remove the hydrostatic motor cover.
Figure 20-23-7
P-28216
Remove the bolt [Figure 20-23-9] (Item 1) from the

steering cylinder pin.
1
P-24924

Remove the wheel position sensor / steering cylinder


Removal And Installation (Front) (Contd)
Figure 20-23-10
1
1
P-26078

P-28217 base end steering cylinder pin.

10].
IMPORTANT

Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 20-23-11 When repairing hydrostatic and hydraulic systems,

damage the system.
1 I-2003-0888
3
2
P101523
Remove the bolts (Item 1) [Figure 20-23-11].
Remove the foot rest (Item 1) [Figure 20-23-11] from the

loader.
Lift up on and remove the access cover (Item 3) [Figure

20-23-11].

CYLINDER (STEERING) (CONT'D) Figure 20-23-15
Removal And Installation (Front) (Cont'd)
Mark the hydraulic hoses for proper installation. 1
Figure 20-23-13
P-26081
Remove the base end cylinder pin (Item 1) [Figure 20-

23-15].
P-26079 Figure 20-23-16

Remove the base end hydraulic hose (Item 1) [Figure
20-23-13].
Figure 20-23-14 1
P-26082
1
Remove the steering cylinder (Item 1) [Figure 20-23-16]

from the loader.
P-26080
Remove the rod end hydraulic hose (Item 1) [Figure 20-

23-14], by going through the motor cover access hole.

Removal And Installation (Rear)
Remove the wheel and tire assembly. (See Mounting on

Page 10-160-1.)
Figure 20-23-17
2 1
2
P-26086
Push the harness connector (Item 1) [Figure 20-23-19]

through the access cover.
1
Remove the access cover from the loader.
P-28218
Figure 20-23-20

Remove the six bolts (Item 2) [Figure 20-23-17] from the

loader access cover. 1
Remove the wheel position sensor / steering cylinder 1

Figure 20-23-18
P-26088
Remove the four bolts (Item 1) [Figure 20-23-20] from

the motor cover.
Remove the motor cover from the loader.
P-26085
Disconnect the wheel position sensor wire (Item 1)

[Figure 20-23-18].

CYLINDER (STEERING) (CONT'D) Mark the hydraulic hoses for proper installation.
Removal And Installation (Rear) (Cont'd) Figure 20-23-23
Figure 20-23-21
1 1
P-26091
P-26089
Remove the base and rod cylinder hoses (Item 1)
[Figure 20-23-23].
Remove the bolt (Item 1) [Figure 20-23-21] from the rod
end cylinder pin.

Figure 20-23-22
P-26090
Remove the rod end cylinder pin (Item 1) [Figure 20-23-

22].
IMPORTANT
damage the system.
I-2003-0888

Removal And Installation (Rear) (Cont'd)
Figure 20-23-24
1
P-26094
Remove the steering cylinder (Item 1) [Figure 20-23-26]

P-26092 from the loader.

base end cylinder pin.

Figure 20-23-25
P-26093
Remove the base end cylinder pin (Item 1) [Figure 20-

23-25].

CYLINDER (STEERING) (CONTD)
1. Bushing
2. Tube
3. Grease Fitting
4. Nut
5. Seal
6. O-ring
7. Piston
8. Back-up ring
9. Rod Seal
10. Head
11. Wiper
12. Rod 1
4 5
6
7

3
6 8 6
9 10 1
11
12
PE1394A

Disassembly 3 2 1

MEL1075 - Adjustable gland nut wrench
MEL1075-1 - Standard Pins
Figure 20-23-27 P16295
Remove the O-ring (Item 1), and seal (Item 2) from the
1
Figure 20-23-30

5
2
1
1
P-53247
4
Insert the adjustable gland nut wrench into the two holes 3
Remove the head and the rod assembly from the N-20611
Figure 20-23-28 Remove the wiper seal (Item 1), rod seal (Item 2), back-
up ring (Item 3), O-ring (Item 4), and O-ring (Item 5)
2 [Figure 20-23-30] from the head.
4 3 1
P16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-23-28] from the rod.

Assembly
3 2
1
Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

MEL1033 - Rod Seal Installation Tool P16295
MEL1396-2 - Piston Ring Compressor
MEL1075-1 - Standard Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-23-32].
Figure 20-23-31
Figure 20-23-33

P7424
N-22358
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-23-31]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it three minutes [Figure 20-23-33].
on the piston.

Assembly (Cont'd)
Figure 20-23-34
P7425

P-7427
Figure 20-23-37
Install the rod seal on the rod seal to [Figure 20-23-34].

Figure 20-23-35
N-22359
Install the wiper seal (Item 1) [Figure 20-23-37] with the

wiper toward the outside of the head.
N20613

23-35].

Assembly (Cont'd)
Figure 20-23-38
2
P-53247
3

Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-23-38].
Figure 20-23-39
1 2 3
P16294A
Install the head (Item 1) and piston (Item 2) [Figure 20-

23-39].
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the seal kit.
Grease the piston where the nut contacts the piston. do

Install the nut (Item 3) [Figure 20-23-39]
Put the base end of the hydraulic cylinder in a vise.


MAIN RELIEF VALVE (EARLY MODELS) NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19 mm (0.75 in) in
Description diameter and connected directly to the
hydraulic tester without using any type of
The main relief valve limits the hydraulic system pressure quick coupler on the connection to the tester.
by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See This procedure will require one operator in the cab and
Hydraulic System on Page SPEC-10-4.) one operator running the tester.
The main relief valve is adjustable and is located on the Figure 20-30-1
hydraulic control valve near the bottom, facing the front of
the loader.
Testing 2
IMPORTANT
1
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

P106632
WARNING Connect the IN port (Item 1) [Figure 20-30-1] of the

hydraulic tester to the bottom (female) quick coupler on
When the engine is running during service, the the loader.
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can Connect the OUT port (Item 2) [Figure 20-30-1] of the
cause injury or death. hydraulic tester to the top (male) quick coupler on the
W-2006-1209
loader.
Figure 20-30-2
WARNING
W-2017-0286 2
1
procedure:
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit NA3172
Lift and block the loader. (See Procedure on Page 10-10-

1.) Start the engine and run at low idle. Press the
AUXILIARY HYDRAULICS Button (Item 1) once to
engage the auxiliary hydraulics. The light (Item 2)
[Figure 20-30-2] will be on.

MAIN RELIEF VALVE (EARLY MODELS) (CONTD) Figure 20-30-4
Testing (Contd)
Figure 20-30-3
1
P106632
Warm the fluid to 60C (140F) by turning the restrictor

P101611 control (Item 1) [Figure 20-30-4] clockwise on the tester
until it reads 6895 kPa (69 bar) (1000 psi).
After activating the auxiliary hydraulics, press the NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
continuous flow control switch (Item 1) [Figure 20-30-3] psi).

to allow constant auxiliary hydraulic oil flow to the front
female coupler (female coupler is pressurized). Turn the restrictor control (Item 1) [Figure 20-30-4]
counterclockwise to obtain free flow.
To stop continuous auxiliary hydraulic oil flow, press the
front auxiliary hydraulic switch (Item 1) [Figure 20-30-3] Check the free flow specification (See Hydraulic System
a second time. on Page SPEC-10-4.)
NOTE: When the operator is seated and raises the NOTE: If free flow is below specification perform the
seat bar, the Auxiliary Hydraulic System direct pump test.
(Front and Rear) will deactivate.
Start turning the restrictor clockwise, causing more
If no flow is indicated on the tester, the hoses are restriction on the flow. The fluid flow should drop off
connected wrong. With the hoses connected correctly, slightly until the pressure reaches approximately 21374
increase the engine speed to full rpm. kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
kPa (237,9 - 241,3 bar) (3450 - 3500 psi) the flow should
be at 0 L/min (0 U.S. gpm). DO NOT exceed 25510 kPa
(255 bar) (3700 psi). Turn the restrictor (Item 1) [Figure
20-30-4] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
If pressure does not match the above information, The

main relief valve needs to be adjusted.
After adjusting the main relief valve, retest the main relief
valve.

MAIN RELIEF VALVE (EARLY MODELS) (CONTD) Removal And Installation
Adjusting

IMPORTANT
Figure 20-30-5
damage the system.
1 I-2003-0888
2
Clean the area around the control valve.
Figure 20-30-6
P-85573

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

out until the pressure is correct. Turning the screw in will
increase pressure.
Retest the main relief valve after adjusting.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
P-85573
pressure setting of the new relief valve.
Remove the main relief valve (Item 1) [Figure 20-30-6]
Installation: Tighten the main relief valve to 51 - 62 Nm

(38 - 45 ft-lb) torque.

MAIN RELIEF VALVE (EARLY MODELS) (CONTD)
Figure 20-30-7
1
3
P-37689
Remove the O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-30-7] from the main relief valve.

Remove the seal (Item 3) [Figure 20-30-7] and the O-
ring located under the seal.
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-30-7]. Install the main relief valve.
Retest the main relief valve after installing. (See Testing

on Page 20-30-1.)

MAIN RELIEF VALVE (LATE MODELS)
Description
The main relief valve and auxiliary relief valve limit 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-10-4.)
Figure 20-31-1

P107749A
The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve (Item 1) is
located on the hydraulic control valve near the bottom,
facing the front of the loader. The auxiliary relief valve (if
equipped) (Item 2) [Figure 20-31-1] is located on the top
of the control valve facing the left side of the machine.

MAIN RELIEF VALVES (LATE MODELS) (CONTD) Raise the operator cab. (See Raising on Page 10-30-2.)
Testing Figure 20-31-3
WARNING
2
When the engine is running during service, the
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can 1
cause injury or death.
W-2006-1209

procedure:
P107935
MEL1355-3 - Pressure gauge 34,5 MPa (345 bar) (5000
psi)
MEL1723 - Coupler Connect the test coupler (Item 1) to the control valve
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased coupler (Item 2) [Figure 20-31-3].
locally. Must be rated for pressures above 4,5 MPa (345
bar) (5000 psi). Route the test gauge so it can be used in the operator

cab when lowered. Make sure the hose will not interfere
with any moving parts.
WARNING Lower the operator cab. (See Raising on Page 10-30-2.)
NOTE: Do not have any attachment connected to the

Hydraulic fluid escaping under pressure can have loader auxiliary quick couplers while testing.
and possible death if proper medical treatment by a
immediately.
W-2145-0290
Figure 20-31-2
1 3
P107936
Install the gauge (Item 1) and coupler (Item 2) to the test

hose (Item 3) [Figure 20-31-2].

MAIN RELIEF VALVES (LATE MODELS) (CONTD) Figure 20-31-4
Testing (Contd)
Enter the loader and engage the parking brake. Start the
engine.
Increase the engine speed to full RPM and make sure

the hydraulic oil is at 60C (140F).
2
NOTE: Remove the bucket or attachment from the 1
loader before testing.
Testing Main Relief Pressure Without Auxiliary Relief

Valve
P-76460C
The main relief valve setting is 23,8 - 24,5 MPa (238 -
245 bar) (3450 - 3550 psi).
Press the auxiliary hydraulics button (Item 1) [Figure 20-
Power the loader lift arms down on the stops and monitor 31-4] to activate the auxiliary hydraulics.
the test gauge for the relief pressure setting
NOTE: The auxiliary indicator (Item 2) [Figure 20-31-
If the relief pressure is not correct, stop the engine and 4] will illuminate when activated.
adjust the relief valve (See Main Relief Valve Adjustment

on Page 20-31-4.). Figure 20-31-5
Right
Testing Main Relief Pressure If Equipped With Auxiliary Steering
Relief Valve Lever
Control
If equipped with the optional auxiliary relief valve, the
main relief valve setting is 25,5 - 26,2 MPa (255 - 262
bar) (3700 - 3800 psi).
Power the loader lift arms down on the stops and monitor 1
the test gauge for the relief pressure setting
If the relief pressure is not correct, stop the engine and

adjust the relief valve (See Main Relief Valve Adjustment
on Page 20-31-4.).
P107006B
Testing Auxiliary Relief Pressure
The auxiliary relief valve setting is 23.8 - 24.5 MPa (238 - Move the front auxiliary hydraulic switch (Item 1) [Figure
245 bar) (3450 - 3550 psi). 20-31-5] to the left or right and monitor the test gauge for
the relief pressure setting.
If the relief pressure is not correct, stop the engine and

adjust the relief valve (See Auxiliary Relief Valve
Adjustment on Page 20-31-5.).
Stop the machine and exit the loader.

MAIN RELIEF VALVES (LATE MODELS) (CONTD) Main Relief Valve Removal And Installation
Main Relief Valve Adjustment
Figure 20-31-6
IMPORTANT
damage the system.
I-2003-0888
2
Clean the area around the control valve.
1 Figure 20-31-7
P107744
Loosen the lock nut (Item 1) [Figure 20-31-6].

Turn the adjustment screw (Item 2) [Figure 20-31-6] in or
out until the pressure is correct. Turning the screw in will
increase pressure. 1
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve.
P107743
Remove the main relief valve (Item 1) [Figure 20-31-7].

MAIN RELIEF VALVES (LATE MODELS) (CONTD) Auxiliary Relief Valve Adjustment
Main Relief Valve Removal And Installation (Contd) Figure 20-31-9
Figure 20-31-8
1 2
P107747
P107745A
Loosen the lock nut (Item 1) [Figure 20-31-9].
Remove the O-ring (Item 1) and back-up washer (Item 2) Turn the adjustment screw (Item 2) [Figure 20-31-9] in or
[Figure 20-31-8] from the relief valve. out until the pressure is correct. Turning the screw in will

increase pressure.
Clean the relief valve in clean solvent. Use air pressure to
dry the valve. NOTE: If the correct pressure can not be reached,
replace the auxiliary relief valve. Test the
Install a new O-ring (Item 1) and back-up washer (Item 2) pressure setting of the new relief valve.
[Figure 20-31-8]. Install the main relief valve and tighten.
Installation: Tighten the relief valve to 51 - 62 Nm (38 -

45 ft-lb) torque.
Test the relief valve (See Testing on Page 20-31-2.).

MAIN RELIEF VALVES (LATE MODELS) (CONTD) Figure 20-31-11
Auxiliary Relief Valve Removal And Installation
IMPORTANT 2
damage the system.
I-2003-0888 1
P107627
Clean the area around the control valve. Remove the O-rings (Item 1) and back-up washer (Item
2) [Figure 20-31-11] from the auxiliary relief valve.
Figure 20-31-10
Clean the relief valve in clean solvent. Use air pressure to
dry the valve.

Install new O-rings (Item 1) and back-up washer (Item 2)
[Figure 20-31-11]. Install the relief valve and tighten.

45 ft-lb) torque.
Test the relief valve (See Testing on Page 20-31-2.).
P107746
Remove the auxiliary relief valve (Item 1) [Figure 20-31-

10].

HYDRAULIC CONTROL VALVE (EARLY MODELS) Removal And Installation
Description
Figure 20-40-1
DANGER
1
P-90328
AVOID DEATH
P-90337
NOTE: The 90 fitting (Item 1) [Figure 20-40-1] has support. Replace if damaged.
been replaced with a tee fitting on late model D-1009-0409

machines.
The hydraulic control valve is located inside the main

frame on the right hand side, below the operators cab. WARNING
The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the Never work on a machine with the lift arms up unless
lift, tilt and auxiliary functions. the lift arms are secured by an approved lift arm
The lift and tilt functions in the hydraulic control valve are support device can allow the lift arms or attachment
operated using electronic control handles / levers that to fall and cause injury or death.
send an electronic signal to the electronic actuators to W-2059-0598
move the lift and tilt spools in the control valve.
The auxiliary function is operated by pilot pressure.

There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
IMPORTANT
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift. When repairing hydrostatic and hydraulic systems,
The hydraulic control valve also contains a main relief parts clean. Always use caps and plugs on hoses,
valve which is adjustable. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (EARLY MODELS) Figure 20-40-3
(CONTD)
Raise the lift arms and install an approved lift arm

support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Drain the hydraulic reservoir. (See Removing And

1
Replacing Hydraulic Fluid on Page 10-130-2.)
Remove the control panel. (See Removal And Installation

on Page 50-100-1.)
P106420
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. Remove the fuel hose (Item 1) [Figure 20-40-3] from the
filler neck.
Clean area around control valve.
Figure 20-40-4
Open rear door.

Figure 20-40-2 1
1 P106421
P106581 Remove the bolts (Item 1) [Figure 20-40-4].
Disconnect the harness (Item 1) [Figure 20-40-2] from

the bottom of the filter.

(CONTD)
Figure 20-40-5
1
P101614
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
P10422 to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
Remove the clamp / hose (Item 1) [Figure 20-40-5] from 1) [Figure 20-40-6].
the tank.

Figure 20-40-7
NOTE: Plug the fuel tank opening.
1
IMPORTANT
parts clean. Always use caps and plugs on hoses, 2
damage the system.
I-2003-0888
P101616
Cut and remove the cable ties (Item 1). Disconnect the
actuator wire harness (Item 2) [Figure 20-40-7].

(CONTD)
Removal And Installation (Cont'd)
Figure 20-40-8
2
2
2
1
P101618
1
Remove the bolt (Item 1) [Figure 20-40-10] and tubeline

clamp.
P101615
Remove the tubelines (Item 2) [Figure 20-40-10] from
the control valve to the front auxiliary hydraulic couplers
Disconnect the wire harness (Item 1) [Figure 20-40-8]
from the control valve.

Figure 20-40-11

control valve to fan motor.
Figure 20-40-9
P101619
1
Remove the bolt (Item 1) [Figure 20-40-11] and clamp.
P107219
Disconnect the hose (Item 1) [Figure 20-40-9] that

routes from the control valve to the brake valve.

routes from the control valve to the fan motor.

(CONTD)
Removal And Installation (Cont'd) 1
Figure 20-40-12
2
3
1
1
4
P101621
1 Remove the hose (Item 1) [Figure 20-40-13] from the

control valve to the junction block at the rear of the
P101620 loader.
Remove the change pressure tubeline (Item 2) [Figure

Remove the tubelines (Item 1) [Figure 20-40-12] from 20-40-13] from the control valve.
the control valve to the junction block at the rear of the

loader. Remove the hose (Item 3) [Figure 20-40-13] from the
control valve to the lift arm bypass control valve.
Disconnect the lift arm bypass drain hose (Item 2)
[Figure 20-40-12] from the control valve. Remove the hose (Item 4) [Figure 20-40-13] from the
bottom of the control valve to the outlet of the hydraulic
pump.
Figure 20-40-14
1
1
P101622
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-40-14].
Remove the control valve from the loader.

(CONTD)
Actuator Removal And Installation (In Loader)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-1.) Remove the two bolts (Item 1) [Figure 20-40-16] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 Nm (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.

Figure 20-40-17
Figure 20-40-15
2 2
2
1
1
P-54566
P101616
Pull the actuator (Item 1) [Figure 20-40-17] away from

Cut and remove the cable ties (Item 1) [Figure 20-40- the control valve.
15].
Use a punch to remove the actuator pin (Item 2) [Figure
Disconnect the actuator wire harness (Item 2) [Figure 20-40-17] from the actuator and spool.
20-40-15].
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration on Page 60-170-4.)

HYDRAULIC CONTROL VALVE (EARLY MODELS) Actuator Removal And Installation (Out Of Loader)
(CONTD)
(Contd) Figure 20-40-19
Figure 20-40-18
1
1
2
1
P101623
P-54568
the tilt actuator.
Inspect the O-ring (Item 1) [Figure 20-40-18] on the face

of the actuator and replace as needed. Installation: Tighten the bolts to 10,2 - 11,3 Nm (90 -
100 in-lb) torque.
Inspect the linkage pin (Item 2) [Figure 20-40-18] and
replace as needed. Figure 20-40-20
P101624
Slide the actuator retainer (Item 1) [Figure 20-40-20]

away from the control valve.
Pull the actuator away from the control valve.

(CONTD)
Actuator Removal And Installation (Out of Loader)

1
(Contd)
Figure 20-40-21
P101626
1 Remove the two bolts (Item 1) [Figure 20-40-23] from

the lift actuator.
P101625 Installation: Tighten the bolts to 10,2 - 11,3 Nm (90 -

100 in-lb) torque.
Using a punch and a hammer, remove the linkage pin

Figure 20-40-24
(Item 1) [Figure 20-40-21] from the actuator and the tilt
spool.
Remove the actuator and linkage pin from the valve.
Figure 20-40-22
1
P101627
2 Slide the actuator retainer (Item 1) [Figure 20-40-24]

P-54340 Pull the actuator away from the control valve.

of the actuator and replace as needed.

replace as needed.

(CONTD)

(Contd) 2
Figure 20-40-25
1
3 P101629
1 NOTE: The two long bolts (Item 1) are used to install

the lift actuator and retainer (Item 2).
The two short bolts (Item 3) are used to install
P101628 the tilt actuator and the retainer (Item 4)
[Figure 20-40-27].

(Item 1) [Figure 20-40-25] from the actuator and the tilt 100 in-lb) torque (Item 1) [Figure 20-40-27]
spool.
Figure 20-40-26
P-54340


replace as needed.

HYDRAULIC CONTROL VALVE (EARLY MODELS)
(CONTD)
Identification Chart
Figure 20-40-28
AR C3
J2
C2 J4
E3
E3 B3
F2
G2
G1 A3
D5
A2
B2 D6
E2
F4
D4 C4 D3
D1
H2 D2
A1
H3
B1

J3 E1
F1 MR
H1 J1 C1
NA5825
ITEM ITEM
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 G1 Auxiliary Solenoid Stem
C1 Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS Solenoid
C3 Load Check Valve Auxiliary Function
H2 BICS Lock Valve (Tilt)
C4 Check Valve
D1 Anti-Cavitation Valve H3 BICS Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief / Anti-Cavitation Valve 27549 kPa J2 Outlet Fluid Flow (Return to Tank)
(275,8 bar) (4000 psi) J3 Lift Arm Bypass Orifice
Lift (Base End)
J4 Drain (Case)
D3 Port Relief / Anti-Cavitation Valve 27549 kPa
MR Main Relief Valve 24132 kPa (241 bar)
(275,8 bar) (4000 psi)
(3500 psi) (optional)
Tilt (Base End)
MR Main Relief Valve 27579 kPa (276 bar)
(275,8 bar) (4000 psi)
Tilt (Rod End) AR Auxiliary Relief Valve 24132 kPa (241 bar)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27549 kPa (275,8 bar) (4000 psi) (optional)
D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
27549 kPa (275 bar) (4000 psi) (optional)

HYDRAULIC CONTROL VALVE (EARLY MODELS) Lift Load Check Valve Removal And Installation
(CONTD)
Figure 20-40-31
Mount Bracket Removal And Installation
Figure 20-40-29
P-90308
P101630 Remove the charge tubeline (Item 1) [Figure 20-40-31]

from the BICS valve fitting on the top of the lift load
check valve.
Support the mount bracket (Item 1) [Figure 20-40-29].

Figure 20-40-32
Figure 20-40-30
2 1
P-90310
P101631
Remove the lift load check valve (Item 1) [Figure 20-40-

Remove the two control valve bracket bolts (Item 1) 32] and fitting from the top of the control valve.
[Figure 20-40-30].
Installation: Lubricate the O-ring and threads. Tighten
Remove the two frame bolts (Item 2) [Figure 20-40-30] the load check valve to 75 - 88 Nm (55 - 65 ft-lb) torque.
Installation: Torque the two frame bolts (Item 2) [Figure

20-40-30] to 406 - 447 Nm (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

(CONTD)
Lift Load Check Valve Removal And Installation

(Contd)
2
Figure 20-40-33
1
1
2 P-90311
Remove the tilt section load check valve (Item 1) [Figure

20-40-34].
3
P-90309 Remove the auxiliary section load check valve (Item 2)
[Figure 20-40-34].
Remove and install new O-rings (Item 1) and back-up

Installation: Tighten the values to 52 - 61 Nm (38 - 45
ring (Item 2) [Figure 20-40-33]. ft-lb) torque.
Inspect the free movement load check valve and spring NOTE: The tilt and auxiliary load check valves are
(Item 3) [Figure 20-40-33]. interchangeable.
Figure 20-40-35
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system. 3
I-2003-0888 4
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-35].
Inspect the orifice (Item 3) [Figure 20-40-35] in the

poppet to be sure it is not plugged.
Remove the O-ring (Item 4) [Figure 20-40-35].

HYDRAULIC CONTROL VALVE (EARLY MODELS) Port Relief / Anti-Cavitation Valve Removal And
(CONTD) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-38

Rod End)
Figure 20-40-36
P-90314
P-90314 Remove the lift section port relief / anti cavitation valve
(Item 1) [Figure 20-40-38].
Remove the lift section anti-cavitation valve (Item 1)

[Figure 20-40-36]. 45 ft-lb) torque.
Installation: Tighten the plug to 52 - 61 Nm (38 - 45 ft- Figure 20-40-39

lb) torque.
Figure 20-40-37
1
1
3
4
P-51640
P-90312 Remove and replace the O-ring (Item 1) [Figure 20-40-

39].

20-40-37].

poppet to be sure it is not plugged.
Remove and replace the O-ring (Item 4) [Figure 20-40-

37].

HYDRAULIC CONTROL VALVE (EARLY MODELS) Port Relief / Anti-Cavitation Valve Removal And
(CONTD) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-42

Installation (Tilt, Base End)
Figure 20-40-40
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-42].
Remove the tilt port relief / anti cavitation valve (Item 1)

Installation: Tighten the relief valve to 52 - 61 Nm (38-
[Figure 20-40-40]. 45 ft-lb) torque.
Installation: Tighten the relief valve to 52 - 61 Nm (38 - Figure 20-40-43

45 ft-lb) torque.
Figure 20-40-41
P-51640
P51640 Remove and replace the O-ring (Item 1) [Figure 20-40-

43].

41].

(CONTD)
Port Relief Valve Removal And Installation (Auxiliary) 1
Figure 20-40-44
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-46].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-44] Installation: Tighten the relief valve to 52 - 61 Nm (38 -
from the auxiliary circuit of the control valve.

45 ft-lb) torque.
Installation: Tighten the plug to 52 - 61 Nm (38 - 45 ft- Figure 20-40-47

lb) torque.
Figure 20-40-45
P-51640
P-90318 Remove and replace the O-ring (Item 1) [Figure 20-40-

47].
Remove and replace the O-rings (Item 1) [Figure 20-40-

45].

(CONTD)
Plug Removal And Installation
Figure 20-40-48
P-93155
Remove the O-rings (Item 1) [Figure 20-40-50].
P-68016
Figure 20-40-49

1
P-51461
Remove the plugs (Item 1) [Figure 20-40-48] and

[Figure 20-40-49]
Installation: Tighten the plugs to 81,3 Nm (60 ft-lb)

torque.

HYDRAULIC CONTROL VALVE (EARLY MODELS) Lift Spool Removal And Installation
(CONTD)
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (Out Of Loader)
on Page 20-40-7.) Remove the end cap block from the control valve.
Figure 20-40-51 Figure 20-40-53
1 2

P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-40-51] from Remove the O-ring (Item 1) [Figure 20-40-53].
the end cap block.
Figure 20-40-54
Remove the two end cap block screws (Item 2) [Figure
20-40-51].
Installation: Tighten the screws to 10,5 - 11,5 Nm (95 -

105 in-lb) torque.
Figure 20-40-52
P-68047
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-54] from the lift spool.
1
P-90339
Remove the end cap block (Item 1) [Figure 20-40-52]


(CONTD)
Lift Spool Removal And Installation (Cont'd)
Figure 20-40-55
1
1
P-68045
1
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-57] from the control valve.
P-68043
Figure 20-40-58
Remove the two screws (Item 1) [Figure 20-40-55] from

the lift spool end cap.

Installation: Tighten to 10,5 - 11,5 Nm (95 - 105 in-lb)
torque.
Figure 20-40-56
P-68046
1 Remove the lift spool seal (Item 1) [Figure 20-40-58]

from the actuator end of the valve.
P-68044
Remove the lift spool end cap (Item 1) [Figure 20-40-56]


(CONTD)
Figure 20-40-59
1
Cut
14 mm Dia
(0.5625) 51 mm
(2.0)
P-51773
38 mm Install the spring tool (Item 1) [Figure 20-40-61] over the

(1.500) 19 mm centering spring.
(0.750) B-14674
Figure 20-40-62
To remove the spring assembly from the spool, a holding

fixture will have to be made from a 19 mm thick X 38 mm

wide x 51 mm long (0.750 inch thick x 0.500 inch wide x 1
2.0 inch long) piece of hardwood. Drill a 14 mm (0.5625
inch) hole in the center of the hardwood block. Cut the
block lengthwise [Figure 20-40-59].
Figure 20-40-60
N-190146
Remove the bolt (Item 1) [Figure 20-40-62].
Installation: Tighten the bolt to 10,5 - 11,5 Nm (95 - 105

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

P-51772
Clamp the hardwood blocks and spool in a vise [Figure

20-40-60].

(CONTD)
Lift Spool Disassembly and Assembly (Contd)
Figure 20-40-63
2
1
4 1
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in)

P-51776 drill.
Drill a hole all the way through the plug using a #36 tap
Remove the adapter (Item 1), collar (Item 2), spring (Item drill.
3) and washer (Item 4) [Figure 20-40-63].

Turn a 6 - 32 tap (Item 1) [Figure 20-40-65] into the plug.
Figure 20-40-64 Pull the tap and plug out of the spool. Be careful, do not
break the tap.
2 Clean all the debris from inside the spool bore.
1
NOTE: DO NOT USE Loctite ON THE STUD

THREADS.
P-51775
Remove the spool seal (Item 1) and the back-up washer

(Item 2) [Figure 20-40-64].

HYDRAULIC CONTROL VALVE (EARLY MODELS) Tilt Spool Removal And Installation
(CONTD)
Remove the end cap block. (See End Cap Block
Lift Spool Disassembly and Assembly (Contd) Removal And Installation on Page 20-40-17.)
Figure 20-40-66 Figure 20-40-68
2
1
P-74183
P-68049
Install the O-ring (Item 1) over the nipple on the plastic Remove the spacer (Item 1) and O-ring (Item 2) [Figure
plug (Item 2) [Figure 20-40-66].

20-40-68] from the tilt spool.
NOTE: Inspect the O-ring for damage. The lift spool Figure 20-40-69
will have an internal leak if there is damage to
the O-ring. Always replace the O-ring and
plastic plug. Inspect the lift spool before the
control valve is replaced.
1
Figure 20-40-67
P-90321
Disconnect the two tubelines (Item 1) [Figure 20-40-69].
Remove the three screws (Item 2) [Figure 20-40-69]

P-74184 from the spool centering block.

Install the plastic plug and O-ring in the spool [Figure 20- 105 in-lb) torque.
40-67].

HYDRAULIC CONTROL VALVE (EARLY MODELS) Tilt Spool Disassembly And Assembly
(CONTD)
Figure 20-40-72
Tilt Spool Removal And Installation (Contd)
Figure 20-40-70 Cut
14 mm Dia
(0.5625) 51 mm
(2.0)
2
38 mm
(1.500) 19 mm
1 (0.750) B-14674
P-90342 To remove the spring assembly from the spool, a holding

fixture will have to be made from a 19 mm thick X 38 mm
wide x 51 mm long (0.750 inch thick x 0.500 inch wide x
Remove the spool centering block (Item 1) [Figure 20- 2.0 inch long) piece of hardwood. Drill a 14 mm (0.5625
40-70] from the control valve.

inch) hole in the center of the hardwood block. Cut the
block lengthwise [Figure 20-40-72].
NOTE: Do not use anything other than hardwood
Figure 20-40-71 blocks to grip the spool or the spool will be
damaged.
Figure 20-40-73
P-68052
Remove the tilt spool, centering spring, back-up washer

P-51772
and spool seal (Item 1) [Figure 20-40-71].
Clamp the hardwood blocks and spool in a vise [Figure

20-40-73].

(CONTD)
Tilt Spool Disassembly And Assembly (Contd)

2 1
Figure 20-40-74
3
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-76].
N-18942
Figure 20-40-77
Put the linkage end of the spool in the vice [Figure 20- 2
40-74].

1
Install the spring tool (Item 1) [Figure 20-40-74] over the

centering spring.
Figure 20-40-75
N-18943
Remove the spool seal (Item 1) and the back-up washer

(Item 2) [Figure 20-40-77].
N-19014
Remove the bolt (Item 1) [Figure 20-40-75] holding the

centering spring to the spool.

in-lb) torque.

(CONTD)
Auxiliary Spool Removal And Installation
Figure 20-40-78
2
1
2
P-68054
1
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-80] from the auxiliary spool.
P-90321
Figure 20-40-81
Disconnect the two tubelines (Item 1) [Figure 20-40-78]

from the spool centering block.

from the spool centering block.

105 in-lb) torque.
2
1
Remove the spool centering block from the control valve.
Figure 20-40-79
P-68076
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-81] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

2 20-40-81] must be replaced, replace the
retainer on the opposite end.
P-68053


20-40-79] must be replaced, replace the
retainer on the opposite end.

HYDRAULIC CONTROL VALVE (EARLY MODELS) Auxiliary Solenoid Removal And Installation
(CONTD)
Figure 20-40-84
Auxiliary Spool Removal And Installation (Contd)
Figure 20-40-82
2
1
2
2 P-90337
P-68077 Remove the screws (Item 1) [Figure 20-40-84] from both

solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the screws to 2,3 - 2,7 Nm (21.6 -

26.4 in-lb) torque.
Figure 20-40-83 Remove the solenoids (Item 2) [Figure 20-40-84].
Figure 20-40-85
P-68078
P-85556
Remove the auxiliary spool (Item 1) [Figure 20-40-83].
Remove the O-rings (Item 1) [Figure 20-40-85] from the

solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.1 - 6.1 ohm.

(CONTD)
Solenoid Removal And Installation
Figure 20-40-86 1
P-90346
Remove the solenoid stem (Item 1) [Figure 20-40-88].
P-90337 Installation: Tighten the stem to 27 - 33 Nm (20 - 24 ft-

lb) torque.
Remove the nut (Item 1) [Figure 20-40-86] from the Figure 20-40-89
solenoid stem.

Installation: Tighten the nut to 6 Nm (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-86]. 3

2
Figure 20-40-87
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-89] from the stem.

N-18693A
Inspect all parts for wear and damage. Replace any worn
or damaged parts.
Remove the O-rings (Item 1) [Figure 20-40-87] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-89] may be
cleaned with solvent. If it is torn the stem must
Use an ohmmeter to measure the solenoid coil to be replaced.
resistance.

(CONTD)
Lock Valve Removal And Installation
Figure 20-40-90
1
2 P-51792
Remove the tilt lock valve (Item 1) [Figure 20-40-92]

P-90310
Installation: Tighten the valve to 27 - 33 Nm (20 - 24 ft-
lb) torque.
Locate the two BICS lock valves. The valve (Item 1)
located towards the front of the loader is for the tilt circuit.

Figure 20-40-93
The valve (Item 2) [Figure 20-40-90] located towards the
rear of the loader is for the lift circuit.
Figure 20-40-91
1
1
1
1
1
2
2
2
P-51564

P-90321 [Figure 20-40-93] from the valve.
Remove the lift lock valve (Item 1) [Figure 20-40-91]


lb) torque.

HYDRAULIC CONTROL VALVE (EARLY MODELS) Main Relief Valve Removal And Installation
(CONTD)
Figure 20-40-96
Lift Arm Bypass Orifice Inspection
Figure 20-40-94
1
P-51794
P-90308 Remove the main relief valve (Item 1) [Figure 20-40-96].

Remove the fitting (Item 1) [Figure 20-40-94] from the lb) torque.
valve.

Figure 20-40-97
Figure 20-40-95
1
1
3
P-90344
P-51437
Remove the O-ring (Item 1), back-up ring (Item 2) and

Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- seal (Item 3) [Figure 20-40-97] from the relief valve.
95].
Remove the O-ring located under the seal (Item 3)
NOTE: This orifice is not removable from the valve [Figure 20-40-97].
casting.

(CONTD)
Check Valve Removal And Installation
Figure 20-40-98
1
P-68869
P-90308 Figure 20-40-101
Remove the tubeline (Item 1) [Figure 20-40-98].

Figure 20-40-99
1 1
P-90326
Inspect the screen (Item 1) [Figure 20-40-101].
P-90310
Remove the check valve fitting (Item 1) [Figure 20-40-

99] from the hydraulic control valve.
Installation: Tighten the fitting to 27 - 33 Nm (20 - 24 ft-

lb) torque.


HYDRAULIC CONTROL VALVE (LATE MODELS) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P107847
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operators cab. D-1009-0409

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt, and auxiliary functions. WARNING
The lift and tilt functions in the hydraulic control valve are
operated using electronic control handles / levers that Never work on a machine with the lift arms up unless
send an electronic signal to the electronic actuators to the lift arms are secured by an approved lift arm
move the lift and tilt spools in the control valve. support device. Failure to use an approved lift arm
The auxiliary function is operated by pilot pressure. to fall and cause injury or death.
There is one solenoid located by each side of the spool. W-2059-0598
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.
The hydraulic control valve is designed with two relief

IMPORTANT
valve ports. The main relief valve is used on the 800, 700,
and 600 series loaders. The auxiliary relief valve is When repairing hydrostatic and hydraulic systems,
standard on the 800 series and may be present on the clean the work area before disassembly and keep all
700 and 600 series. parts clean. Always use caps and plugs on hoses,
The relief valves are adjustable and located on the damage the system.
I-2003-0888
hydraulic control valve. The main relief valve port is
adjacent to the actuator side. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

HYDRAULIC CONTROL VALVE (LATE MODELS) Figure 20-41-3
(CONTD)

support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)

1

on Page 50-100-1.)
P106420
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. Remove the fuel hose (Item 1) [Figure 20-41-3] from the
filler neck.
Clean area around control valve.
Figure 20-41-4
Open rear door.

Figure 20-41-2 1
1 P106421
P106581 Remove the bolts (Item 1) [Figure 20-41-4].


(CONTD)
Figure 20-41-5
1
P-90267
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
P10422 to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
Remove the clamp / hose (Item 1) [Figure 20-41-5] from 1) [Figure 20-41-6].
the tank.

Figure 20-41-7
1
IMPORTANT
damage the system.
I-2003-0888
P101616
Cut and remove the cable ties (Item 1). Disconnect the
actuator wire harness (Item 2) [Figure 20-41-7].

(CONTD)
Figure 20-41-8
2
2
2
1
P101618
1
Remove the bolt (Item 1) [Figure 20-41-10] and tubeline

clamp.
P101615
Remove the tubelines (Item 2) [Figure 20-41-10] from
the control valve to the front auxiliary hydraulic couplers

Figure 20-41-11

control valve to fan motor.
Figure 20-41-9
P101619
1
Remove the bolt (Item 1) [Figure 20-41-11] and clamp.
P107219

routes from the control valve to the brake valve.

routes from the control valve to the fan motor.

(CONTD)
Figure 20-41-12
2
3
1
1
4
P101621
1 Remove the hose (Item 1) [Figure 20-41-13] from the

control valve to the junction block at the rear of the
P101620 loader.
Remove the change pressure tubeline (Item 2) [Figure

Remove the tubelines (Item 1) [Figure 20-41-12] from 20-41-13] from the control valve.
the control valve to the junction block at the rear of the

loader. Remove the hose (Item 3) [Figure 20-41-13] from the
control valve to the lift arm bypass control valve.
Disconnect the lift arm bypass drain hose (Item 2)
[Figure 20-41-12] from the control valve. Remove the hose (Item 4) [Figure 20-41-13] from the
bottom of the control valve to the outlet of the hydraulic
pump.
Figure 20-41-14
1
1
P101622
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-14].

(CONTD)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-1.) Remove the two bolts (Item 1) [Figure 20-41-16] from
the actuator retainer.
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.

Figure 20-41-17
Figure 20-41-15
2 2
2
1
1
P-54566
P101616
Pull the actuator (Item 1) [Figure 20-41-17] away from

Cut and remove the cable ties (Item 1) [Figure 20-41- the control valve.
15].
Use a punch to remove the actuator pin (Item 2) [Figure
Disconnect the actuator wire harness (Item 2) [Figure 20-41-17] from the actuator and spool.
20-41-15].
Remove the actuator from the hydraulic control valve.

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration on Page 60-170-4.)

HYDRAULIC CONTROL VALVE (LATE MODELS) Actuator Removal And Installation (Out Of Loader)
(CONTD)
(Contd) Figure 20-41-19
Figure 20-41-18
1
1
2
1
P101623
P-54568
the tilt actuator.

of the actuator and replace as needed. Installation: Tighten the bolts to 10,2 - 11,3 Nm (90 -
100 in-lb) torque.
replace as needed. Figure 20-41-20
P101624
Slide the actuator retainer (Item 1) [Figure 20-41-20]

Pull the actuator away from the control valve.

(CONTD)

1
(Contd)
Figure 20-41-21
P101626
1 Remove the two bolts (Item 1) [Figure 20-41-23] from

the lift actuator.
P101625 Installation: Tighten the bolts to 10,2 - 11,3 Nm (90 -

100 in-lb) torque.

Figure 20-41-24
(Item 1) [Figure 20-41-21] from the actuator and the tilt
spool.
Figure 20-41-22
1
P101627
2 Slide the actuator retainer (Item 1) [Figure 20-41-24]

P-54340 Pull the actuator away from the control valve.


replace as needed.

(CONTD)

(Contd) 2
Figure 20-41-25
1
3 P101629
1 NOTE: The two long bolts (Item 1) are used to install

the lift actuator and retainer (Item 2).
The two short bolts (Item 3) are used to install
P101628 the tilt actuator and the retainer (Item 4)
[Figure 20-41-27].

(Item 1) [Figure 20-41-25] from the actuator and the tilt 100 in-lb) torque (Item 1) [Figure 20-41-27]
spool.
Figure 20-41-26
P-54340


replace as needed.

HYDRAULIC CONTROL VALVE (LATE MODELS)
(CONTD)
Figure 20-41-28
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1

F1 MR C1
H1
J3
J1
NA5825
ITEM ITEM
A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulic Rod End E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Base End F1 Lift Spool
C1 Load Check F2 Tilt Spool
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Solenoid
D1 Anti-Cavitation Valve
H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve 27579 kPa H3 BICS Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
J3 Lift Arm Bypass Orifice
(2756 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve 27579 kPa MR Main Relief Valve 24132 kPa (241 bar)
(276 bar) (4000 psi) (3500 psi) (Standard)
Tilt (Rod End) MR Main Relief Valve 27579 kPa (276 bar)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) (4000 psi) (Optional)
27579 kPa (276 bar) (4000 psi) (Optional) AR Auxiliary Relief Valve 24132 kPa (241 bar)
(3500 psi) (Optional)

HYDRAULIC CONTROL VALVE (LATE MODELS) Lift Load Check Valve Removal And Installation
(CONTD)
Mount Bracket Removal And Installation
Figure 20-41-29 IMPORTANT

1 When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Figure 20-41-31
P101630
Support the mount bracket (Item 1) [Figure 20-41-29].

Figure 20-41-30 1
2
P107848
Remove the charge tubeline (Item 1) [Figure 20-41-31]

from the BICS valve fitting on the top of the lift load
check valve.
P101631
Remove the two control valve bracket bolts (Item 1)

[Figure 20-41-30].
Remove the two frame bolts (Item 2) [Figure 20-41-30]
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-30] to 406 - 447 Nm (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (LATE MODELS) Load Check Valve Removal And Installation (Tilt And
(CONTD) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-34

(Contd)
Figure 20-41-32
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
34].
Remove the lift load check valve (Item 1) [Figure 20-41-

32] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-41-34].
tighten to 68 - 94 Nm (50 - 70 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are
Figure 20-41-33 interchangeable.
Figure 20-41-35
1
5
1
2
2
3 4 4
P107716
3
P107624
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-33].
Inspect the spring (Item 3) and the free movement load 20-41-35].
check valve (Item 4) [Figure 20-41-33].
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-41-33].
Installation: Install a new O-ring (Item 4) [Figure 20-41-
35] and lubricate with oil before installing. Tighten the
plug to 51 - 61 Nm (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (LATE MODELS) Port Relief / Anti-Cavitation Valve Removal And
(CONTD) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-38

Rod End)
Figure 20-41-36
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-38].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-41-36]. Figure 20-41-39
Figure 20-41-37
1
2
2
4 1
P107952
3
P107624
Remove the O-ring (Item 1) [Figure 20-41-39] from the
port relief / anti cavitation relief valve.
20-41-37]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-39] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-41-37] in the needed.
poppet to make sure it is not plugged.
Installation: Tighten the port relief / anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 Nm (38 - 45 ft-lb) torque.
37] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 Nm (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 Nm (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (LATE MODELS) Port Relief / Anti-Cavitation Valve Removal And
(CONTD) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-42

Installation (Tilt, Base End)
Figure 20-41-40
P107628
P107628 Remove the tilt port relief / anti cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-42]
from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1)

[Figure 20-41-40] from the base end of the tilt section. Figure 20-41-43
Figure 20-41-41
1
1
P107952
P107629
port relief / anti cavitation relief valve.
port relief / anti cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-43] for wear or damage and replace as
Installation: Tighten to 51 - 61 Nm (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief / anti-cavitation relief

valve to 51 - 61 Nm (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 Nm (35 ft-lb) torque.

(CONTD)
Port Relief Valve Removal And Installation
Figure 20-41-44
P107628

P107628
Remove the port relief plug (Item 1) [Figure 20-41-44] Figure 20-41-47

Figure 20-41-45
1
1
2
P107629
P107630 Remove the O-ring (Item 1) [Figure 20-41-47] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 Nm (38 - 45 ft-lb) torque.
[Figure 20-41-45] from the port relief plug.
Installation: Tighten to 51 - 61 Nm (38 - 45 ft-lb) torque.

(CONTD)
Port Relief Valve Removal And Installation (Contd)
Figure 20-41-48
P107628

P107628
Remove the port relief plug (Item 1) [Figure 20-41-48] Figure 20-41-51

Figure 20-41-49
1
1
2
P107629
P107630 Remove the O-ring (Item 1) [Figure 20-41-51] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 Nm (38 - 45 ft-lb) torque.
[Figure 20-41-49] from the port relief plug.

(CONTD)
Plug Removal And Installation
Figure 20-41-52
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-54].
P107631
Figure 20-41-55
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-52].

Figure 20-41-53
1
P107633

plug.
P107633
Installation: Tighten to 81,3 Nm (60 ft-lb) torque.

plug.
Installation: Tighten to 81,3 Nm (60 ft-lb) torque.

HYDRAULIC CONTROL VALVE (LATE MODELS) Lift Spool Removal And Installation
(CONTD)
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-6.) Remove the end cap block from the control valve.
Figure 20-41-56 Figure 20-41-58

2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-56] from Remove the O-ring (Item 1) [Figure 20-41-58].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-41-56].
Figure 20-41-59
Installation: Lubricate the screws and tighten to 10,4 -
11,6 Nm (95 - 105 in-lb) torque.
Figure 20-41-57
1
P107753
1
P107852 20-41-59] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-57]


(CONTD)
Figure 20-41-60
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-62] from the control valve.
P107854
Figure 20-41-63
Remove the four screws (Item 1) [Figure 20-41-60] from

the spool centering block.

Installation: Lubricate the screws and tighten to 10,4 -
11,6 Nm (95 - 105 in-lb) torque.
Figure 20-41-61
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-41-63]

from the actuator end of the valve.
P107855
Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-41-61] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-41-

61] and lubricate lightly with oil before installation of the
spool centering block.

(CONTD)
Lift Spool Disassembly And Assembly
Figure 20-41-64
1
P107647

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-
41-64].

Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-67
Figure 20-41-65
3
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-41-67].
centering spring.

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

Removal And Installation on Page 20-41-18.)
Figure 20-41-68 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-70].
2 Figure 20-41-71
P107856

20-41-68] from the tilt spool.
Figure 20-41-69
P107770
Remove the spool seal (Item 1) [Figure 20-41-71].
P107769
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the spool centering block.

(CONTD)
Tilt Spool Disassembly And Assembly

2 1
Figure 20-41-72
3
N-18944B
3), and washer (Item 4) [Figure 20-41-74].
P107646
Put the actuator end of the spool in the vice [Figure 20-
41-72].

NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-41-73
P107647


in-lb) torque.

(CONTD)
Auxiliary Spool Removal And Installation
Figure 20-41-75
2
1
2 P107760

1 (Item 2) [Figure 20-41-77] from the auxiliary spool.
P107758
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.

Figure 20-41-78
retainer on the opposite end also.
Figure 20-41-76
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (LATE MODELS) Auxiliary Solenoid Removal And Installation
(CONTD)
Figure 20-41-80
Auxiliary Spool Removal And Installation (Contd)
Figure 20-41-79
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-41-80] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-41-79]. Remove the solenoids (Item 2) [Figure 20-41-80].

Installation: Tighten the screws to 2,3 - 2,7 Nm (21.4 -
23.9 in-lb) torque.
Figure 20-41-81
P107798

[Figure 20-41-81] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-41-81].

(CONTD)
Figure 20-41-82 1
P107857
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 Nm (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-82] from the Figure 20-41-85
solenoid stem.

Installation: Tighten the nut to 6 Nm (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-82]. 3

2
Figure 20-41-83
N-18694

[Figure 20-41-85] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-83] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-85] may be
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.

(CONTD)
Lock Valve Removal And Installation
Figure 20-41-86
1 2 P107937
The inside diameter of the BICS valve (Item 1) [Figure

20-41-88] is threaded for easier removal and installation.
P107858
Figure 20-41-89
Locate the two BICS lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-

86]. 1 3
Figure 20-41-87 2
1
P107767
Remove and inspect the spring (Item 2) and BICS

P107859 valve (Item 3) [Figure 20-41-89].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-41-87] from the back of the control valve.
Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 Nm (55 - 60 ft-lb) torque.

(CONTD)
Lock Valve Removal And Installation (Contd)
Figure 20-41-90
1 P107937
The inside diameter of the BICS valve (Item 1) [Figure

20-41-91] is threaded for easier removal and installation.
P107860
Figure 20-41-92
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-41-90] from the front of the control valve.

1 3
Installation: Lightly lubricate the lock valve retaining cap
O-ring and tighten to 75 - 81 Nm (55 - 60 ft-lb) torque. 2
P107767
Remove and inspect the spring (Item 2) and BICS

valve (Item 3) [Figure 20-41-92].

HYDRAULIC CONTROL VALVE (LATE MODELS) Main Relief Valve Removal And Installation
(CONTD)
Figure 20-41-95
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-93
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-41-95].
Figure 20-41-96
Remove the fitting (Item 1) [Figure 20-41-93] from the
valve.

Figure 20-41-94
1 1
P107659

P-51437 main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-41-
94].
NOTE: This orifice is not removable from the valve

casting.

HYDRAULIC CONTROL VALVE (LATE MODELS) Check Valve Removal And Installation
(CONTD)
Figure 20-41-99
Auxiliary Relief Valve Removal And Installation
Figure 20-41-97
1 1
P107848
P107863 Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100
Remove the auxiliary relief valve (Item 1) [Figure 20-41-
97].

Figure 20-41-98
2 1
P107864
1
Remove the check valve fitting (Item 1) [Figure 20-41-
P107627 100] from the hydraulic control valve.
Remove the O-rings (Item 1) [Figure 20-41-98] and

back-up ring (Item 2) [Figure 20-41-98] from the auxiliary
relief valve.

HYDRAULIC CONTROL VALVE (LATE MODELS)
(CONTD)
Check Valve Removal And Installation (Contd)
Figure 20-41-101
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-101].

Installation: Tighten the fitting to 27 - 33 Nm (20 - 24 ft-

lb) torque.

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

side of the machine.
The lift arm bypass control valve is manually operated by

turning the lift arm bypass control knob (Item 1) [Figure
20-50-1] 90 clockwise. Then pull up and hold the lift arm
bypass control knob. The valve releases the hydraulic
fluid from the base end of the lift cylinder(s) which allows
the lift arm to slowly come down to the transport position.
Testing
Figure 20-50-1

P-85290B P-85290A
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] 90 clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob must return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONTD) Figure 20-50-2

1
DANGER
3 2
P101612
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
Disconnecting or loosening any hydraulic 50-2] and loosen the nut on the lift arm bypass control
tubeline, hose, fitting, component or a part failure valve shaft.
Keep out of this area when lift arms are raised Remove the knob (Item 1). Remove the nut (Item 2)
unless supported by an approved lift arm [Figure 20-50-2] from the valve shaft.

D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
WARNING
W-2059-0598
Lower the lift arms.
IMPORTANT
damage the system.
I-2003-0888

LIFT ARM BYPASS CONTROL VALVE (CONTD) Disassembly And Assembly
Removal And Installation (Contd) Figure 20-50-5
Figure 20-50-3
1
2
3
2
1
P-85673
P101613
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Disconnect the hydraulic tubeline (Item 1) and hose (Item damage and replace if necessary.
2) [Figure 20-50-3].

Remove the two bolts and nuts (Item 3) [Figure 20-50-3]. lb) torque.
Installation: Tighten the bolts to 21 - 23 Nm (15 - 17 ft- Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
lb) torque. the valve block for damage and replace if necessary.
Remove the lift arm bypass valve.
Bracket Removal And Installation
Figure 20-50-4
P-85672
Remove the two bolts (Item 1) [Figure 20-50-4] to

replace the bypass valve bracket if necessary.


HYDRAULIC PUMP
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (CONT'D) Figure 20-60-1
Pump Test At Quick Couplers

2
IMPORTANT
position before you start the engine. 1
I-2024-0284
WARNING P106632
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-60-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-60-1] of the
hydraulic tester to the top (male) quick coupler on the

loader.
WARNING
W-2017-0286

procedure:

MEL10006 - Hydraulic Test Kit

1.)
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19 mm (0.75 in)
diameter and connected directly to the
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

Pump Test At Quick Couplers (Contd)
Figure 20-60-2
1
2 1
P-16903 P106632

P-76460C control (Item 1) [Figure 20-60-4] clockwise on the tester
so it reads 6895 kPa (69 bar) (1000 psi).
Start the engine and run at low idle. Press the Auxiliary
hydraulics button (Item 1) once to activate the auxiliary NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
hydraulics. The light (Item 2) [Figure 20-60-2] will be on. psi).

Figure 20-60-3 Turn the restrictor control (Item 1) [Figure 20-60-4]
Check the free flow specification (See Hydraulic System

on Page SPEC-10-4.)
NOTE: If free flow is below specification perform the

direct pump test.
1
restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
P101611
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-60-3]
20-60-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
female coupler (female coupler is pressurized).
If pressure does not match the above information, the
main relief valve needs to be adjusted. (See Adjusting on
front auxiliary hydraulic switch (Item 1) [Figure 20-60-3]
Page 20-30-3.)
a second time.
If flow does not match specifications go to the Direct
NOTE: When the operator is seated and raises the
Pump Testing. (See Direct Pump Test (Standard Section)
seat bar, the Auxiliary Hydraulic System
on Page 20-60-4.)
(Front and Rear) will deactivate.
If no flow is indicated on the tester, the hoses are

connected wrong. With the hoses connected correctly,
increase the engine speed to full rpm.

Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7003031 - Remote Start Tool

MEL10006 - Fitting Kit
WARNING 1
P101693
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-6
1.)

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

P106631
W-2059-0598
Raise the operator cab. Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-5]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE 20-60-6] from the tester to the control valve fitting on the
START TOOL (SERVICE TOOL) KIT - 7217666 on Page control valve.
10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
IMPORTANT
I-2024-0284
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6895 kPa (69 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.

On the remote start tool engage the auxiliary hydraulics,
the light will come ON. Pull the trigger on the right joystick
for fluid flow to the quick coupler (fluid pressure will go
over main relief). Record the highest pressure (psi) and
flow (U.S. gpm). The high pressure flow must be at least
80% of free flow.
HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
FREE FLOW (U.S. gpm)
A low percentage may indicate a failed pump.
*For system relief pressure and full rpm (See Hydraulic

System on Page SPEC-10-4.)

Direct Pump Test (Charge Section)

procedure:

WARNING 1
P100729
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-7].
W-2017-0286
Figure 20-60-8

1.)

2 1
WARNING
P106631
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-8] from
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-8] from the tester to the inlet fitting on the fan.
Tester, to prevent any contamination to the
Hydrostatic Pumps.
Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE
START TOOL (SERVICE TOOL) KIT - 7217666 on Page
10-61-1.)

Direct Pump Test (Charge Section) (Contd)
IMPORTANT
I-2024-0284
rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.

Turn the restrictor down to system operating pressure
approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=
*For system relief pressure and full rpm. (See Hydraulic


HYDRAULIC PUMP (CONTD) Figure 20-60-9
Direct Pump Test (Steering Section)

1
procedure:

2
WARNING
P-43805A
Failure to use jackstands can allow the machine to Disconnect the steering pump OUTLET hose (Item 1)
fall or move and cause injury or death. [Figure 20-60-9] from the inline steering filter.
W-2017-0286
Check to make sure steering inline filter (Item 2) [Figure

Lift and block the loader. (See Procedure on Page 10-10- 20-60-9] in not plugged. Replace the steering filter as
1.) needed.

Raise the lift arms and install an approved lift arm Figure 20-60-10
WARNING
2 1
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) P106631

TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE Connect the INLET hose (Item 1) [Figure 20-60-10] from
START TOOL (SERVICE TOOL) KIT - 7217666 on Page the tester to the OUTLET hose (Item 1) [Figure 20-60-9]
10-61-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-10] from the tester to the steering filter (Item 2)
NOTE: The control panel is shown removed for photo [Figure 20-60-9].
clarity.

HYDRAULIC PUMP (CONTD)
Direct Pump Test (Steering Section) (Cont'd)
IMPORTANT
I-2024-0284
rpm*.

control on the tester clockwise to 6895 kPa (69 bar)
(1000 psi). DO NOT EXCEED system relief pressure.
gpm) at full rpm.

Record the flow (U.S. gpm) at 18616 kPa (186 bar) (2700
psi), this is the high pressure flow. The high pressure flow

%=


HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 130-2.)

WARNING
Figure 20-60-11
W-2059-0598 1
1
1
DANGER 1
P-90180
Disconnect the four hoses (Item 1) [Figure 20-60-11]

from the hydraulic pump.
P-90328 Remove the Power Bob-Tach block if equipped. (See

AVOID DEATH
Disconnecting or loosening any hydraulic Figure 20-60-12
support. Replace if damaged. 1
D-1009-0409
IMPORTANT 1

parts clean. Always use caps and plugs on hoses, P-90509
damage the system.
I-2003-0888
Disconnect the outlet hoses (Item 1) [Figure 20-60-12]
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


Figure 20-60-13
1
2
P-43940
1

P106593 15] from the hydraulic pump.
Reverse the removal procedure to install the hydraulic

Remove the bracket mounting bolt / nut (Item 1) [Figure pump.
20-60-15].

Installation: Tighten the bolt / nut to 34 - 38 Nm (25 - 28
ft-lb) torque.
Figure 20-60-14
P106594
Remove the two mounting bolts (Item 2) [Figure 20-60-

15] and [Figure 20-60-15].
Installation: Tighten the bolts to 75 - 85 Nm (55 - 60 ft-

lb) torque.
Remove the hydraulic pump.

HYDRAULIC PUMP (CONT'D) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Hydraulic Pump Startup arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
NOTE: This procedure is necessary to prevent a dry of cylinder stroke.
startup of the hydraulic pump.
With the loader parked on a level surface and lift arms
Fill the system with hydraulic fluid. (See Removing And down, check and fill the hydraulic reservoir as required.
Replacing Hydraulic Fluid on Page 10-130-2.) Check for hydraulic leaks.
Figure 20-60-16

P100685
Figure 20-60-17
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-16] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-17].
Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.

Figure 20-60-18
1. Bolt 13.Auxiliary Pump Center Section

2. Charge Pump End Section 14. Auxiliary Pump End Section
3. Section Seal 15. Shaft Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
7
8

9
3
10
3 2
4
6 5
8
4
11
7
8
3 12
4
6 13
4 8
10
11
15 3
14
P-66540

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-60-13.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 1)

[Figure 20-60-18] to 50 Nm (37 ft-lb) torque.
NOTE: Position the wear plates (Item 4) [Figure 20-

60-18 on Page 20-60-13] as shown with the
bronze side toward the gears.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.

HYDRAULIC PUMP (HIGH FLOW)
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
The high flow hydraulic pump has an additional pump

section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched
from a button on the panel in the cab.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-1
Pump Test At Quick Couplers
IMPORTANT
position before you start the engine. 1
I-2024-0284
WARNING P106632
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-61-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-61-1] of the
hydraulic tester to the top (male) quick coupler on the

loader.
WARNING
W-2017-0286

procedure:


1.)
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) If no flow is indicated on the tester, the hoses are
connected wrong. With the hoses connected correctly,
Pump Test At Quick Couplers (Contd) increase the engine speed to full rpm.
2 1
P-76460C P106632
P-16903
Start the engine and run at low idle. Press the Auxiliary Warm the fluid to 60C (140F) by turning the restrictor
hydraulics button (Item 1) once to activate the auxiliary control (Item 1) [Figure 20-61-4] clockwise on the tester

hydraulics. The light (Item 2) [Figure 20-61-2] will be on. so it reads 6895 kPa (69 bar) (1000 psi).
Figure 20-61-3 NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
Turn the restrictor control (Item 1) [Figure 20-61-4]

Check the free flow specification (See Hydraulic System

on Page SPEC-10-4.)
1
NOTE: If free flow is below specification perform the
direct pump test.

restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
P101611 (213,7 bar) (3100 psi) the flow should start decreasing
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-61-3]
female coupler (female coupler is pressurized).
20-61-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
front auxiliary hydraulic switch (Item 1) [Figure 20-61-3]
If pressure does not match the above information, the
a second time.
main relief valve needs to be adjusted. (See Adjusting on
Page 20-30-3.)
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System If flow does not match specifications go to the Direct
(Front and Rear) will deactivate. Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-61-4.)

Direct Pump Test (Standard Section)

procedure:

WARNING 1
P101693
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-6
1.)

WARNING 2 1

P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-6] from
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE 20-61-6] from the tester to the fitting on the control valve.
10-61-1.)

clarity. IMPORTANT
I-2024-0284

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7003031 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses MEL10003 - Hydraulic Tester
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

control on the tester to 6895 kPa (69 bar) (1000 psi). DO
NOT exceed system relief pressure. Open the restrictor
WARNING
control and record the free flow (U.S. gpm) at full rpm*.
On the remote start tool engage the auxiliary hydraulics, of the frame before running the engine for service.
the light will come ON. Pull the trigger on the right joystick Failure to use jackstands can allow the machine to
for fluid flow to the quick coupler (fluid pressure will go fall or move and cause injury or death.
over main relief). Record the highest pressure (psi) and W-2017-0286
flow (U.S. gpm). The high pressure flow must be at least
80% of free flow. Lift and block the loader. (See Procedure on Page 10-10-
1.)
%=
FREE FLOW (U.S. gpm) Raise the lift arms and install an approved lift arm


WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

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

10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Contd) tester, the hoses are connected wrong. With the hoses
Figure 20-61-7 rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi).
NOTE: DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (69 bar) (1000 psi). DO NOT
1
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
P100729 must be at least 80% of free flow.
%=
Disconnect the inlet hose (Item 1) [Figure 20-61-7].

Figure 20-61-8
*For pump flow and rpm. (See Hydraulic System on Page
SPEC-10-4.)
2 1
P106631
Connect the INLET hose (Item 1) [Figure 20-61-8] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-8] from the tester to the inlet fitting on the fan.
IMPORTANT
I-2024-0284

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-9] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 60C (140F) by turning the restrictor
control on the tester to about 6895 kPa (69 bar) (1000
Direct Pump Test (High Flow Section) (Cont'd) psi).
Figure 20-61-10 NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
2 gpm) at full rpm. Increase the restriction and the flow
should drop to 0 L/min (0 U.S. gpm) between 24132 kPa
(241 bar) (3500 psi) and 25510 kPa (255 bar) (3700 psi).
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-10.)
1
Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.
P101694 HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
Disconnect the high flow pump OUTLET hose (Item 1) A low percentage may indicate a failed pump.
from the high flow check valve INLET fitting (Item 2)

[Figure 20-61-10]. *For system relief pressure and full rpm. (See Hydraulic
Figure 20-61-11
2 1
P106631

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-10]. Connect the OUTLET hose (Item 2)
[Figure 20-61-11] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-10].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241 bar) (3500

psi) stop the engine. The relief screw (Item 1) [Figure 20-
61-14] will need to be turned clockwise a 1/4 turn and
retested with the procedure above. (1/4 turn equals
approximately 1379 kPa (13,8 bar) (200 psi).
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation 1
section. (See High Flow Relief Valve Removal 2
And Installation on Page 20-61-10.) If relief
valve has been checked and is OK, go to the P101699
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-18.) Locate the high flow relief valve (Item 1) [Figure 20-61-
13] along the right side of the engine.
Remove right rear wheel. (See Wheel Nuts on Page 10-
170-1.) Remove the plug (Item 2) [Figure 20-61-13] located on
the bottom of the high flow relief valve.
Figure 20-61-12

Figure 20-61-14
P101698
P101697
Remove the bolts (Item 1) [Figure 20-61-12] from the

access cover and remove the cover from the loader. If the pump reaches 25510 kPa (255 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned counterclockwise 1/4 turn and retested with the
procedure above [Figure 20-61-14].
NOTE: The relief valve is shown removed from the

loader for photo clarity.

High Flow Relief Valve Removal And Installation
WARNING
of the frame before running the engine for service. 1
W-2017-0286
Remove right rear wheel. (See Wheel Nuts on Page 10- P101699
170-1.)
Figure 20-61-15 Remove the relief valve (Item 1) [Figure 20-61-16] from
the pump.

35 ft-lb) torque.

Figure 20-61-17
1
1
P101698
2
Remove the bolts (Item 1) [Figure 20-61-15] from the 3

access cover and remove the cover from the loader.
P101696
Inspect the relief valve and replace the O-rings (Item 1)

and back-up ring (Item 2) [Figure 20-61-17].
If the relief valve is bad, it must be replaced as a

complete unit.
Remove the plug (Item 3) and O-ring (Item 4) [Figure 20-

61-17].

Direct Pump Test (Steering Section)

1
procedure:

2
WARNING
P-43805A
Failure to use jackstands can allow the machine to Disconnect the steering pump OUTLET hose (Item 1)
fall or move and cause injury or death. [Figure 20-61-18] from the inline steering filter.
W-2017-0286
Check to make sure steering inline filter (Item 2) [Figure

Lift and block the loader. (See Procedure on Page 10-10- 20-61-18] in not plugged. Replace the steering filter as
1.) needed.

Raise the lift arms and install an approved lift arm Figure 20-61-19
WARNING
2 1
W-2059-0598

Connect the remote start tool. (See REMOTE START the tester to the OUTLET hose (Item 1) [Figure 20-61-
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE 18] of the pump. Connect the OUTLET hose (Item 2)
START TOOL (SERVICE TOOL) KIT - 7217666 on Page [Figure 20-61-19] from the tester to the steering filter
10-61-1.) (Item 2) [Figure 20-61-18].

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (Steering Section) (Cont'd)
IMPORTANT
I-2024-0284
rpm*.

control (Item 1) [Figure 20-61-17] on the tester clockwise
to 6895 kPa (69 bar) (1000 psi).
NOTE: DO NOT EXCEED system relief pressure.

gpm) at full rpm.
Record the flow (U.S. gpm) at 18616 kPa (18 bar) (2700
psi), this is the high pressure flow. The high pressure flow

%=


Figure 20-61-20
1
1 2
2 P-45462
Remove the O-rings (Item 1) and back-up ring (Item 2)

P101889 [Figure 20-61-22].
Disconnect the electrical connector. Remove the nut

(Item 1) and coil (Item 2) [Figure 20-61-20].

Installation: Tighten the solenoid nut to 9 - 11 Nm (6.5 -
8 in-lb)
Figure 20-61-21
P101888
Remove the solenoid valve (Item 1) [Figure 20-61-21].
Installation: Tighten the solenoid valve to 47 - 54 Nm

(35 - 40 ft-lb).

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 130-2.)
Remove the Power Bob-Tach block if equipped. (See

WARNING
Figure 20-61-23
W-2059-0598
DANGER
1
1

P101889
Disconnect the inlet hoses (Item 1) [Figure 20-61-23]

P-90328 from the front of the hydraulic pump.
AVOID DEATH
Figure 20-61-24
D-1009-0409
IMPORTANT
1
tubelines and ports to keep dirt out. Dirt can quickly P-90185
damage the system.
I-2003-0888
Disconnect the hoses (Item 1) [Figure 20-61-24] from
the back of the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)


Figure 20-61-25
1
P106594
Remove the two mounting bolts (Item 2) [Figure 20-61-

P-90509A 28] and [Figure 20-61-28].

Disconnect the outlet hoses (Item 1) [Figure 20-61-25] lb) torque.

Remove the hydraulic pump.
Figure 20-61-26
Figure 20-61-28
P106593
P-43940
Remove the bracket mounting bolt / nut (Item 1) [Figure

20-61-28]. Remove the O-ring (Item 1) [Figure 20-61-28].
Installation: Tighten the bolt / nut to 34 - 38 Nm (25 - 28 Reverse the removal procedure to install the hydraulic
ft-lb) torque. pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Hydraulic Pump Startup arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
NOTE: This procedure is necessary to prevent a dry of cylinder stroke.
startup of the hydraulic pump.
With the loader parked on a level surface and lift arms
Fill the system with hydraulic fluid. (See Removing And down, check and fill the hydraulic reservoir as required.
Replacing Hydraulic Fluid on Page 10-130-2.) Check for hydraulic leaks.
Figure 20-61-29

P100685
Figure 20-61-30
P100352

Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.

Figure 20-61-31
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal

13
17. Center Housing
4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-17.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 7)

NOTE: Position the wear plate (Item 4) [Figure 20-61-

31 on Page 20-61-17] inlet as shown with the
bronze side toward the gears on all wear
plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.

HYDRAULIC / HYDROSTATIC FILTERS (EARLY
MODELS)
Description
The hydraulic / hydrostatic filters help to remove

contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including oil returning from the main valve.
The charge flow filter removes contaminants after the

charge pump.

HYDRAULIC / HYDROSTATIC FILTERS (EARLY Drain the fluid from the reservoir. (See Removing And
MODELS) (CONTD) Replacing Hydraulic Fluid on Page 10-130-2.)
Housing Removal And Installation Figure 20-70-1
DANGER
1
2
P-90328 2
AVOID DEATH P100205
from the hydraulic / hydrostatic filter sender.

Remove the three hoses (Item 2) [Figure 20-70-1].
D-1009-0409
WARNING
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888


MODELS) (CONTD)
Housing Removal And Installation (Contd)
Figure 20-70-2
1
1
P106626
Remove the hoses (Item 1) [Figure 20-70-2].

Figure 20-70-3
P106623
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.


HYDRAULIC / HYDROSTATIC FILTERS (LATER Housing Removal And Installation
MODELS)
Description
The hydraulic / hydrostatic filters help to remove DANGER

contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including oil returning from the main valve.
P-90328
The charge flow filter removes contaminants after the
charge pump. AVOID DEATH
D-1009-0409

WARNING
W-2059-0598

Drain the fluid from the reservoir. (See Removing And


HYDRAULIC / HYDROSTATIC FILTERS (LATER Figure 20-71-3
MODELS) (CONTD)
Housing Removal And Installation (Contd)

1
Figure 20-71-1
2
1
2
P115774
1
P121308 Remove the hydraulic / hydrostatic filter housing from the

loader.
Disconnect the electrical connector (Item 1) [Figure 20-

71-1] from the hydraulic / hydrostatic filter sender.

Remove and plug the three hoses (Item 2) [Figure 20-
71-1] from the hydraulic / hydrostatic filter housing.
Figure 20-71-2
P-90013
Remove and plug the three hoses (Item 1) [Figure 20-

71-2] from the bottom of the hydraulic / hydrostatic filter
housing.

HYDRAULIC FLUID RESERVOIR (EARLY MODELS) Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loaders hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
1
contaminants from entering the reservoir while adding
fluid.
The hydraulic fluid reservoir is located behind the

operators cab under the rear grille on the right side of the 2
loader.

P101894
Remove the clamp and hose (Item 1) [Figure 20-80-2].
Remove the fan duct. (See Lower Fan Duct Removal And
Installation on Page 70-50-3.) Remove the clamp and supply hose (Item 2) [Figure 20-
80-2].
Replacing Hydraulic Fluid on Page 10-130-2.) Figure 20-80-3

Remove the Hydraulic / Hydrostatic Filter Housing (See
Housing Removal And Installation on Page 20-70-2.)
Remove the rear grille (See Removing on Page 50-60-1.)
Figure 20-80-1
1 1
P101895
Remove the two bolts / bracket (Item 1) [Figure 20-80-3].
Remove the hydraulic fluid reservoir from the loader.
P101894
Installation: Tighten the mount bolts and nuts to 21,7 -
24,4 Nm (16 - 18 ft-lb) torque.
Remove the right side louver bolts (Item 1) [Figure 20-

80-1] and remove the louver.

HYDRAULIC FLUID RESERVOIR (EARLY MODELS)
(CONT'D)
Hydraulic Fluid Screen

1.)
Figure 20-80-4
P100055

Remove the hydraulic fluid reservoir breather cap (Item
1) [Figure 20-80-4] from the reservoir.
Figure 20-80-5
P-90506
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-5] from the reservoir.
Wash the screen in clean solvent and air dry before

installing.

HYDRAULIC FLUID RESERVOIR (LATER MODELS) Figure 20-81-2
Description
The hydraulic fluid reservoir is a storage container for the

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.
Removal And Installation 1


Replacing Hydraulic Fluid on Page 10-130-2.) Remove the two bolts (Item 1) [Figure 20-81-2].
Remove the Hydraulic / Hydrostatic Filter Housing. (See Remove the hydraulic fluid reservoir from the loader.
MODELS) on Page 20-70-1.) and (See HYDRAULIC / Installation: Tighten the mount bolts and nuts to 21,7 -
HYDROSTATIC FILTERS (LATER MODELS) on Page 24,4 Nm (16 - 18 ft-lb) torque.

20-71-1.)

1.)
Figure 20-81-1
P115773
Remove the clamp and the hose (Item 1) [Figure 20-81-

1].

HYDRAULIC FLUID RESERVOIR (LATER MODELS)
(CONT'D)
Hydraulic Fluid Screen

1.)
Figure 20-81-3
P121074A
Remove the hydraulic fluid reservoir breather cap (Item

1) [Figure 20-81-3] from the reservoir.
Figure 20-81-4
P121073A
Remove the hydraulic fluid screen (Item 1) [Figure 20-

81-4] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER (EARLY MODELS) Figure 20-90-2
Description
1
The oil cooler is used to cool the loaders hydraulic and
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
2
The oil cooler is located underneath the rear grille
between the A/C condenser (if equipped) and the
radiator.
P107194B
IMPORTANT Remove hose clamp (Item 1) and hose (Item 2) [Figure

20-90-2].
clean the work area before disassembly and keep all Figure 20-90-3
4

damage the system. 4 2
I-2003-0888 5
Remove the rear grille from the loader. (See Removing 3

on Page 50-60-1.)
Figure 20-90-1 2
2
1
P107194
Unhook the rubber straps (Item 1) [Figure 20-90-3]

1
Remove the bolts (Item 2) and remove the condenser
guards (Item 3) [Figure 20-90-3].
Remove the pins (Item 4) [Figure 20-90-3].

P107194A
Remove the bolt (Item 5) [Figure 20-90-3] from the prop
rod.
Remove hose clamp (Item 1) and hose (Item 2) [Figure
20-90-1]. Lift up and remove the cooler from the loader.


OIL COOLER (LATER MODELS)
The oil cooler and radiator are removed from the loader
as a unit. (See Radiator Removal And Installation on
Page 70-50-1.)


BUCKET POSITION VALVE Solenoid Removal And Installation
Description
The bucket position valve is an option that allows the

operator to hold the attachment at the same angle from IMPORTANT
the ground to maximum lift height without using the tilt
function. When repairing hydrostatic and hydraulic systems,
The bucket position valve is mounted to the inside lower parts clean. Always use caps and plugs on hoses,
right rear side of the loader frame. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
See Hydraulic Schematic for more circuit information. I-2003-0888
P-90328

AVOID DEATH
D-1009-0409


BUCKET POSITION VALVE (CONT'D) Figure 20-100-3
Solenoid Removal And Installation (Contd)
Figure 20-100-1 1
2
P100253
1
P107818A
Figure 20-100-4


2
Remove the two bolts (Item 2) and reposition the fuel
filter assembly (Item 3) [Figure 20-100-1].
Figure 20-100-2 1
P106422
Reposition the clamp (Item 1) and remove the fuel fill

1 hose (Item 2) [Figure 20-100-4] from the tank.
Cover the fuel tank inlet.
NOTE: Engine and fuel filter removed for photo

P106420
clarity.
Remove the clamp / hose (Item 1) [Figure 20-100-2]

from the filler neck.

BUCKET POSITION VALVE (CONT'D) Solenoid Testing
Solenoid Removal And Installation (Contd) Refer to Bobcat Advanced Troubleshooting System
(B.A.T.S.) for electrical testing and troubleshooting
Figure 20-100-5 information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
1 P101161
Disconnect the wire harness connector (Item 1) [Figure

20-100-5] from the bucket position shut-off solenoid.

Disconnect and cap the two tubelines (Item 2) [Figure
20-100-5].
Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-5].
Installation: Tighten the solenoid stem to 40,7 - 50,2

Nm (31 - 37 ft-lb) torque.
Installation: Tighten the solenoid nut to 8 Nm (6 ft-lb)

torque. Overtightening may cause valve failure.
Figure 20-100-6
1
2
N-18191
Inspect the solenoid stem and replace the O-rings (Item

1) and the back-up ring (Item 2) [Figure 20-100-6].

DANGER
P106420
P-90328
AVOID DEATH Remove the clamp / hose (Item 1) [Figure 20-100-8]

Disconnecting or loosening any hydraulic from the filler neck.
can cause lift arms to drop. Figure 20-100-9

D-1009-0409 1

Figure 20-100-7
3
P100253

2
P107818A



Figure 20-100-10
1
1 2
4 3
P101157
Disconnect and cap the tilt base inlet hose (Item 1), the
P106422 tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-12]
that route from the control valve.
hose (Item 2) [Figure 20-100-10] from the tank. Figure 20-100-13

Cover the fuel tank inlet.
NOTE: Engine and fuel filter removed for photo

clarity.
Figure 20-100-11
2
1
P-90189A
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-13]
from the valve block.
1 P101161
Disconnect the electric solenoid connector (Item 1)

[Figure 20-100-11].
Mark all hoses and tubelines for correct installation.

BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 20-100-16
Figure 20-100-14
2
1 3
2
2
1 P-90192
P-90197A
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-16].
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2) Assembly: Tighten the nut to a maximum of 8 Nm (6 ft-

[Figure 20-100-14] that route from the lift cylinders. lb) torque. Overtightening may cause valve failure.
Figure 20-100-15 Assembly: Tighten the solenoid stem to 40,7 - 50,2 Nm

Figure 20-100-17
1 1
P101159
Remove the nuts (Item 1) [Figure 20-100-15] and bolts.

P-90195
Remove the bucket position valve from the loader.

Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-100-17].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 Nm (27 - 36 ft-lb) torque.

BUCKET POSITION VALVE (CONT'D)
Disassembly And Assembly (Contd)
Figure 20-100-18
3
1
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-18]. Inspect for

wear and replace as needed.
Assembly: Tighten the plug to 75,9 - 86,8 Nm (56 - 64

ft-lb) torque.
Figure 20-100-19
1
2 3
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-19]. Inspect for wear and
replace as needed.
Assembly: Tighten the plug to 75,9 - 86,8 Nm (56 - 64

ft-lb) torque.


REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts oil from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
1 4.6 - 5.7 ohm.
Figure 20-110-3

2
3
3
P100766
The rear auxiliary diverter valve has two types of solenoid

coils, one type with a pigtail connector (Item 1) and one
type with a molded connector (Item 2) [Figure 20-110-1].
P100763
The solenoid coils have color coded tie-straps (Item 3)
[Figure 20-110-1] that correspond with color coded tie-
straps on the wiring harness. Use a test meter to measure coil resistance [Figure 20-
110-3]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a molded connector
is 8.1 - 9.9 ohm.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-4
DANGER
P-90583
P-90328
AVOID DEATH Disconnect the tubelines (Item 1) [Figure 20-110-4]

tubeline, hose, fitting, component or a part failure Figure 20-110-5

D-1009-0409
1 1
Put jackstands under the rear corners of the loader.


Replacing Hydraulic Fluid on Page 10-130-2.) P-93303
Disconnect the tubelines (Item 1) [Figure 20-110-5]
IMPORTANT
damage the system.
I-2003-0888

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Contd) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-6 assembly.
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure to dry. Install new
1 O-rings and back-up washers.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.
Figure 20-110-8
P100810
Disconnect the accessory wiring harness (Item 1)

[Figure 20-110-6] from the main harness.

Figure 20-110-7
1
2 1
P100760
1 Several plugs (Item 1) [Figure 20-110-8] are located on

the diverter valve and can be removed for clean out
purposes.
Figure 20-110-9
P103330
1
Remove the two bolts (Item 1) and remove the valve
(Item 2) [Figure 20-110-7]
P-48752
Assembly: Put oil on O-ring (Item 1) [Figure 20-110-9].

Tighten to 10 ft.-lb. (13,6 Nm) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
damage the system.
I-2003-0888 1
P100761
Figure 20-110-10
Remove the differential sensing valve (Item 1) [Figure

20-110-12] from diverter valve.
Figure 20-110-13
1

1
1
P100761
Figure 20-110-11
P-48757
Inspect the O-rings and back-up washers (Item 1)

2 [Figure 20-110-13] for damage.
2 2
1 Assembly: Put oil on O-rings and back-up washers.
Tighten to 50 - 55 ft.-lb. (68 - 75 Nm) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-10]

and [Figure 20-110-11] from diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
110-11] for damage.
Assembly: Put oil on the O-rings and back-up washers.

Tighten to 10 - 12 ft.-lb. (14 - 16 Nm) torque.

Figure 20-110-14 1
P100762
1
Remove the nut (Item 1) [Figure 20-110-16] from the

P-48753 solenoid valve stem.
Assembly: Tighten the nut to 4,1 Nm (3 ft-lb) torque.

Remove the relief valve (Item 1) [Figure 20-110-14] and
[Figure 20-110-15]. Figure 20-110-17

Figure 20-110-15
P100764
P-48754
Remove the solenoid valve coils (Item 1) [Figure 20-110-
17].
Inspect the O-rings and back-up rings (Item 1) [Figure
20-110-15] for damage.
Assembly: Put oil on O-rings and back-up washers.

Tighten to 27 - 34 Nm (20 - 25 ft-lb) torque.
NOTE: Before removing the solenoid coils make note

of the color coded tie-straps and their
position on the solenoid valve stem.

NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Figure 20-110-18
1 1
1
P-48763
Inspect the O-rings and back-up washers (Item 1)

[Figure 20-110-20] for damage.

P-48761 Tighten to 27 - 34 Nm (20 - 25 ft-lb) torque.

Figure 20-110-21
Remove the nuts (Item 1) [Figure 20-110-18] from the
solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 Nm (4 - 6 ft-lb) 1

torque.
Figure 20-110-19
1 P-48763A
Remove the solenoid valve stem (Item 1) [Figure 20-

110-21].
P-48762
Remove the solenoid valve stem (Item 1) [Figure 20-

110-19].

Figure 20-110-22
1
1
1
P-48766
Remove and inspect the orifice (Item 1) [Figure 20-110-

P-48764 24] for dirt and debris.
Assembly: Tighten the orifice to 29,8 Nm (22 ft-lb)

Inspect the O-rings and back-up washers (Item 1) torque.
[Figure 20-110-22] for damage.

Figure 20-110-25
Tighten to 41 - 47 Nm (30 - 35 ft-lb) torque.
Figure 20-110-23
P-48765
Remove the plug (Item 1) [Figure 20-110-25].

P-48765
Assembly: Tighten the plug to 13,6 Nm (10 ft-lb) torque.
Assembly: Tighten the plug to 51,5 Nm (38 ft-lb) torque.

REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-26
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].

Assembly: Tighten the orifice to 4,5 Nm (3.3 ft-lb)
torque.
Figure 20-110-27
P100767
Remove the plugs (Item 1) [Figure 20-110-27].
Assembly: Tighten the plug to 19 Nm (14 ft-lb) torque.

BOB-TACH (POWER) BLOCK (EARLY MODELS) Removal And Installation
Description
The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
The power Bob-Tach block is mounted on the right side of to fall and cause injury or death.
the machine in front of the engine on the back side of the W-2059-0598
hydraulic pump.
DANGER

P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (EARLY MODELS) Figure 20-120-2
(CONT'D)

1
Figure 20-120-1
2 2
P101862
Disconnect and cap the outlet hose (Item 1) [Figure 20-

120-2] from block.
P100806
Disconnect and cap the hoses (Item 2) [Figure 20-120-2]
from block.
1.)

Figure 20-120-3

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

1
Disconnect the two electrical solenoid coil connectors 1
(Item 1) [Figure 20-120-1] from the loader electrical
harness.
P101859
Remove the four mounting bolts (Item 1) [Figure 20-120-

3].
Installation: Tighten the mounting bolts to 35 - 40 ft-lb

(48 - 54 Nm) torque.
Remove the power Bob-Tach block.

(CONT'D)
2
IMPORTANT
1
damage the system.
I-2003-0888
P100769
Figure 20-120-4
Clean the block (Item 1) to remove dirt before
disassembly. Block ports are labeled for correct
assembly.[Figure 20-120-5]

1

Installation: Tighten the plug to 67,8 Nm (50 ft-lb)
torque.
Figure 20-120-6
3
P100820
Do not remove these plugs (Item 1) [Figure 20-120-4]. 1
NOTE: Do not remove the two plugs located next to 2

the outlet port. A new Power Bob-tach valve
will be required if tampered with. All other
plugs can be removed.
4
P100770
Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-6] and inspect. Replace damaged parts
as needed.
Inspect the O-ring (Item 4) [Figure 20-120-6] on the plug

and replace as needed.

(CONT'D)
Figure 20-120-7
2
1
1
P107069
Remove the spool (Item 1), spring (Item 2) and the orifice
(Item 3) [Figure 20-120-8]. Inspect the spring, spool and
P100823 orifice replace as needed.
Installation: Clean threads on the orifice and apply

Remove the plug (Item 1) [Figure 20-120-7], inspect the Loctite 603. Tighten the orifice (Item 3) [Figure 20-120-
O-ring and replace as needed.

9].
Installation: Tighten the plug (Item 1) [Figure 20-120-7] Figure 20-120-9

to 17,6 Nm (13 ft-lb) torque.
P100826
Remove the plug (Item 1) [Figure 20-120-9], inspect the

O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-120-9]

to 17,6 Nm (13 ft-lb) torque.

(CONT'D)
Figure 20-120-10
2
P100773
1
Remove the first solenoid coil (Item 1) and the second
solenoid coil (Item 2) [Figure 20-120-12].
P100821
Figure 20-120-13
Remove the orifice screw (Item 1) [Figure 20-120-10].

Installation: Tighten the orifice screw (Item 2) [Figure
20-120-10] to 8,1 - 10,8 Nm (6 - 8 ft-lb) torque.
Figure 20-120-11
1
1 P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

13].
Installation: Tighten the solenoid coil stem to 27,14 Nm

NOTE: Mark the solenoid coil orientation for ease of

installation.
Remove the solenoid coil nut (Item 1) [Figure 20-120-

11].
Installation: Tighten the solenoid coil valve stem nut to

6,8 Nm (5 ft-lb) torque.

(CONT'D)
Figure 20-120-14
2 2 2
P100829
1 1 1 1
Inspect the O-ring (Item 1) [Figure 20-120-16] and

replace as needed.
P100776
Figure 20-120-17
Inspect the O-rings (Item 1) and the back-up washers

(Item 2) [Figure 20-120-14].

Figure 20-120-15
1
P100840
Remove the plug (Item 1) [Figure 20-120-17], inspect

the O-ring and replace as needed.
P100828
Installation: Tighten the plug (Item 1) [Figure 20-120-
17] to 17,6 Nm (13 ft-lb) torque.
Remove the fitting (Item 1) [Figure 20-120-15].

(CONT'D)
Figure 20-120-18
2
1
P100843
1
Remove the shuttle seat (Item 1) and check ball (Item 2)
[Figure 20-120-20]. Inspect the shuttle seat and check
P100841 ball, replace as needed.
Figure 20-120-21
Remove the filter assembly (Item 1) [Figure 20-120-18],
inspect and replace as needed.

Figure 20-120-19
P100845

P100842 the O-ring and replace as needed.

Remove the plug (Item 1) [Figure 20-120-20], inspect 21] to 30 Nm (22 ft-lb) torque.


(CONT'D)
Figure 20-120-22
P100837

P100839

Figure 20-120-25

Figure 20-120-23
2
1 P100838
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-25], inspect and replace as needed.
P100835
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-23], inspect and replace as needed.

(CONT'D)
Figure 20-120-26
P100847
Remove pilot piston (Item 1) [Figure 20-120-28].
P100846 Figure 20-120-29


2 2
26] to 30 Nm (22 ft-lb) torque.
1
Figure 20-120-27
P100834
1
Inspect the pilot piston (Item 1), the back-up washers

(Item 2) and the O-ring (Item 3) [Figure 20-120-29] for
damage and replace as needed.
P100853
Using a small diameter tool remove the pilot piston (Item

1) [Figure 20-120-27].

(CONT'D)

1
Figure 20-120-30
P100850

P100852
32] to 30 Nm (22 ft-lb) torque.

Figure 20-120-33

Figure 20-120-31
1
2 P100851

P100849
Remove the annular orifice shaft (Item 1) and the annular
orifice shaft guide (Item 2) [Figure 20-120-31], inspect

BOB-TACH (POWER) BLOCK (EARLY MODELS)
(CONT'D)
Figure 20-120-34
P100854

replace.


BOB-TACH (POWER) BLOCK (LATER MODELS)
Description
The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right

switch panel.
The power Bob-Tach block is mounted on the right side of

the machine in front of the engine on the back side of the
hydraulic pump.

BOB-TACH (POWER) BLOCK (LATER MODELS) Figure 20-121-2
(CONT'D)
Testing Relief Valve
1
WARNING
not use your bare hand. Wear safety goggles. If fluid P106674
W-2072-0807 Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
Figure 20-121-3
WARNING

explosion or fire. 1
W-2103-0508
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-121-1 P122238
Install the gauge (Item 1) [Figure 20-121-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH WEDGES DOWN Switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

121-1].
Push and hold BOB-TACH WEDGES UP switch until

levers are in the unlocked position (Wedges fully raised).

(CONT'D)
Testing Relief Valve (Contd)
Figure 20-121-4
P122229
NOTE: Relief valve removed from block for photo

clarity.

If adjustment is required loosen the jam nut (Item 1) and
turn the adjusting screw (Item 2) [Figure 20-121-4]
clockwise to increase pressure or counter clockwise to
decrease pressure.
Test the relief valve setting after adjustment has been

made.

BOB-TACH (POWER) BLOCK (LATER MODELS) NOTE: After repairing a machine that required the
(CONT'D) power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
Removal And Installation make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
WARNING Maintenance Manual, the electrical

connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
Never work on a machine with the lift arms up unless inspection to verify the wedges function
the lift arms are secured by an approved lift arm correctly.
support device can allow the lift arms or attachment Lift and block the loader. (See LIFTING AND BLOCKING
to fall and cause injury or death. THE LOADER on Page 10-10-1.)
W-2059-0598

DANGER
Replacing Oil And Filter on Page 10-120-2.)
Remove the fan duct panels (See Removal And

Installation on Page 50-180-1.)
Figure 20-121-5
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1
D-1009-0409
P122161
IMPORTANT
Disconnect the two wire connectors (Item 1) [Figure 20-
When repairing hydrostatic and hydraulic systems, 121-5] from the solenoid coils.
damage the system.
I-2003-0888

(CONT'D)
Figure 20-121-6
2 2
P122162
Disconnect and cap the hose (Item 1) [Figure 20-121-6]

from block.

Disconnect and cap the hoses (Item 2) [Figure 20-121-6]
from block.
Figure 20-121-7
1 1
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-121-

7].
Installation: Tighten the mounting bolts to 48 - 54 Nm

Remove the power Bob-Tach block.

(CONT'D)
IMPORTANT 3

1
damage the system. 2
I-2003-0888
4 P122197
Figure 20-121-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.

torque.

Replace the O-ring (Item 4) [Figure 20-121-9] on the
1
plug.
Figure 20-121-10
1
P122196
Do not remove these plugs (Item 1) [Figure 20-121-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
1
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-121-10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 Nm (5 ft-lb) torque.

(CONT'D)

2
Figure 20-121-11
P122201
3
Replace the O-rings (Item 1) and the back-up rings (Item

1 2) [Figure 20-121-13].
P122199
Figure 20-121-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-121-

11].
Figure 20-121-12
2
1
P122202
Remove the fitting (Item 2) [Figure 20-121-12] and

1 replace the O-ring (Item 1) [Figure 20-121-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-121-

12].
Installation: Tighten the solenoid stem to 27,14 Nm

(20 ft-lb) torque.

(CONT'D)
Figure 20-121-15
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-18]. Inspect and replace
P122203 as needed.
Figure 20-121-18
Remove the plug (Item 1) [Figure 20-121-15] and
replace the O-ring.

torque. 1
Figure 20-121-16
P122205

1
torque.
P122205


(CONT'D)
Figure 20-121-19
2
3 1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert

1 (Item 2) [Figure 20-121-21]. Inspect and replace as
P122207 needed.
Figure 20-121-22
Remove the O-ring (Item 1), the spring (Item 2) and the
check ball (Item 3) [Figure 20-121-23]. Inspect and

replace as needed.
Figure 20-121-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
P122208 Installation: Tighten the relief valve to 20 Nm (15 ft-lb)

torque.

torque.

(CONT'D)
Figure 20-121-23
P122212
Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-121-23].

Figure 20-121-24
P122213
Replace the O-ring (Item 1) [Figure 20-121-24].
NOTE: After repairing a machine that required the

power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535

If unable to identify the supplier part number on the male
coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONTD)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

Nm (59 ft-lb) torque. Tighten the case drain coupler to
50 Nm (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONTD)
Disassembly And Assembly (FFI/FI) (Contd)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7]

1
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and inspect the seal

(Item 1) [Figure 20-130-14] for damage and replace as
needed.

(CONTD)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
Remove the springs (Item 1) [Figure 20-130-13].
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].

Installation: Tighten the coupler fittings (Item 1) [Figure
20-130-11] to 110 Nm (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

Nm (59 ft-lb) torque. Tighten the case drain coupler to
50 Nm (37 ft-lb) torque.

(CONTD)
Disassembly And Assembly (FFH/FH) (Contd)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].

Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assemble if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.


HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11599 & BELOW) . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)

(S/N ATDW11600 AND ATDY11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11

HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-7
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-21
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-29
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-32

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
TWO-SPEED / BRAKE VALVE (S/N ATDW11599 & BELOW) . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
TWO-SPEED / BRAKE VALVE (S/N ATDW11600 & ABOVE

AND ATDY11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

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.

HYDROSTATIC SYSTEM INFORMATION (CONTD)
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-100-
1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 4, 5, 6, 9
The hydrostatic system is overheating. 7, 8
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The hydrostatic pump has damage.
3. The final drive chains are broken.
4. The hydrostatic motor has damage.
5. The tires do not have the correct tire pressure.
6. The tires are not the same size.
7. The hydrostatic fluid is not at the correct level.
8. The oil cooler has a restriction.
9. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N
ATDW11599 & BELOW)
Description
WARNING
The hydrostatic motors are driven by high pressure from Never work on a machine with the lift arms up unless
the hydrostatic pumps. the lift arms are secured by an approved lift arm
This hydrostatic motor contains a spring applied pressure support device can allow the lift arms or attachment
release braking system. This braking system is located to fall and cause injury or death.
on the end of the hydrostatic motor. W-2059-0598
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing case
drain oil with cooled low pressure oil from the charge
circuit. The shuttle valve is shifted by the high pressure IMPORTANT
oil coming from the hydrostatic pumps. If the shuttle valve
sticks, a delay or lack of drive may or may not be felt in When repairing hydrostatic and hydraulic systems,
the controls and / or an overheated hydrostatic motor will clean the work area before disassembly and keep all
result. parts clean. Always use caps and plugs on hoses,
There are two hydrostatic motors mounted to motor damage the system.
carriers. The motor carriers are mounted to the I-2003-0888
transmission chaincase which houses the drive chains.

Removal And Installation 1.)

DANGER support device. (See Installing on Page 10-20-1.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-20-1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1
D-1009-0409
P100257
Remove the motor cover bolts (Item 1) [Figure 30-20-1].
Mark the hoses for correct installation.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Figure 30-20-4
ATDW11599 & BELOW) (CONT'D)
Figure 30-20-2
2 3
4 1
P100901
Installation: Install both flanges and tighten the bolts to

2 half of the required torque in the sequence shown
P100206 [Figure 30-20-4].
Tighten all bolts to the correct torque in the same

Disconnect the hydraulic hose (Item 1) [Figure 30-20-2] sequence.
that goes to the two-speed port on the two-speed / brake

block. Figure 30-20-5
Disconnect the hydraulic hose (Item 2) [Figure 30-20-2]

that goes to the brake port on the two-speed / brake
block.

that goes to the make-up port on the two-speed / brake
block.
1
Figure 30-20-3
P-90496
2
Remove the ten (12 mm) bolts (Item 1) [Figure 30-20-5]

from the motor.
1
NOTE: The two smaller diameter bolts (8 mm), hold
2 the cam ring to the motor and do not have to
be removed for motor removal.
P100208 Remove the motor from the loader.
Installation: Tighten the ten bolts to 149 Nm (110 ft-lb)

Disconnect the hydraulic hose (Item 1) [Figure 30-20-3] torque [Figure 30-20-5].
that goes to the drain manifold.
Remove the eight flange bolts (Item 2) [Figure 30-20-3]

from the high pressure hoses on the motor.

Figure 30-20-6
12 1
11
13
10 2
9 3
8 4
7 5
6
N-22535
Remove the O-ring (Item 13) [Figure 30-20-6] with new

O-ring

Installation: Install the O-ring (Item 1) by pressing the O-
ring into the groove starting at the 12 oclock position
then 6,2,10,3,9,4,8,5,7,1 and 11 [Figure 30-20-6] until
the O-ring is fully seated in the groove.
NOTE: Do not twist the O-ring in to the groove. Verify

the O-ring is flush with no protrusions.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11599 & BELOW) (CONT'D)
1. Rotary Group
2. Block
3. Piston
4. Roller 11
5. Pin
6. Cam Ring
7. O-ring 11
8. Distributor Assembly
9. Distributor 11
10. Spring
11. Seal 10
12. Housing Assembly 9
13. Plug
14. O-ring 7
15. Spool 8
16. Washer 6
17. Housing
18. Bolt 4
19. Bushing 5
20. Snap Ring 3
21. Brake Assembly
22. Shim 23
23. Brake Disc

24. Brake Housing 18 22
25. Shaft 2
26. Seal 20
27. Piston 1
28. Spring 5
29. Gasket
30. Cover 13
14 25
16
15 19
13 10 14 21
13
14
14
20
10 16
14 10
18
15 30
13
29
28
12 14
27
20
14
26
21
NA2535S

Disassembly
Figure 30-20-7
1
2
N-22492
Remove the gasket (Item 1) [Figure 30-20-9].

1
N-22489 Remove the brake spring (Item 2) [Figure 30-20-9] from
the brake housing.
Place the cam sealing surface (Item 1) [Figure 30-20-7]
on a protective material. NOTE: Mark the top side of the brake spring for

proper installation.
NOTE: Mark the side of the motor, brake, and motor
carrier housings for correct assembly. Figure 30-20-10
NOTE: Always protect any sealing surfaces. Any
scratches or marks will cause premature
failure.
Drain the oil from the motor housing. 1

2
Figure 30-20-8
N-22493
Remove the piston (Item 1) [Figure 30-20-10] from the

brake housing.
NOTE: Use low air pressure through the brake line

N-22490
fitting (Item 2) [Figure 30-20-10] to aid in
piston removal.
Remove the twelve mounting bolts (Item 1) [Figure 30-
20-8] from the brake cover plate. Remove the O-ring from the piston.
NOTE: Remove the bolts one turn at a time to

maintain equal preload on the cover and the
brake spring.
Remove the cover plate (Item 2) [Figure 30-20-8] from

the brake housing.

Disassembly (Cont'd)
1
Figure 30-20-11
P-69985
Remove the brake disks (Item 1) [Figure 30-20-13] from

the brake shaft. Mark the position of the brake disks and
P-69973 the shims.
Figure 30-20-14
Remove the five bolts (Item 1) [Figure 30-20-11] from
the brake housing.

1
Remove the brake housing (Item 2) [Figure 30-20-11]
from the housing. 2
Figure 30-20-12
P-69978
Remove the two-speed spool (Item 1) [Figure 30-20-14]

from the housing assembly.
1
P-73062
Remove the snap ring (Item 1) [Figure 30-20-12] and the

seal from the brake housing.

Figure 30-20-15
1
P-73057
3
1
2 Remove the flushing spool assembly (Item 1) [Figure 30-
20-17] from the housing.
N-22501
Figure 30-20-18
Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) from the spool (Item 4) [Figure 30-20-15]

1
2 3 4
NOTE: If the two speed spool (Item 1) [Figure 30-20-
15] is damaged the entire housing assembly
has to be replaced
Figure 30-20-16
N-22504
Remove the spring (Item 1), washer (Item 2), spool (Item
3) and spring (Item 4) [Figure 30-20-18].
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-20-

16] from the housing.
Installation: Tighten the plug to 30 Nm (22 ft-lb) torque.

Figure 30-20-19
3
2
1 1
N-22507
Remove the spring (Item 1) and shim (Item 2) from the

poppet (Item 3) [Figure 30-20-21].
P-69981
Figure 30-20-22
Remove the plug (Item 1) [Figure 30-20-19] from the

housing.

Installation: Tighten the plug to 22 Nm (18 ft-lb) torque. 1 1
Figure 30-20-20
P-73058
Remove the two (8 mm) cam ring bolts (Item 1) [Figure

30-20-22].
Remove the housing and rotating group from the cam

P-69982 ring.
NOTE: The cylinder block may stay with the cam ring.
Remove the poppet assembly (Item 1) [Figure 30-20-20]
from the housing.

Figure 30-20-23
N-22511
Remove the roller / piston assembly (Item 1) [Figure 30-

20-25] from the cylinder block.
N-22510
NOTE: Install the roller / piston assembles back in
the original bore.
Inspect the cam ring surface (Item 1) [Figure 30-20-23]
for wear and scratches.

Figure 30-20-26
Figure 30-20-24
P-73059
N-22509
Remove the shaft from the distributor [Figure 30-20-26].
Remove the cylinder block (Item 1) [Figure 30-20-24] NOTE: The end of the shaft with the snap ring (Item 1)
from the housing. [Figure 30-20-26] must be toward the brake
housing during assembly.
housing. Remove the distributor from the housing.

Disassembly (Cont'd) 1
Figure 30-20-27
N-22523
P-69984 Figure 30-20-30
Remove the distributor by lifting the housing (Item 1)

[Figure 30-20-27] 51 - 76 mm (2 - 3 in) above a wooden

surface, and dropping the housing [Figure 30-20-27].
Figure 30-20-28
2
1 1
2 N-22519
Remove the six seals (Item 1), and six O-rings (Item 2)
from the distributor [Figure 30-20-30].
N-22521
Remove the locating pin (Item 1) [Figure 30-20-28] from

the distributor.
Remove the springs (Item 1) [Figure 30-20-28] from the

distributor.

Assembly 1

Replace any worn or damaged parts. Apply oil to and
install new O-rings and back-up rings.
Figure 30-20-31
2 N-22525
Install the bushing (Item 1) [Figure 30-20-33] in the

distributor.
1 Install the O-rings (Item 2) [Figure 30-20-34] and seals
on the distributor.

N-22511 NOTE: Apply a light coating of oil to the seal and the
mating surfaces of the distributor. Install the
O-rings and seals. Allow 30 minutes for the
During installation of pistons in the bore, position the seals to set on the distributor before installing
piston ring gap 180 from one piston to the next. One the distributor in the housing.
piston installed with the gap to the right, the next piston
installed with the gap to the left. Figure 30-20-34
Dip each of the roller / piston assemblies (Item 1) [Figure

30-20-31] in oil and install the piston assembly in its
original bore.
Figure 30-20-32
1
1
P-73060
Apply assembly lube to the springs (Item 1) [Figure 30-

20-34] and install the springs into the distributor valve.
N-22518
Apply assembly lube to the locating pin (Item 1) [Figure

30-20-32] and install the locating pin in the housing

Assembly (Cont'd) 1
Figure 30-20-35
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

20-37].
N-22515
Install the cam ring to the housing. Apply thread adhesive
(Loctite 243) to the two cam ring mounting bolts. Install
Install the distributor (Item 1) [Figure 30-20-35] in the the bolts finger tight.
housing.

Figure 30-20-38
Figure 30-20-36
2
1
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring and cylinder
The pin in the distributor must align with the hole in the block [Figure 30-20-38].
housing (Item 1) [Figure 30-20-36]. Use a hand press to
push the distributor in place. NOTE: Use care when turning or moving the motor
so the cylinder block stays in the motor
When installed correctly, the distributor will spring back housing and the sealing surfaces are
slightly when pushed by hand into the housing. protected.
Tighten the two cam ring mounting bolts (Item 1) [Figure

30-20-38] to 35 - 39 Nm (26 - 29 ft-lb) torque.
Install the shaft (Item 2) [Figure 30-20-38].

1
Assembly (Cont'd) 2
Figure 30-20-39
P-69986
1
Install the brake housing (Item 1) [Figure 30-20-41] on
the motor housing.
P-69978
Apply thread adhesive (Loctite 243) to the five mounting
bolts. Install the bolts (Item 2) [Figure 30-20-41] to 117 -
Install the O-rings (Item 1) [Figure 30-20-39] on the 122 Nm (86 - 90 ft-lb) torque.
housing assembly.

Figure 30-20-42
Install the two speed spool (Item 2) [Figure 30-20-39].
Figure 30-20-40
P-73064
N-18347 If needed, install the shims first, then install the brake
disc pack starting with an outer disc (Item 1) [Figure 30-
20-42] and alternating with an inner disc, throughout the
Clamp the disc pack in a vise and measure the height pack.
[Figure 30-20-40]. The height must be 31,1 mm (1.22
in). End the disc pack with an outer disc
The thickness of a new brake disc is 1 mm (0.039 in).
If any individual disc's thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

Assembly (Cont'd)
Figure 30-20-43
1
2
N-22493
Install the piston (Item 1) [Figure 30-20-45] in the brake

housing.
P-73055
Figure 30-20-46
Install the brake seal (Item 1) [Figure 30-20-43].

NOTE: Install the seal with the metal case end
towards the brake pack. 2
1
Install the snap ring (Item 2) [Figure 30-20-43].
Install a new O-ring (Item 3) [Figure 30-20-43] in the

seal.
Figure 30-20-44
N-22492
Install the brake spring (Item 1) [Figure 30-20-46].

1
Install the gasket (Item 2) [Figure 30-20-46].
N-22498
Install the piston seal (Item 1) [Figure 30-20-44].

Assembly (Cont'd)
Figure 30-20-47
2
1
N-22490
Install the cover (Item 1) [Figure 30-20-47].

Install the twelve bolts (Item 2) [Figure 30-20-47]and
NOTE: Tighten the bolts one turn at a time to

brake spring.


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Removal And Installation
ATDW11600 AND ATDY11001 & ABOVE)
Description
DANGER
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps.
This hydrostatic motor contains a spring applied pressure

release braking system. This braking system is located
on the end of the hydrostatic motor.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing case P-90328
drain oil with cooled low pressure oil from the charge
circuit. The shuttle valve is shifted by the high pressure AVOID DEATH
oil coming from the hydrostatic pumps. If the shuttle valve Disconnecting or loosening any hydraulic
sticks, a delay or lack of drive may or may not be felt in tubeline, hose, fitting, component or a part failure
the controls and / or an overheated hydrostatic motor will can cause lift arms to drop.
result. Keep out of this area when lift arms are raised
There are two hydrostatic motors mounted to motor support. Replace if damaged.
carriers. The motor carriers are mounted to the D-1009-0409
transmission chaincase which houses the drive chains.

WARNING
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888

1.)

Drain the hydraulic reservoir. (See Removal And


ATDW11600 AND ATDY11001 & ABOVE) (CONT'D)
Figure 30-21-1
2
1 2
P100208

that goes to the drain manifold.
P100257
Remove the eight flange bolts (Item 2) [Figure 30-21-3]
from the high pressure hoses on the motor.
Remove the motor cover bolts (Item 1) [Figure 30-21-1].

Figure 30-21-4
Mark the hoses for correct installation.
Figure 30-21-2
2 3
4 1
P100901
Installation: Install both flanges and tighten the bolts to

2 half of the required torque in the sequence shown
P100206 [Figure 30-21-4].
Tighten all bolts to the correct torque in the same

Disconnect the hydraulic hose (Item 1) [Figure 30-21-2] sequence [Figure 30-21-4].
that goes to the two-speed port on the two-speed / brake
block.

that goes to the brake port on the two-speed / brake
block.

that goes to the make-up port on the two-speed / brake
block.

Removal And Installation (Cont'd) 12 1

11
Figure 30-21-5 13
10 2
9 3
8 4
7 5
1 6
N-22535
Remove the O-ring (Item 13) [Figure 30-21-6] with new

O-ring
P-90496
Installation: Install the O-ring (Item 1) by pressing the O-
ring into the groove starting at the 12 oclock position
Remove the ten (12 mm) bolts (Item 1) [Figure 30-21-5] then 6,2,10,3,9,4,8,5,7,1 and 11 [Figure 30-21-6] until
from the motor.

the O-ring is fully seated in the groove.
NOTE: The two smaller diameter bolts (8 mm), hold NOTE: Do not twist the O-ring in to the groove. Verify
the cam ring to the motor and do not have to the O-ring is flush with no protrusions.
be removed for motor removal.
Remove the motor from the loader.
Installation: Tighten the ten bolts to 149 Nm (110 ft-lb)

torque [Figure 30-21-5].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11600 AND ATDY11001 & ABOVE) (CONT'D)
1. Rotary Group
2. Block
3. Piston
4. Roller 11
5. Pin
6. Cam Ring
7. O-ring 11
8. Distributor Assembly
9. Distributor 11
10. Spring
11. Seal 10
12. Housing Assembly 9
13. Plug
14. O-ring 7
15. Spool 8
16. Washer 6
17. Housing
18. Bolt 4
19. Bushing 5
20. Snap Ring 3
21. Brake Assembly
22. Shim 23
23. Brake Disc

24. Brake Housing 18 22
25. Shaft 2
26. Seal 20
27. Piston 1
28. Spring 5
29. Gasket
30. Cover 13
14 25
16
15 19
13 10 14 21
13
14
14
20
10 16
14 10
18
15 30
13
29
28
12 14
27
20
14
26
21
NA2535S

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Remove the cover plate (Item 2) [Figure 30-21-8] from
ATDW11600 AND ATDY11001 & ABOVE) (CONT'D) the brake housing.
Disassembly Figure 30-21-9
Figure 30-21-7
1
2
N-22492
1
N-22489
Remove the gasket (Item 1) [Figure 30-21-9].
Place the cam sealing surface (Item 1) [Figure 30-21-7] Remove the brake spring (Item 2) [Figure 30-21-9] from
on a protective material.

the brake housing.
NOTE: Mark the side of the motor, brake, and motor NOTE: Mark the top side of the brake spring for
carrier housings for correct assembly. proper installation.
NOTE: Always protect any sealing surfaces. Any Figure 30-21-10

scratches or marks will cause premature
failure.
Drain the oil from the motor housing.
Figure 30-21-8 1
2
N-22493
Remove the piston (Item 1) [Figure 30-21-10] from the

brake housing.
N-22490 NOTE: Use low air pressure through the brake line
fitting (Item 2) [Figure 30-21-10] to aid in
piston removal.
Remove the twelve mounting bolts (Item 1) [Figure 30-
21-8] from the brake cover plate. Remove the O-ring from the piston.
NOTE: Remove the bolts one turn at a time to

brake spring.

1
Figure 30-21-11
P-69985
Remove the brake disks (Item 1) [Figure 30-21-13] from

the brake shaft. Mark the position of the brake disks and
P-69973 the shims.
Figure 30-21-14
Remove the five bolts (Item 1) [Figure 30-21-11] from
the brake housing.

1
Remove the brake housing (Item 2) [Figure 30-21-11]
from the housing. 2
Figure 30-21-12
P-69978
Remove the two-speed spool (Item 1) [Figure 30-21-14]

from the housing assembly.
1
P-73062
Remove the snap ring (Item 1) [Figure 30-21-12] and the

seal from the brake housing.

Figure 30-21-15
1
P-73057
3
1
2 Remove the flushing spool assembly (Item 1) [Figure 30-
21-17] from the housing.
N-22501
Figure 30-21-18
Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) from the spool (Item 4) [Figure 30-21-15]

1
2 3 4
NOTE: If the two speed spool (Item 1) [Figure 30-21-
15] is damaged the entire housing assembly
has to be replaced
NOTE: There is an inner make-up spool inside the

two speed spool (Item 4) [Figure 30-21-15].
The make-up spool is not serviceable. If the
two speed spool is disassembled, both the
make-up spool and the two speed spool will
be damaged.
N-22504
Figure 30-21-16
1 Remove the spring (Item 1), washer (Item 2), spool (Item
3) and spring (Item 4) [Figure 30-21-18].
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-21-

16] from the housing.
Installation: Tighten the plug to 30 Nm (22 ft-lb) torque.

Figure 30-21-19
3
2
1 1
N-22507
Remove the spring (Item 1) and shim (Item 2) from the

poppet (Item 3) [Figure 30-21-21].
P-69981
Figure 30-21-22
Remove the plug (Item 1) [Figure 30-21-19] from the

housing.

Installation: Tighten the plug to 22 Nm (18 ft-lb) torque. 1 1
Figure 30-21-20
P-73058
Remove the two (8 mm) cam ring bolts (Item 1) [Figure

30-21-22].
Remove the housing and rotating group from the cam

P-69982 ring.
NOTE: The cylinder block may stay with the cam ring.
Remove the poppet assembly (Item 1) [Figure 30-21-20]
from the housing.

Figure 30-21-23
N-22511
Remove the roller / piston assembly (Item 1) [Figure 30-

21-25] from the cylinder block.
N-22510
NOTE: Install the roller / piston assembles back in
the original bore.
Inspect the cam ring surface (Item 1) [Figure 30-21-23]
for wear and scratches.

Figure 30-21-26
Figure 30-21-24
P-73059
N-22509
Remove the shaft from the distributor [Figure 30-21-26].
Remove the cylinder block (Item 1) [Figure 30-21-24] NOTE: The end of the shaft with the snap ring (Item 1)
from the housing. [Figure 30-21-26] must be toward the brake
housing during assembly.
housing. Remove the distributor from the housing.

Disassembly (Cont'd) 1
Figure 30-21-27
N-22523
P-69984 Figure 30-21-30
Remove the distributor by lifting the housing (Item 1)

[Figure 30-21-27] 51 - 76 mm (2 - 3 in) above a wooden

surface, and dropping the housing [Figure 30-21-27].
Figure 30-21-28
2
1 1
2 N-22519
Remove the six seals (Item 1), and six O-rings (Item 2)
from the distributor [Figure 30-21-30].
N-22521
Remove the locating pin (Item 1) [Figure 30-21-28] from

the distributor.
Remove the springs (Item 1) [Figure 30-21-28] from the

distributor.

Assembly 1

install new O-rings and back-up rings.
Figure 30-21-31
2 N-22525
Install the bushing (Item 1) [Figure 30-21-33] in the

distributor.
1 Install the O-rings (Item 2) [Figure 30-21-34] and seals
on the distributor.

N-22511 NOTE: Apply a light coating of oil to the seal and the
mating surfaces of the distributor. Install the
O-rings and seals. Allow 30 minutes for the
During installation of pistons in the bore, position the seals to set on the distributor before installing
piston ring gap 180 from one piston to the next. One the distributor in the housing.
piston installed with the gap to the right, the next piston
installed with the gap to the left. Figure 30-21-34
Dip each of the roller / piston assemblies (Item 1) [Figure

30-21-31] in oil and install the piston assembly in its
original bore.
Figure 30-21-32
1
1
P-73060
Apply assembly lube to the springs (Item 1) [Figure 30-

21-34] and install the springs into the distributor valve.
N-22518
Apply assembly lube to the locating pin (Item 1) [Figure

30-21-32] and install the locating pin in the housing

Assembly (Cont'd) 1
Figure 30-21-35
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

21-37].
N-22515
Install the cam ring to the housing. Apply thread adhesive
(Loctite 243) to the two cam ring mounting bolts. Install
Install the distributor (Item 1) [Figure 30-21-35] in the the bolts finger tight.
housing.

Figure 30-21-38
Figure 30-21-36
2
1
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring and cylinder
The pin in the distributor must align with the hole in the block [Figure 30-21-38].
housing (Item 1) [Figure 30-21-36]. Use a hand press to
push the distributor in place. NOTE: Use care when turning or moving the motor
so the cylinder block stays in the motor
When installed correctly, the distributor will spring back housing and the sealing surfaces are
slightly when pushed by hand into the housing. protected.
Tighten the two cam ring mounting bolts (Item 1) [Figure

30-21-38] to 35 - 39 Nm (26 - 29 ft-lb) torque.
Install the shaft (Item 2) [Figure 30-21-38].

1
Assembly (Cont'd) 2
Figure 30-21-39
P-69986
1
Install the brake housing (Item 1) [Figure 30-21-41] on
the motor housing.
P-69978
Apply thread adhesive (Loctite 243) to the five mounting
bolts. Install the bolts (Item 2) [Figure 30-21-41] to 117 -
Install the O-rings (Item 1) [Figure 30-21-39] on the 122 Nm (86 - 90 ft-lb) torque.
housing assembly.

Figure 30-21-42
Install the two speed spool (Item 2) [Figure 30-21-39].
Figure 30-21-40
P-73064
N-18347 If needed, install the shims first, then install the brake
disc pack starting with an outer disc (Item 1) [Figure 30-
21-42] and alternating with an inner disc, throughout the
Clamp the disc pack in a vise and measure the height pack.
[Figure 30-21-40]. The height must be 31,1 mm (1.22
in). End the disc pack with an outer disc
The thickness of a new brake disc is 1 mm (0.039 in).
If any individual disc's thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

Assembly (Cont'd)
Figure 30-21-43
1
2
N-22493
Install the piston (Item 1) [Figure 30-21-45] in the brake

housing.
P-73055
Figure 30-21-46
Install the brake seal (Item 1) [Figure 30-21-43].

NOTE: Install the seal with the metal case end
towards the brake pack. 2
1
Install a new O-ring (Item 3) [Figure 30-21-43] in the

seal.
Figure 30-21-44
N-22492
Install the brake spring (Item 1) [Figure 30-21-46].

1
Install the gasket (Item 2) [Figure 30-21-46].
N-22498
Install the piston seal (Item 1) [Figure 30-21-44].

Assembly (Cont'd)
Figure 30-21-47
2
1
N-22490
Install the cover (Item 1) [Figure 30-21-47].

Install the twelve bolts (Item 2) [Figure 30-21-47]and
NOTE: Tighten the bolts one turn at a time to

brake spring.


HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission chain
case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONTD) Remove drive motor. (See Removal And Installation on
Page 30-20-1.)
If the motor carrier is removed from the right side, remove
the lift arm bypass valve, (See Removal And Installation
on Page 20-50-2.) and remove the control panel. (See
DANGER Removal And Installation on Page 50-100-1.)
Remove the actuators. (See Actuator Removal And

Installation (In Loader) on Page 20-40-6.)
Figure 30-30-1
P-90328
1
AVOID DEATH
1

D-1009-0409
P5467A
Remove the six bolts (Item 1) [Figure 30-30-1] from the

WARNING carrier.
Installation: Tighten the bolts to 461 - 488 Nm (340 -

Never work on a machine with the lift arms up unless 360 ft-lb) torque.
support device. Failure to use an approved lift arm Slide the motor carrier toward the rear and remove the
support device can allow the lift arms or attachment rear drive chain.
W-2059-0598

1.)
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the fluid from the chain case. (See Removing

And Replacing Fluid on Page 10-140-1.)
Remove the two speed / brake valve. (See Valve Block

Remove the center chain case cover. (See Center Cover

Remove the front axle sprocket. (See Chain Removal

And Installation on Page 40-30-9.)

HYDROSTATIC MOTOR CARRIER (CONTD)
Figure 30-30-2
1 1
P5489A
Slide the motor carrier out of the chain case far enough to
install a chain (Item 1) [Figure 30-30-2] and chain hoist

to the carrier.
NOTE: For ease of installation, wire the front drive

chain to the chain case in two areas (Item 2)
[Figure 30-30-2].
Pull the motor carrier away from the chain case and out
of the loader. [Figure 30-30-2].

1. Housing
2. Seal
3. Race
4. Bearing
5. Snap Ring
6. Shaft

2
2
3
4
3
NA5767S

HYDROSTATIC MOTOR CARRIER (CONTD) Figure 30-30-5
Disassembly
Figure 30-30-3
P-28155
Remove the snap ring (Item 1) [Figure 30-30-5] from the

P5760 shaft.
Figure 30-30-6

Figure 30-30-4
P5766
P106444
Press the shaft out of the housing [Figure 30-30-6].
Position the motor carrier in a hydraulic press [Figure 30-

30-4].
Apply a small amount of pressure on the shaft to release

the pre-load on the snap ring.

Disassembly (Contd)
Figure 30-30-7 2
1 1
P-28164
Remove the two seals (Item 1) [Figure 30-30-9] from the

P-28157 housing.
Remove the bearing race (Item 2) [Figure 30-30-9] from

Install the bearing puller tool (Item 1) [Figure 30-30-7] both sides.
under the bearing.

Figure 30-30-8
P-28158
Press the bearing off of the shaft [Figure 30-30-8].

Assembly

install new O-rings.
1
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool
Figure 30-30-10
P10645
2
Press the bearing (Item 1) [Figure 30-30-12] on the

1 shaft.
Install the shaft / bearing assembly into the housing.
Figure 30-30-13

2
P5764
Install the first seal (Item 1) [Figure 30-30-10] into the

housing with the seal lip facing down.
1
Use the tool (Item 2) [Figure 30-30-10] to install the seal.
Figure 30-30-11
P-5769
Press the bearing (Item 1) on the shaft using the tool

(MEL1431) (Item 2) [Figure 30-30-13].
P5762
NOTE: Do not press the bearing on the shaft farther

Install the second seal (Item 1) [Figure 30-30-11] into the than is needed to install the snap ring.
housing with the seal lip facing up.
Use the tool (Item 2) [Figure 30-30-11] to install the seal.

Assembly (Cont'd)
Figure 30-30-14
P-28155
Install the snap ring (Item 1) [Figure 30-30-14] on the

shaft.

Figure 30-30-15
3 2
P-76467
Install a dial indicator (Item 1) [Figure 30-30-15] as

shown.
Use a pry bar (Item 2) to lift the carrier shaft (Item 3)

[Figure 30-30-15]. Record the end play on the dial
indicator.
The carrier shaft must turn free and end play must not
exceed 0,33 mm (0.013 in)

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

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor internal leakage
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

CHARGE PRESSURE (CONTD)
Testing WARNING
WARNING the lift arms are secured by an approved lift arm
When the engine is running during service, the to fall and cause injury or death.
driving and steering controls must be in neutral and W-2059-0598
the parking brake engaged. Failure to do so can
Raise the loader lift arms and install an approved lift arm
W-2006-1209
The tools listed will be needed to do the following Place the loader on jackstands. (See Procedure on Page
procedure: 10-10-1.)
MEL1355-2 - Pressure gauge 6,9 MPa (68,9 bar) (1000 Raise the operator cab. (See Raising on Page 10-30-2.)
psi)
MEL1723 - Female Test Coupler
Hydraulic hose - Must be rated for pressures above 6,9
MPa (68,9 bar) (1000 psi).

WARNING
immediately.
W-2145-0290
Figure 30-40-1
3
1
2
P-43196C
Assemble the gauge (Item 1), hose (Item 2) and the test
coupler (Item 3) [Figure 30-40-1]. Tighten all fittings.

CHARGE PRESSURE (CONTD) Sender Removal And Installation
Testing (Contd) Figure 30-40-4
Figure 30-40-2
P-90302
P109149B
from the sender.
Figure 30-40-3
Remove the sender (Item 2) [Figure 30-40-4] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 Nm (7.4 - 8.1 ft-lb) torque.
P107933
Connect the test coupler (Item 1) [Figure 30-40-3] to the

quick coupler (Item 1) [Figure 30-40-2].

10-61-1.)
Start the loader and warm the hydraulic fluid to 60C

(140F).
Charge pressure at high idle, with the fluid temperature of

60C (140F) is 2482 - 2827 kPa (24,8 - 28,3 bar) (360 -
410 psi) with the pump in neutral.

CHARGE PRESSURE (CONTD) Figure 30-40-6
Adjusting
IMPORTANT
damage the system. 1 2 4 3
I-2003-0888
P-64435
Figure 30-40-5
Inspect the poppet (Item 1), spring seat (Item 2) and

spring (Item 3) [Figure 30-40-6] for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.

1 There are several different thickness of shims (Item 4)
[Figure 30-40-6] used to adjust the charge pressure.
NOTE: 1,0 mm shim = 300 kPa (3 bar) (43.5 psi) in

pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.
P-64431
The charge pressure at high idle is 2482 - 2827 kPa
(24,82 - 28,27 bar) (360 - 410 psi).
If the charge pressure is not correct remove the charge
relief valve (Item 1) [Figure 30-40-5].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Installation: Tighten the plug to 41 - 68 Nm (30 - 50 ft-

lb) torque.

HYDROSTATIC PUMP The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The hydrostatic pump is a fully proportional dual piston forward or reverse drive motor rotation is obtained.
pump in one pump casing. The endcaps are removable
to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are supplied with charge
pressure from an external charge pump. 12 volt electrical Ports are labeled on the hydrostatic pump casting.
solenoids shift a spool in the hydraulic controller that
directs flow to a servo piston.
Figure 30-50-1
X1
X1 X2 X2
R

G
MB MB
RIGHT PUMP LEFT PUMP
MA MG
B A M A M G MA A B T NA5939A
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of A Port
MB Operating Pressure of B Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (CONT'D) Figure 30-50-2
Hydraulic Controller Removal And Installation
The loaders right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loaders left hand side hydraulic controller can only be
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount. 1
Controller solenoids can be bled of trapped air in the
controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install an approved lift arm P-90207
Locate the two hydraulic controllers (Item 1) [Figure 30-

50-2] on the hydrostatic pumps.


to fall and cause injury or death. 1
W-2059-0598
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
WARNING 1
P-90239

of the frame before running the engine for service. Disconnect the wire harness (Item 1) [Figure 30-50-3]
Failure to use jackstands can allow the machine to from both sides of the hydrostatic pump.
W-2017-0286

IMPORTANT
damage the system.
I-2003-0888

Hydraulic Controller Removal And Installation

(Cont'd)
Figure 30-50-4
2 2
1
1
1
P-90209
Install the controller with the feedback lever (Item 4)

[Figure 30-50-5] in the center of the servo piston groove
P-90208 (Item 1) [Figure 30-50-6].
NOTE: DO NOT remove the three screens (Item 2)

Remove the four bolts (Item 1) [Figure 30-50-4] from the [Figure 30-50-6] they will be damaged during

hydraulic controller. removal and must be replaced.
Installation: Tighten the bolts to 10,4 Nm (7.7 ft-lb). NOTE: When a hydraulic controller is replaced, the
hydrostatic pumps must be calibrated. (See
Figure 30-50-5 Hydraulic Controller Neutral Adjustment on
Page 30-51-32.)
3
2
1
4
P-90210
Remove the cover (Item 1) gaskets (Item 2) and control

(Item 3) [Figure 30-50-5] from the pump.

Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-10.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-50-8] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-50-7 Remove the pump pulley from the pump drive shaft.
Figure 30-50-9
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-50-7] on the
hydrostatic pump drive shaft.
Remove the two bolts and nuts (Item 1) [Figure 30-50-9].
Installation: Tighten the nut to 258 - 325 Nm (190 - 240
ft-lb) torque Installation: Tighten the bolts and nuts to 88 - 95 Nm
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-50-5.)

HYDROSTATIC PUMP (CONT'D)
Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump must be filled with hydrostatic fluid.
This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry will cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Fill the hydrostatic pump by removing a plug at the top of

the hydrostatic pump. A clean funnel should be used to
avoid washing contaminants into the hydrostatic pump.
Fill the hydrostatic pump case as much as possible
before startup.
Figure 30-50-10

1
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-50-10].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Installation: Tighten plugs to 25 Nm (18 ft-lb) torque.
NOTE: The hydrostatic pump is removed from the

loader for photo clarity.

3 1
1. O-ring 4 1
2. Bolt 5
3. End Housing
4. Right Rotating Assembly 6
5. Timing Pin 7
6. Bearing
7. Spacer/Coupler
8. Positioning Wire
9. Positioning Pin
10. Position Sensor
11. Washer 8 9 2
10
16 12
2
16 14 2

15
13
23
13 16
17
14 20
19
18 5
22
12. Steel Cover

13. Hydraulic Controller
14. High Pressure Relief
2 15. Case Housing
6 16. Plug
17. Dowel Pin
21 18. Charge Pressure Relief
19. Left Servo
1 8 20. Right Servo
9 21. Left Rotating Assembly
22. End Housing
23. Screen
10
2
12 2
NA2245S

High Pressure Relief And Bypass Valve
Figure 30-50-11
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-50-13]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-50-13] for

There are four system high pressure relief valves (Item 1) breakage.
[Figure 30-50-11] in the back of the hydrostatic pump.

Inspect the seats inside the case housing.
Remove the relief valve cap (Item 1) [Figure 30-50-11].
Do not disassemble the relief valve assembly. If
Installation: Tighten cap to 150 - 170 Nm (111 - 125 ft- replacement is required, replace as an assembly.
lb) torque.
Factory setting on the relief valve is 39500 kPa (395 bar)
Figure 30-50-12 (5729 psi).
4
3
2 1
P-64436
Replace the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-50-12].
Remove relief valve assembly (Item 3) [Figure 30-50-12]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-50-12] for

damage.

Charge Relief Valve

1 4 5
Figure 30-50-14 6
2 3
1 P-64435

P-64431
Inspect the poppet (Item 2) and the spring seat (Item 3)
[Figure 30-50-15] for damage or foreign material. Must
The charge relief valve (Item 1) [Figure 30-50-14] is move freely in the relief valve bore.
located on the back of the hydrostatic pump.

Inspect the sealing ring (Item 4) [Figure 30-50-15] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Installation: Tighten the charge relief valve to 70 Nm
(52 ft-lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-50-15].
NOTE: 1,0 mm shim = 300 kPa (3 bar) (43.5 psi) in

pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.

Disassembly
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on 1
Page 70-10-10.)
Remove the hydrostatic pump. (See Removal And

Figure 30-50-16 1
2
P-90228
Remove the bolts (Item 1) for the swash plate angle

1 sensor (Item 2) [Figure 30-50-18].
1
Figure 30-50-19

1
P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-50-

16]. (See Hydraulic Controller Removal And Installation
on Page 30-50-2.)
Figure 30-50-17
3 3
2 2 P-90218
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-50-17].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-50-17] from both sides.

Figure 30-50-20
P-64464
1
Remove the end housing / rotating group assembly
P-64445 [Figure 30-50-22] from both ends of the pump.
Figure 30-50-23
Remove the bolts (Item 1) from the right end housing
(Item 2) [Figure 30-50-20] 1

Figure 30-50-21
P-64465
1
Remove O-ring (Item 1) [Figure 30-50-23].
P-64447
Remove the four bolts (Item 1) from the left end housing
(Item 2) [Figure 30-50-21].

Figure 30-50-24
RIGHT SIDE
B25012
Disassemble the right side rotating group [Figure 30-50-

P-64454 26].
Figure 30-50-27
Remove valve plate (Item 1) [Figure 30-50-24] from the
right side pump.

NOTE: The valve plates are NOT interchangeable
between the right and left sides.
Figure 30-50-25
LEFT SIDE
B25011
Disassemble the left side rotating group [Figure 30-50-

27].
P-64501
Remove valve plate (Item 1) [Figure 30-50-25] from the

left side pump.
NOTE: The valve plates are NOT interchangeable

between the right and left sides.

1
Figure 30-50-28
P-64471
Remove the spherical washer (Item 1) [Figure 30-50-

P-64475 30].
Figure 30-50-31
Remove the pistons (Item 1) [Figure 30-50-28] from the
rotating block.
1

Figure 30-50-29
1
P-64472
Do Not remove the pins (Item 1) [Figure 30-50-31] from

P-64476 the cylinder block.
Remove the pistons (Item 1) [Figure 30-50-29] from the

piston retainer.

2 2
Figure 30-50-32
P109266
2
Figure 30-50-35
P109265
Remove the swash plate (Item 1) from the endcap

housing (Item 2) [Figure 30-50-32].

Remove the link (Item 3) [Figure 30-50-32],
1
Figure 30-50-33
1
P109268
Remove the positioning pin (Item 1) [Figure 30-50-34]

and [Figure 30-50-35].
2
Remove the bearing races (Item 2) [Figure 30-50-34].
P109269
Remove the bearing (Item 1) [Figure 30-50-33].
Remove the positioning wire (Item 2) [Figure 30-50-33].

Figure 30-50-36
LEFT SIDE
1
P-76742
Remove the pump seal (Item 1) [Figure 30-50-38] by

P-64486 inserting a screw into the seal and prying out.
Figure 30-50-39
Figure 30-50-37
RIGHT SIDE

1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-50-36] and a rubber mallet.
[Figure 30-50-37] from the end housing.
Remove the snap ring (Item 1) and remove the bearing
(Item 2) [Figure 30-50-39].

Figure 30-50-40
P-90231
Rotate the servo piston cover (Item 1) [Figure 30-50-42].

P-64490
Figure 30-50-43
Measure and record servo piston depth at the adjustment

screw [Figure 30-50-40].

Figure 30-50-41
1 1
P-90237
Slide the servo piston assembly out of the bore. [Figure

30-50-43].
P-90232
Remove servo piston bolts (Item 1) [Figure 30-50-41].

Figure 30-50-44 1
2
1 2
P-64496
Remove the servo cover (Item 1) [Figure 30-50-46] from

P-64493 the servo piston.

Remove the bushings (Item 1), seals and O-rings (Item 2) cover.
[Figure 30-50-44] from the pump housing.

Figure 30-50-47
Figure 30-50-45
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-50-47] from the

Remove the lock nut (Item 1) [Figure 30-50-45] from the servo piston.
servo piston.

Figure 30-50-48
1
2
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-50-48] from the servo piston.

Remove the O-ring (Item 2) [Figure 30-50-48]
Figure 30-50-49
2
1
P-64502
Remove the bearings (Item 1) [Figure 30-50-49].
Remove the coupler (Item 2) [Figure 30-50-49].

Inspection
Figure 30-50-50
P-64477
Inspect the mating surface of the piston retainer for

P-86718 scoring or scratches (Item 1) [Figure 30-50-52].
Figure 30-50-53
Inspect the valve plates (Item 1) [Figure 30-50-50] for
scratches or scoring. Replace a valve plate if the 1

scratches are deep enough to catch with a fingernail. 1
Figure 30-50-51
P-64472
1
Inspect the pins (Item 1) [Figure 30-50-53]. The pins

must be all the same length.
P-64476
Inspect the pistons for scoring and scratches. The holes

(Item 1) [Figure 30-50-51] in the slippers must not be
plugged.

Inspection (Contd)
Figure 30-50-54
P109265
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-50-56].
Figure 30-50-57
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-50-54].

2
Figure 30-50-55
2
1
3
P-64482
Inspect the bearings (Item 1) and machined surfaces

P-64478 (Item 2) [Figure 30-50-57] on swash plate for scratches
or scoring.
Inspect the back surface of the rotating block (Item 1)

[Figure 30-50-55] where the valve plate seals. There
must be no scratches or scoring.
Inspect that the spring (Item 2) and snap ring (Item 3)

[Figure 30-50-55] are not bent or damaged.

Inspection (Contd)
Figure 30-50-58 1
1
P-64498
Inspect the servo piston stop adjustment (Item 1) [Figure

P-86723 30-50-60] for broken parts.
Figure 30-50-61
Inspect bearing surfaces (Item 1) [Figure 30-50-58] for
scratches or scoring.

Figure 30-50-59
3
1
3 1
P109268
Inspect the positioning pin (Item 1) [Figure 30-50-61] for

P-64488 wear or damage and replace as needed.
Inspect the bearing (Item 1) [Figure 30-50-59].
Inspect wear surfaces (Item 2) for scratches. Inspect the

splines (Item 3) for excessive wear.

Assembly
Figure 30-50-62
P-64497
2
P-64502
Figure 30-50-65
Install the coupler (Item 1) [Figure 30-50-62].

Install the bearings (Item 2) [Figure 30-50-62].
Figure 30-50-63
1
1
P-64496
2
Install the O-ring (Item 1) [Figure 30-50-65] on the servo
cover.
Figure 30-50-66
P-64498
Install the piston stop adjustment mechanism (Item 1) in 1

to the servo piston (Item 2) [Figure 30-50-63].
2
P-64495
Install the servo cover (Item 1) on the servo piston to the

dimension recorded earlier. Install the lock nut (Item 2)
[Figure 30-50-66].

Assembly (Contd)
Figure 30-50-67
1
2
1
2
P-64466
Align the servo piston with the guide slot (Item 1) [Figure
P-64493 30-50-69] parallel to the driveshaft center line.
Figure 30-50-70
Install the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-50-67] in the pump housing.

Figure 30-50-68
1 1
P-90232
Install the bolts (Item 1) [Figure 30-50-70].

P-90237
Tighten the bolts to 10,4 Nm (7.7 ft-lb) torque.
Install the servo piston assembly [Figure 30-50-68].

Assembly (Contd) LEFT SIDE

Figure 30-50-71 1
2
RIGHT SIDE
1 P-64503
2
Align the timing pin (Item 1) [Figure 30-50-71] and
P-64455 [Figure 30-50-72] in the case housing with the notch
(Item 1) [Figure 30-50-73] and [Figure 30-50-74] that
does not go through the valve plate.
Figure 30-50-72
Align the shoulder of the roller bearing (Item 2) [Figure

LEFT SIDE 30-50-71] and [Figure 30-50-72] with the beveled edge
on the valve plate (Item 2) [Figure 30-50-73] and [Figure
30-50-74].
NOTE: Valve plate must sit FLUSH with the case

housing when properly installed.
Figure 30-50-75
1
2
P-64502
2
1
Figure 30-50-73
RIGHT SIDE
1
2
P-64488
Install the bearing (Item 1) and snap ring (Item 2) [Figure

30-50-75] on the shaft.
Install the shaft in both end housings.
P-64456

Assembly (Contd)
2
Figure 30-50-76
LEFT SIDE 2
1
1
P109266
Install the positioning pin (Item 1). Install the bearing

P-64486 races with the tall edge (Item 2) [Figure 30-50-78] of the
race towards the outside of the housing.
Install the snap ring (Item 1) [Figure 30-50-76] on both Figure 30-50-79
sides of the pump.

Figure 30-50-77
RIGHT SIDE 2
2 1
4 3
P109271
P-76743 Install the locating wires (Item 1) through the bearings

and into the hole (Item 2) [Figure 30-50-79] in both sides
of the swash plate.
Install the seal (Item 1) and snap ring (Item 2) [Figure
30-50-77] on the right side pump. Install the positioning wire (Item 3) into the hole (Item 4)
[Figure 30-50-79] in the side of the swash plate.

Assembly (Contd)
Figure 30-50-80 2
1
1 1
2 2
P109274
The swash plate (Item 1) must move smoothly on the

P-64480A bearings. Install the feedback link (Item 2) [Figure 30-50-
82] on the swash plate.
Install the swash plate assembly over the shaft and into Figure 30-50-83
the end cap housing. The locating wires (Item 1) must

engage the holes (Item 2) [Figure 30-50-80] of the end
1
cap housing.
Figure 30-50-81
P-64471
2
Install the ball guide (Item 1) [Figure 30-50-83] on the
cylinder.
P109273
Install the positioning wire (Item 1) into the positioning pin

(Item 2) [Figure 30-50-81].

Assembly (Contd)
Figure 30-50-84
P-64469A
Install the cylinder block / piston assembly (Item 1)

P-64476 [Figure 30-50-86] on the shaft.
Figure 30-50-87
Install the pistons (Item 1) [Figure 30-50-84] in the piston
retainer. 1 2

Figure 30-50-85
P-64465

P-64475
Install the piston / retainer (Item 1) [Figure 30-50-85]

assembly in the cylinder block.

Assembly (Contd)
Figure 30-50-88
1 1
1 1
1
P-64445
Figure 30-50-91
P-64466
Install the end housing assembly into the pump housing.

The feedback link (Item 2) [Figure 30-50-87] must 1 1

engage the notch in the servo piston (Item 1) [Figure 30-
50-88].
Figure 30-50-89
1 1
1
P-64447
Install the bolts (Item 1) [Figure 30-50-90] and [Figure

2 30-50-91]. Tighten the bolts to 130 Nm (96 ft-lb) torque.
Figure 30-50-92
1
P-64463
Align the dowel pin (Item 1) with the hole in the case
(Item 2) [Figure 30-50-89] as the end cap is installed.
P-90218

Assembly (Contd)
2 2
Figure 30-50-93
1 1
2 2
2 P-90227
Install the covers (Item 1) and bolts (Item 2) [Figure 30-

P-90217 50-95]. Tighten the bolts to 51 Nm (38 ft-lb) torque.
Install the hydraulic controllers. (See Hydraulic Controller

Install the swash plate angle sensor (Item 1) into the slot Removal And Installation on Page 30-50-2.)
of the positioning pin (Item 2) [Figure 30-50-93].

Figure 30-50-94
P-90228
Install the bolts (Item 1) [Figure 30-50-94]. Tighten the

bolts to 3,1 Nm (27.4 in-lb) torque.

Mechanical Neutral Adjustment

WARNING
The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
immediately.
Place the loader on jackstands. (See Procedure on Page W-2145-0290
10-10-1.)
Figure 30-50-96
WARNING 1
1

W-2017-0286

Raise the lift arms, and install an approved lift arm
P-64973
WARNING
Connect a hydraulic hose (Item 1) [Figure 30-50-96]
Never work on a machine with the lift arms up unless between port X1 and port X2 on each side of the
the lift arms are secured by an approved lift arm hydrostatic pump, to equalize the pressures on both ends
support device. Failure to use an approved lift arm of the servo pistons.
to fall and cause injury or death. Figure 30-50-97
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) 1

1
Connect the remote start tool. (See Remote Start Tool -
MEL1563 on Page 10-60-1.) or (See REMOTE START
TOOL (SERVICE TOOL) KIT - 7217666 on Page 10-61-
1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect. P-90242
Disconnect the speed sensors (if equipped) located on

Remove the plugs (Item 1) [Figure 30-50-97] from the
the top of the motor carriers. This prevents
MB ports on the front side of the pump, and install 51711
uncommanded wheel movement error codes from
kPa (517 bar) (7500 psi) pressure gauges.
occurring during adjustments.

Mechanical Neutral Adjustment (Contd)
Figure 30-50-98
P-90226
Loosen the pump neutral adjustment locknut (Item 1)

P-90227A [Figure 30-50-100].
Start the loader using the remote start tool and run at
Remove the plugs (Item 1) [Figure 30-50-98] from the idle.
MA ports on the bottom of the pump, and install 51711

kPa (517 bar) (7500 psi) pressure gauges.

Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1 1
Figure 30-50-101
1 1
P-90243
Remove the drive hoses from the A and B ports (Item 1)

[Figure 30-50-99]. Plug the ports with metal caps. The
1
caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the P-90238
pump mechanical neutral setting.
Turn the adjustment screw (Item 1) [Figure 30-50-101]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

Mechanical Neutral Adjustment (Contd)
Figure 30-50-102
P-90238
1
While holding the adjustment screw (Item 1) in position,

P-90238 tighten the lock nut (Item 2) [Figure 30-50-104] to 30
Nm (22 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-50-102] Shut the loader OFF.
counterclockwise, until the other gauge registers an

increase in system pressure. Mark the position of the Remove the hydraulic hose from the X1 and X2 ports on
adjustment screw. the pump. Install the plugs and tighten to 25 Nm (18 ft-
lb) torque.
Figure 30-50-103
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 Nm (18
ft-lb) torque.
NOTE: The Hydraulic Controller Neutral Adjustment

must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-50-
32.)
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment aligns the

pump swash plate and the control spool so that a zero 1
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted, removed or after the pump mechanical neutral
setting is adjusted. The pump mechanical neutral setting
must be correct before performing the hydraulic controller
neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic 1

controller. Procedure is the same for the right P-90239
side hydraulic controller, with the exception
of the following procedures. Disconnect the
electrical connectors for the right side Disconnect the wire harness (Item 1) [Figure 30-50-105]
hydraulic controller and connect pressure from the controller being adjusted.
gauges in the X1 and X2 ports on the right
side of the pump. Figure 30-50-106

10-10-1.)
1
WARNING
2
W-2017-0286
P-90226
Raise the lift arms, and install an approved lift arm
Remove the X1 plug (Item 1) and X2 plug (Item 2)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 30-50-106] from the side of the hydrostatic pump
being adjusted.
10-61-1.)

Hydraulic Controller Neutral Adjustment (Contd)
Figure 30-50-107
P-90236

P-64975 clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Install 3447 kPa (34 bar) (500 psi) pressure gauges in the
X1 and X2 ports [Figure 30-50-107]. Figure 30-50-110

Figure 30-50-108
1
1
P-90236
P-90236
counterclockwise, until the other gauge registers an
Loosen the screw (Item 1) [Figure 30-50-108]. increase in system pressure. Mark the position of the
adjustment screw.
Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Contd)
Figure 30-50-111
P-90236

clockwise, to a position halfway between the recorded

positions. The pressure gauges should read equal
pressures.
Figure 30-50-112
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

tighten the locking screw (Item 2) [Figure 30-50-112] to
6,1 Nm (4.5 ft-lb) torque.
Shut the loader OFF.
Remove the pressure gauges from the X1 and X2 ports

on the pump. Install the plugs and tighten to 25 Nm (18
ft-lb) torque.
Connect the wire harness to the controller.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-170-1.)

DRIVE BELT Figure 30-60-2
Belt Adjustment
1
The drive belt does not need adjustment. The belt has a
spring loaded idler which constantly maintains the correct
belt tension. The spring loaded idler stop adjustment,
detailed below, is critical for long belt life.
2
Stop Adjustment
See your SERVICE SCHEDULE for the correct interval to

check the idler stop adjustment. (See SERVICE
SCHEDULE on Page 10-80-1.)
Stop the engine and open the rear door. (See REAR
P109784A
DOOR (TAILGATE) on Page 50-70-1.)
Figure 30-60-1 Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-60-2].
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-1] to 105 - 115 Nm (78 - 85 ft-lb) torque.
1

P115668
Loosen the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-1].

DRIVE BELT (CONTD) Figure 30-60-5
Belt Replacement
Stop the engine and open the rear door. (See REAR 1
DOOR (TAILGATE) on Page 50-70-1.)
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
2
Figure 30-60-3
P-90470
1
Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a 1/2 in breaker bar (Item 2) [Figure 30-60-5] into
the slot provided in the stop arm as shown and push
breaker bar down to release tension on drive belt.
Tighten the adjustment bolt (Item 1) [Figure 30-60-5] to

hold the spring loaded idler off the drive belt.
P107205
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley. Inspect the pulleys for wear.
Remove the drive belt shield bolt (Item 1) [Figure 30-60-
3]. Install new drive belt.
Figure 30-60-4 Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-5] and allow the idler to contact the drive
belt.
Continue the procedure on the next page.

1
P107208
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item
2)[Figure 30-60-4] toward the back of the loader to
unseat the shield from the top and bottom drive belt
shield mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-60-4].

Belt Replacement (Contd) Top Mounting Bolt
Figure 30-60-6
1
P-90468A
1
Bottom Mounting Bolt
2
P115669
Adjust a torque wrench for the 54,2 Nm (40 ft-lb). Insert

the torque wrench (Item 2) [Figure 30-60-6] into the slot
P-90469A

provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated. Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
Maintain torque on th stop arm and tighten the spring of the loader to fully seat the shield onto the top and
loaded idler adjustment bolt (Item 1) [Figure 30-60-6] to bottom mounting bolts (Items 1 and 2) [Figure 30-60-7].
105 - 115 Nm (78 - 85 ft-lb) torque.
Figure 30-60-8
NOTE: This procedure is required to preload a new
drive belt in order to achieve the correct stop
adjustment after the initial belt break-in
period.
Tighten the spring loaded idler adjustment bolt (Item 1) 1

P107205
Install the drive belt shield bolt (Item 1) [Figure 30-60-8].

Install the battery. (See Removal And Installation on
Page 60-20-1.)
NOTE: The stop arm MUST be adjusted after 50 hours
operation with the new drive belt.
See the SERVICE SCHEDULE for the correct
service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-80-1.)

Figure 30-60-10
DRIVE BELT (CONTD)
Tensioner Pulley Removal And Installation
Remove the belt. (See Belt Replacement on Page 30-60-

2.)
1
Figure 30-60-9
2
1
P106539
2 Remove the two bolts (Item 1) [Figure 30-60-10].
Remove the tensioner pulley (Item 2) [Figure 30-60-10].
Installation: Apply Loctite 242 to the mounting bolts

(Item 1) [Figure 30-60-10].

P-85520
Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a breaker bar (Item 2) [Figure 30-60-9] into the
slot provided in the stop arm as shown and push breaker
bar down to release tension on drive belt.
Tighten the adjustment bolt (Item 1) [Figure 30-60-9] to

hold the spring loaded idler off the drive belt.

Tensioner Pulley Disassembly And Assembly
Figure 30-60-11
1
1
1
P-90303
3 Disassembly the tensioner pulley as shown [Figure 30-

P-90306 60-13].
Check the parts for wear and replace as needed.

Loosen the two bolts (Item 1) [Figure 30-60-11] but do
not remove. NOTE: The wheel and arm assembly (Item 1) [Figure

30-60-13] are not serviceable and must be
Release the spring tension by allowing the adjustment replaced as a complete assembly.
plate (Item 2) to slide past the tensioner pulley stop (Item
3) [Figure 30-60-11].
Remove the two bolts (Item 1) and the adjustment plate

(Item 2) [Figure 30-60-11].
Figure 30-60-12
P-90304
Remove the pivot sleeve (Item 1) [Figure 30-60-12].


TWO-SPEED / BRAKE VALVE (S/N ATDW11599 &
BELOW)
Description
Figure 30-70-1
P101605
The two-speed / brake valve (Item 1) [Figure 30-70-1] is

located on top of the chaincase in front of the hydrostatic

pump. The high range is selected by a switch located on
the left control.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

BELOW) (CONT'D)
Valve Block Removal And Installation

IMPORTANT
DANGER clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Figure 30-70-2
1
P-90328
AVOID DEATH 1
Keep out of this area when lift arms are raised 1

1
D-1009-0409
P101606
WARNING Disconnect the six hydraulic hoses (Item 1) [Figure 30-

70-2] from both sides of the brake / two speed valve
Never work on a machine with the lift arms up unless block.
support device. Failure to use an approved lift arm Figure 30-70-3
W-2059-0598
1
WARNING
1
1
W-2017-0286
P101607
1.)
Remove the tubelines (Item 1) [Figure 30-70-3] from the
Raise the operator cab. (See Raising on Page 10-30-2.) hydraulic valve and brake / two speed block.
Mark all hydraulic hoses for proper installation.

BELOW) (CONT'D)
Valve Block Removal And Installation (Contd)
Figure 30-70-4
1
1 P101608
Disconnect the wire harness (Item 1) [Figure 30-70-4].

Figure 30-70-5
P101610
Remove the two bolts (Item 1) [Figure 30-70-5] from the

valve block.
Remove the two speed / brake block from the loader.

TWO-SPEED / BRAKE VALVE (S/N ATDW11599 & Figure 30-70-8
BELOW) (CONT'D)
Valve Block Disassembly And Assembly

1
Figure 30-70-6
1
2
1 N-22580
Remove the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-70-8].
P-90548
Figure 30-70-9
Remove the hydraulic fittings (Item 1) [Figure 30-70-6] 1


Figure 30-70-7
2
1
2 3
P-90550
Remove the two bolts (Item 1) from the brake valve

solenoid (Item 2) [Figure 30-70-9].
P-90549
Installation: Tighten the bolts to 2,7 Nm (24 in-lb)
torque.
Remove the check valves (Items 1 and 2) [Figure 30-70-
7] from the two-speed valve. Remove the nut (Item 3) from the make-up solenoid (Item
4) [Figure 30-70-9].
Installation: Tighten the nut to 6,78 - 9,49 Nm (60 - 84

in-lb) torque.

BELOW) (CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-10
P-90552
Remove the make-up solenoid (Item 1) [Figure 30-70-

12] from the valve block.
P-90435
Installation: Tighten the solenoid valve to 27,1 Nm (20
ft-lb) torque.
Use a test meter and test the solenoid coils (Item 1)
[Figure 30-70-10] for resistance.

Figure 30-70-13
The resistance value for the solenoid coil can be found on

the electrical schematic.
2 2 2
2
Figure 30-70-11
1
1 1 1
1
N-22584

[Figure 30-70-13].
P-90551



BELOW) (CONT'D)
Figure 30-70-14
1
P-90547
1
Use a test meter and test the solenoid (Item 1) [Figure
30-70-16] for resistance.
P-90553
Remove the plugs (Item 1) [Figure 30-70-14] from the
brake / two-speed valve block.

Figure 30-70-15
P-90554
Remove the two speed solenoid bolts (Item 1) [Figure

30-70-15].
Installation: Tighten the bolts to 2,7 Nm (24 in-lb)

torque.

ABOVE AND ATDY11001 & ABOVE)
Description
Figure 30-71-1
P101605
The two-speed / brake valve (Item 1) [Figure 30-71-1] is

located on top of the chaincase in front of the hydrostatic

pump. The high range is selected by a switch located on
the left control.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

ABOVE AND ATDY11001 & ABOVE) (CONT'D)
Valve Block Removal And Installation

IMPORTANT
DANGER clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Figure 30-71-2
1
P-90328
AVOID DEATH 1
Keep out of this area when lift arms are raised 1

1
D-1009-0409
P101606
WARNING Disconnect the six hydraulic hoses (Item 1) [Figure 30-

71-2] from both sides of the brake / two speed valve
Never work on a machine with the lift arms up unless block.
support device. Failure to use an approved lift arm Figure 30-71-3
W-2059-0598
1
WARNING
1
1
W-2017-0286
P101607
1.)
Remove the tubelines (Item 1) [Figure 30-71-3] from the
Raise the operator cab. (See Raising on Page 10-30-2.) hydraulic valve and brake / two speed block.

Valve Block Removal And Installation (Contd)
Figure 30-71-4
1
1 P101608
Disconnect the wire harness (Item 1) [Figure 30-71-4].

Figure 30-71-5
P101610

valve block.
Remove the two speed / brake block from the loader.

Valve Block Disassembly And Assembly
Figure 30-71-6
1
1
P107100

P107098
Remove the hydraulic fittings (Item 1) [Figure 30-71-6]

Figure 30-71-9
Figure 30-71-7
2
3
P107101
P107099
Remove the two bolts (Item 1) from the brake valve
solenoid (Item 2) [Figure 30-71-7]. The resistance value for the solenoid coil can be found on
Assembly: Tighten the bolts to 2,7 Nm (2 ft-lb) torque.
Remove the electrical solenoid nut (Item 3) from the

make-up solenoid (Item 4) [Figure 30-71-7].
Assembly: Tighten the nut to 6,78 - 9,49 Nm (60 - 84 in-

lb) torque.

Figure 30-71-10
P107104
Remove the make-up solenoid (Item 1) [Figure 30-71-

10] from the valve block.

Assembly: Tighten the solenoid valve to 27,1 Nm (20 ft-
lb) torque.
Figure 30-71-11
1
1
2 2 2
P107103

[Figure 30-71-11].


DRAIN MANIFOLD Figure 30-80-2
Description
The drain manifold is an external assembly in the drain 1

circuit that returns the hydraulic oil to the reservoir.
3
Drain Manifold Removal And Installation
IMPORTANT
P101650
damage the system. Disconnect the wiring harness from the oil temperature
I-2003-0888 switch (Item 1) [Figure 30-80-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the tubeline (Item 2) [Figure 30-80-2].
Drain the hydraulic reservoir. (See Removing And Remove the two bolts and nuts (Item 3) [Figure 30-80-2].

Mark all hoses and tubeliners for ease of installation.
Figure 30-80-1
1
1
1
2 1
P101649
Remove the hoses (Item 1) and tubeline (Item 2) [Figure

30-80-1].


DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
STEERING BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-30-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2

Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-3
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-11


BRAKE
Description
Figure 40-10-1
P-90668C
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-10-1]

located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure oil to
the brakes. The charge pressure oil pushes the spring
away from the brake discs allowing the drive motor to
move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure oil to hold the spring away from the brake discs.
When the hold signal is interrupted the solenoid will close

the circuit. The charge oil will be shut off and the spring
will apply the brakes. This will happen if the engine rpm
drops below a set rpm, the seat bar sensor fails or if there
is a break in the wires for the brake block solenoid.


STEERING BLOCK
Description
The steering block controls the four steering cylinders.

The steering block is solenoid activated to let certain
amounts of oil into the cylinders depending on the
Joystick movement. The steering block has a dedicated
section of the gear pump to provide accurate flow to the
steering block at all times.
The steering block is located on the center chaincase

cover below the brake block.

STEERING BLOCK (CONTD)
Identification

PPP-10168
P101682
2
9 1
4
8 5
P-26439

STEERING BLOCK (CONTD)
Identification (Contd)
Solenoid No. Function Connector ColoreD Tie Wiring Harness No.

1 Front Left Rod C443 Blue 4040 and 2890
2 Front Left Base C449 red 4030 and 2940
3 Front Right rod C461 white 4020 and 2950
4 Front right Base C440 purple 4010 and 2960
5 Left Rear rod C447 black 4170 and 2850
6 Left rear base C446 pink 4160 and 2840
7 right rear Rod C445 yellow 4070 and 2830
8 right rear base C444 green 4050 and 2820
9 Pressure Control Solenoid C448 Orange 4060 and 2870

STEERING BLOCK (CONTD) Figure 40-20-2

1
IMPORTANT 2

damage the system.
I-2003-0888
P101680
Raise the lift arms and install an approved lift arm device.
(See Procedure on Page 10-10-1.) Remove the tubeline (Item 1) and hose (Item 2) [Figure
40-20-2].
Figure 40-20-3

Figure 40-20-1
2 2
1
1 1 P101681
P101679 Mark the wire connectors for proper installation and

disconnect the nine solenoid wire harnesses (Item 1)
[Figure 40-20-3].
Remove the four hydraulic hoses (Item 1) and four
tubelines (Item 2) [Figure 40-20-1] from the steering
block.

STEERING BLOCK (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Mark all solenoids for proper installation.
P101683 P103576
Remove the two bolts and nuts (Item 1) [Figure 40-20-4]. Remove the solenoid nut (Item 1) [Figure 40-20-5].

Remove the steering block from the loader. Installation: Tighten the nut to 6,8 Nm (5 ft-lb) torque.
Figure 40-20-6
P103575

solenoid nut.

STEERING BLOCK (CONT'D) Figure 40-20-9
Figure 40-20-7 2
1 P103579
Remove the O-ring (Item 1) from the washer (Item 2)

P103577 [Figure 40-20-9].
Figure 40-20-10
Remove the rod end solenoid (Item 1) [Figure 40-20-7]
from the right front wheel solenoid stem.

Figure 40-20-8
1
1
P103580
Remove the base end solenoid (Item 1) [Figure 40-20-

P103578 10] from the right front wheel.
Remove the washer and O-ring (Item 1) [Figure 40-20-8]

from base end solenoid.


2
2
Figure 40-20-11 2
2
1
1
1
P103583
Remove the four O-rings (Item 1) and six back-up rings

P103581 (Item 2) [Figure 40-20-13] from the solenoid stem.
Figure 40-20-14
solenoid stem.

Figure 40-20-12 1
3
2
1
P103584
Repeat the procedure to disassemble the left front (Item

P103582 1), left rear (Item 2) and right rear (Item 3) [Figure 40-20-
14] solenoids.
Remove the solenoid stem (Item 1) [Figure 40-20-12]
Installation: Tighten the solenoid stem to 16,3 Nm (12

ft-lb) torque.

Figure 40-20-15
1
P103586
Remove the solenoid (Item 1) [Figure 40-20-17].

P103585
Figure 40-20-18
Remove the nut (Item 1) [Figure 40-20-15] from

pressure control solenoid.

Installation: Tighten the nut to 5,4 - 6,8 Nm (4 - 5 ft-lb)
torque.
Figure 40-20-16
2
P103587

solenoid stem.
1
P103588 Installation: Tighten the solenoid stem to 16,3 Nm (12

ft-lb) torque.

solenoid nut.


1
Figure 40-20-19 1
P103591
1 2
Remove the plugs (Item 1) [Figure 40-20-21].
P103589
Figure 40-20-22
Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 40-20-19].

Figure 40-20-20
P-26457

1 plug.
P103590
The adjustment screw on the end of the solenoid stem

(Item 1) [Figure 40-20-20] is sealed to prevent any
adjustment. The adjustment screw is preset and sealed
from the factory. DO NOT attempt to adjust the screw.

Figure 40-20-23
1 2
1
2
P103595
Remove the left side relief valve (Item 1) [Figure 40-20-

P103592 25].

Remove the upper right relief valve (Item 1) [Figure 40-
20-23]. Figure 40-20-26

Remove the upper left relief valve (Item 2) [Figure 40-20-
23].
2
Figure 40-20-24
P103593
2
Remove the two O-rings (Item 1) and back-up ring (Item
1 2) [Figure 40-20-26] from the four relief valves.
P103594
Remove the right side relief valve (Item 1) [Figure 40-20-

24].

STEERING BLOCK (CONT'D)
Figure 40-20-27
P-26457
Remove the O-ring (Item 1) [Figure 40-20-27] from both

plugs.


DRIVE COMPONENTS
Description

P-68556
The drive components consist of the chaincase, drive

chains, sprockets, axleshafts, hubs and drive motor
carrier.
The brake is a separate block and the brake discs are

part of the drive motor.
The chaincase is partially filled with hydraulic fluid to

lubricate the chains and bearings.
On the bottom of the chaincase, there is a cover for

access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT'D) Figure 40-30-3
Axle Seal Removal And Installation

1.)
2
Remove the tire / wheel assembly.
Installation: Tighten the wheel nuts to 142 - 155 Nm

1
Remove the hub assembly. (See Removal on Page 40-
50-1.)
Figure 40-30-1 P-24945
Before installing the axle seal, pack the seal spring

1
groove (Item 1) [Figure 40-30-3] with a high quality
lithium base grease.
Also apply a light coat of grease to the seal surface (Item

2) [Figure 40-30-3] that contacts the hub yoke surface.

Figure 40-30-4
P-24946
Remove the seal (Item 1) [Figure 40-30-1] from the

loader axle.
Figure 40-30-2
P-24947
1 Install the axle seal on the seal driver, MEL1604 [Figure

40-30-4].
P-24944
The axle seal must be installed with the metal side (Item
1) [Figure 40-30-2] facing the loader hub.

DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation (Cont'd)
Figure 40-30-5
P-24946
Install the new seal in the loader axle (Item 1) [Figure 40-
30-5].

Install the hub assembly on the axle, being careful not to
damage the axle seal.

DRIVE COMPONENTS (CONT'D) Remove the control panel. (See Removal And Installation
on Page 50-100-1.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the center chaincase cover. (See Center Cover
MEL1420 - Bearing Driver
MEL1607 - Snap Ring Installer Remove the fluid from the chaincase. (See Removing
NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings Figure 40-30-6
is for a front axle. This procedure will be the
same for the rear axle.
DANGER

1
P-26427
P-90328
AVOID DEATH Remove the axle seal (Item 1) [Figure 40-30-6].

D-1009-0409
WARNING
W-2059-0598


1.)


Installation (Cont'd)
Figure 40-30-7
P-34487
1 Install a 3/4 in x 16 (fine thread) adapter (Item 1) [Figure

40-30-9] into the outer end of the axle. Install a slide
P-34485 hammer to the adapter and continue pulling the axle.
Figure 40-30-10
Loosen the axle bolt (Item 1) [Figure 40-30-7].

Figure 40-30-8
2
1
P-26430
1
P-34486 Remove the axle (Item 1) and spacer (Item 2) [Figure

40-30-10] from the axle tube.
Install a spacer (Item 1) [Figure 40-30-8] between the

axle bolts. Use a wrench and loosen the axle bolt
pushing the axle from the bearing.


Figure 40-30-11
P-26433
Using a 3-13/16 inch bearing driver, drive the bearing out

of the shaft, into the chain case [Figure 40-30-13].
P-26431
Figure 40-30-14
Remove the spacer (Item 1) [Figure 40-30-11] and

replace as needed.
Figure 40-30-12
P-26433
Install the bearing in the axle. The bearing must be

installed square in the axle tube (Item 1) [Figure 40-30-
P-26432 14].
Remove the snap ring (Item 1) [Figure 40-30-12].


Installation (Cont'd) 1
Figure 40-30-15
P-26435
Install a plate (Item 1) and nut on the threaded rod at the

axle end [Figure 40-30-17].
P-26436
Tighten the nuts and draw the bearing into the axle tube.
Use MEL1420 Bearing Driver Tool and a threaded rod Figure 40-30-18

[Figure 40-30-15].
Figure 40-30-16
1
P-26432
P-26434 Install the snap ring (Item 1) [Figure 40-30-18].
Install bearing driver and threaded rod in the chain case

end of the axle tube [Figure 40-30-16].


Figure 40-30-19
1
P-26426
1
Install the washer and bolt (Item 1) [Figure 40-30-21].
P-26437 Installation: Tighten the axle sprocket bolt to 447 Nm

(330 ft-lb) torque.
Install the axle and spanner (Item 1) [Figure 40-30-19] Replace the oil in the chaincase.

into the axle tube.
Install the chaincase cover.
Figure 40-30-20
P-26438
Align the axle, sprocket and chain [Figure 40-30-20].

Using a pry bar hold the sprocket and chain in position.
Align the axle splines into the sprocket splines, and lightly
drive the axle into place.

DRIVE COMPONENTS (CONT'D) Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Chain Removal And Installation Page 40-30-4.)
Remove the motor carrier. (See Removal And Installation

on Page 30-20-1.)
DANGER Figure 40-30-22
P-90328
AVOID DEATH
Disconnecting or loosening any hydraulic Front Drive
Chain
tubeline, hose, fitting, component or a part failure Rear Drive
Chain
unless supported by an approved lift arm P-68194

D-1009-0409
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
removed [Figure 40-30-22].
WARNING
W-2059-0598


1.)

on Page 50-100-1.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-40-1.)
Remove the center chaincase cover. (See Center Cover

Remove the fluid from the chaincase. (See Removing


DRIVE COMPONENTS (CONT'D)
Chain Removal And Installation (Contd)
The tool listed is needed for the following procedure:
MEL1269 - Chain Breaker

MEL1246 - Chain Link Press Tool
MEL1364 - Chain Link Installation Tool
Use the chain breaker MEL1269 to separate the chain.
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use the chain link installation tool MEL1364 to hold both

ends of the chain.
Figure 40-30-23

B-13504A
Secure the tool MEL1246 and place the connector link in

the tool, as shown [Figure 40-30-23].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-30-23]. Tighten the
threaded rod of the chain link tool to 339 Nm (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-40-1
Description 3
The chaincase contains the drive components and

makes up the lower portion of the mainframe. There are
three chain covers that allow access into the chain area.
2 1
Front Cover Removal And Installation
3
Raise the loader operator cab. (See Raising on Page 10-
30-2.)
P-68559
on Page 50-100-1.)
Remove the bolts (Item 1) from the front chaincase cover
(Item 2) [Figure 40-40-1].
DANGER Remove the cover.
NOTE: There are tabs (Item 3) [Figure 40-40-1] on the

bottom side of the cover to help pry the
covers off.
Installation: Apply polyurethane sealer to the mating

surfaces. Polyurethane sealant should be applied to the
bolt threads to prevent oil leaks. Tighten the bolts to 34 -
38 Nm (25 - 28 ft-lb) torque.
P-90328
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598
Clean the area around the cover to keep dirt and debris
from entering the chaincase area.

CHAINCASE (CONTD) Clean the area around the cover to keep dirt and debris
Center Cover Removal And Installation
Figure 40-40-2
DANGER
1
P-90328 1
AVOID DEATH
Disconnecting or loosening any hydraulic P100402

can cause lift arms to drop. Remove the bolts (Item 1) [Figure 40-40-2].
unless supported by an approved lift arm Remove the cover (Item 2) [Figure 40-40-2].

D-1009-0409
NOTE: There are tabs (Item 3) [Figure 40-40-2] on the
covers off.
WARNING Installation: Apply polyurethane sealer to the mating

bolt threads to prevent oil leaks. Tighten the bolts to 34 -
38 Nm (25 - 28 ft-lb) torque.
W-2059-0598

on Page 50-100-1.)
Remove the two speed valve. (See Valve Block Removal

Remove the steering block. (See Removal And


CHAINCASE (CONTD) Figure 40-40-3
Rear Cover Removal And Installation
DANGER
P-68255
P-90328
AVOID DEATH Remove the bolts (Item 1) [Figure 40-40-3] from the rear
Disconnecting or loosening any hydraulic chaincase cover.
can cause lift arms to drop. Remove the cover.
unless supported by an approved lift arm NOTE: There are tabs (Item 2) [Figure 40-40-1] on the

D-1009-0409
covers off.
Installation: Apply polyurethane sealer to the mating

WARNING bolt threads to prevent oil leaks. Tighten the mounting
bolts to 34 - 38 Nm (25 - 28 ft-lb) torque.
W-2059-0598


on Page 50-100-1.)
Remove the two-speed valve. (See Valve Block Removal

Remove the drain manifold. (See Drain Manifold Removal

Clean the area around the cover to keep dirt and debris


HUB Figure 40-50-3
Description
The hub connects the axle to the wheel. The hub

contains a wheel position sensor.
1
Removal

1.)
Figure 40-50-1
P-24931
Remove the retainer bolt (Item 1) [Figure 40-50-3] from

the steering cylinder pin.
Figure 40-50-4

1
P-24816
Remove the tire / wheel assembly [Figure 40-50-1].
Figure 40-50-2
P-24932
1

4].
P-24930
Attach a hook and hoist to the hub (Item 1) [Figure 40-

50-2].
Support the hub for removal.

HUB (CONT'D) Figure 40-50-7
Removal (Cont'd)
1
Figure 40-50-5
P-24935
Remove the bearing seal (Item 1) [Figure 40-50-7] from

P-24933 the top and bottom king pins.
Figure 40-50-8
Remove the bolts (Item 1) [Figure 40-50-5] from the top
and bottom king pins.

Remove the king pins from the hub assembly.
Figure 40-50-6 1
1
P-24936
Remove the bearing (Item 1) [Figure 40-50-8] from the

top and bottom king pins.
P-24934 Remove the wheel position sensor (Item 2) [Figure 40-

50-8] from the top king pin. (See Sensor Removal And
Slide the hub assembly (Item 1) [Figure 40-50-6] off of
the loader axle.

HUB (CONT'D)
Removal (Cont'd)
Figure 40-50-9
P-34484
Figure 40-50-10

1
P-24940
Remove the bearing race (Item 1) [Figure 40-50-9] and

[Figure 40-50-10] from the top and bottom king pins.

Installation
Figure 40-50-11
1 2
1
P-24936
Install the wheel position sensor (Item 1) [Figure 40-50-

P-24940 13] in the top king pin. (See Sensor Removal And
Install the race (Item 1) [Figure 40-50-11] in the top and
Pack the bearings (Item 2) [Figure 40-50-13], and install
bottom king pins.
the bearings in the top and bottom races.

Figure 40-50-12
Figure 40-50-14
P-24941
P-24942 P-24935
Using a 2-13/16 inch driver, seat the race (Item 1)

Install the seal (Item 1) [Figure 40-50-14] metal side
[Figure 40-50-12] in the top and bottom king pins.
towards the outside, in the top and bottom king pins.

Figure 40-50-15
2
1
P-24969
1
Install the lower king pin (Item 1) [Figure 40-50-17], with
P-24968 the grease fitting toward the loader.
Install the four bolts and finger tighten.

NOTE: Before installation, pack the internal splines
in the hub (Item 1) [Figure 40-50-15] with Figure 40-50-18

grease.
Align the hub assembly (Item 1) with the loader axle (Item
2) [Figure 40-50-15].
Figure 40-50-16
P-24970
1
Remove the plug (Item 1) [Figure 40-50-18] from the top
king pin.
P-24967
Rotate the hub (Item 1) [Figure 40-50-16] until the

splines on the hub align with the splines on the loader
axle.
Slide the hub assembly in until the king pin holes on the
hub assembly align with the holes in the axle.

Figure 40-50-19
P-24974
Install the upper king pin (Item 1) [Figure 40-50-21], with

P-24971 the grease fitting toward the loader.
Figure 40-50-22
Figure 40-50-20
1

1
P-24975
P-24972
Install the bolts (Item 1) [Figure 40-50-22] in the upper

Remove the wheel position indexing pin (Item 1) [Figure king pin.
40-50-19] and [Figure 40-50-20] from the upper king pin.
Tighten the upper and lower king pin bolts to 95 Nm (70
ft-lb) torque.

Figure 40-50-23
1 1
1
P-24981
Slightly turn the indexing pin until the positioning lobes on

P-24973 the pin drops into the indexing grooves (Item 1) [Figure
40-50-25] in the king pin.
Figure 40-50-24 Figure 40-50-26

2
1
3
P-24978A
3 3
P-24977A P-24976 P-24933
Install the wheel position indexing pin (Item 1) [Figure Install the plug (Item 1) [Figure 40-50-26] in the upper
40-50-23] in the upper king pin (Item 1) [Figure 40-50- king pin. Tighten the plug to 27 Nm (20 ft-lb) torque.
24].
Install the tire / wheel assembly.
The fork (Item 2) [Figure 40-50-23] and [Figure 40-50-
24] on the end of the indexing pin must align with the Remove the loader from jackstands.
notches (Item 3) [Figure 40-50-24] in the wheel position
sensor.

Disassembly

1.)
Remove the tire / wheel assembly.
Figure 40-50-27
P-26032
1 2
Remove the hub assembly (Item 1) [Figure 40-50-29]
from the shaft.
Figure 40-50-30

P-26031
Remove the bolt (Item 1) and washer (Item 2) [Figure 1

40-50-27].
Figure 40-50-28
P-26033
Turn the hub over and remove the spacer (Item 1)

[Figure 40-50-30].
P-26040

back of the washer.

Figure 40-50-31
1
P-26037
Tap the u-joint yoke assembly (Item 1) [Figure 40-50-33]

P-26034 out of the housing.
Figure 40-50-34
Remove the bearing (Item 1) [Figure 40-50-31] from the
hub.

1
Figure 40-50-32
P-26038
Remove the outer housing seal (Item 1) [Figure 40-50-

P-26035 34].
Inspect the hub for damage to the splines (Item 1)

[Figure 40-50-32] or to the bearing surface.

3
Figure 40-50-35 2
1
1
1
1 1
1
P-26046
Remove the eight bolts (Item 1). Remove the male yoke
P-26039 (Item 2) and the female yoke (Item 3) [Figure 40-50-37]
from the U-joint.
Remove the bearing races (Item 1) [Figure 40-50-35] Check the female yoke, male yoke and the universal joint
from the housing. for damage or excessive wear.

Figure 40-50-36
P-26045
Remove the inner seal (Item 1) [Figure 40-50-36] from

the yoke assembly.

Assembly

Inspect all parts for wear or damage. Replace all worn or
1
damaged parts.
The tools listed are needed for the following procedure:
MEL1605 - Bearing Race Installer

MEL1606 - Seal Installer
Figure 40-50-38
P-26039
2
Using MEL1605, install the bearing races (Item 1)

[Figure 40-50-40] in the housing.
Figure 40-50-41

1 3
P-26047
1
Install the female yoke (Item 1) and the male yoke (Item
2) to the U-joint (Item 3) [Figure 40-50-38].
Figure 40-50-39
P-26051
1 Pack the bearing (Item 1) [Figure 40-50-41] and install

1
the bearing in the inside of the housing.
1 1
P-26046
Install the eight mounting bolts (Item 1) [Figure 40-50-

39] and tighten to 122 - 149 Nm (90 - 110 ft-lb) torque.

Assembly (Cont'd)
Figure 40-50-42
P-26053
Install the yoke assembly (Item 1) [Figure 40-50-44] into

P-26043 the seal.
Figure 40-50-45
Figure 40-50-43

1
1
P-26037
P-26052
Using MEL1606, install the seal (Item 1) [Figure 40-50-

Using MEL1606, install the inner seal (Item 1) [Figure 45] with the letter stamped side away from the bearing.
40-50-42] and [Figure 40-50-43] with the metal side of
the seal away from the bearing.

Assembly (Cont'd)
1
Figure 40-50-46
P-26054
Install the hub assembly (Item 1) [Figure 40-50-48] on

P-26034 the spline shaft in the housing.
Pack the bearing (Item 1) [Figure 40-50-46] with lithium

grease and install the bearing on the hub.

Figure 40-50-47
P-26033
Install the spacer (Item 1) [Figure 40-50-47] on the hub.

HUB (CONT'D)
Assembly (Cont'd)
Figure 40-50-49
P-26040
Install the O-ring (Item 1) [Figure 40-50-49] on the back

of the washer.

Figure 40-50-50
P-26031
Install the washer (Item 1) and bolt (Item 2) [Figure 40-

50-50] tighten the bolt to 475 Nm (350 ft-lb) torque.

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4

3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
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 . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
FLOOR PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
JOYSTICK CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Installation (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Removal And Installation (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4

ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1


SEAT BAR Installation: Tighten the nuts to 34 - 38 Nm (25 - 28 ft-
lb) torque.
Description
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P101580

2 Remove the seat bar (Item 1) [Figure 50-10-3] from the
operator cab.
P-85653 P101579 Reverse the above procedure to install the seat bar into
the operator cab.
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P-85652
Remove the seat bar nuts (Item 1) [Figure 50-10-2] (both

sides).

SEAT BAR (CONT'D) Installation: Tighten the bolt (Item 2) [Figure 50-10-4]
and [Figure 50-10-5] to 34 - 38 Nm (25 - 28 ft-lb) torque.
Figure 50-10-6
Figure 50-10-4
4 5
6
5 4 6
7
3
3
2 7
2 9 8
10
1
1
P-90023
P-90022
Figure 50-10-7
Figure 50-10-5

4 5
5 9 3 6
8
2
3 6
7
2 10
1
7
1
N-19220
N-19219
Assemble the parts as shown for the right side of the seat
Assemble the parts as shown for the left side of the seat bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- 7].
5].
Seat Bar Mount (Item 1)
Seat Bar Mount (Item 1) Nut (Item 2)
Bolt (Item 2) Pivot Bushing (Item 3)
Keyed Plastic Bushing (Item 3) Spacer Bushing (Item 4)
Seat Bar (Item 4) Seat Bar (Item 5)
Magnetic Bushing Assembly (Item 5) Keyed Plastic Bushing (Item 6)
Pivot Bushing (Item 6) Bolt (Item 7)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8) Installation: Tighten the bolt (Item 7) [Figure 50-10-6]
Sensor Mounting Bolt (Item 9) and [Figure 50-10-7] to 34 - 38 Nm (25 - 28 ft-lb) torque.
Nut (Item 10)
Installation: Tighten the bolt (Item 9) [Figure 50-10-4]

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

SEAT BAR (CONT'D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Bushing (Item 4)
Assembly: Adjust the compression spring by turning the Clevis (Item 5)
bolt in past the end of the clevis three turns. Pin (Item 6)
Bushing (Item 7)
Clip (Item 8)


OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
Raise the operator cab (See Raising on Page 10-30-2.)
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without

the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Figure 50-20-1
2
1
1 3
P-85652
Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

Gas Spring Bracket Disassembly And Assembly

2
Figure 50-20-4
3 1
1
1
P100756
2
Unhook the four fasteners (Item 1) and remove the cover

P-85661 (Item 2) [Figure 50-20-5].
Figure 50-20-6
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-

20-4]. 1
Installation: Apply a small amount of thread-locker on

the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4].
2
1
WARNING
AVOID INJURY 1
Cylinders for raising and lowering operator cab have
P100879
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
Disconnect the expansion / heater unit wiring connectors
(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40- NOTE: Cap the heater hoses and the heater valve with
2.) plugs to prevent coolant loss from the
system.

Figure 50-20-7 1
1
1
1 P107406
Disconnect the cab harness (Item 1) [Figure 50-20-8].

P103082
Figure 50-20-9
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].

Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Installation: Tighten the A/C hoses to 30 Nm (22 ft-lb)

torque.
1
WARNING
P-85658
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without Remove the two cab bolts and nuts (Item 1) [Figure 50-
the gas spring(s) operational, the cab will fall and 20-9] from both sides of the cab.
could cause injury or death.
W-2760-0309
Installation: Tighten the cab bolts and nuts to 24,4 - 29,8
Remove the engine speed control cable from the cab.
(See Removal And Installation (Contd) on Page 70-20-
2.)
Remove the operator cab gas spring(s). (See Gas Spring

NOTE: Use the hoist connected to the operator cab

grab handles to lower or raise the operator
cab when the gas spring(s) are disconnected.

Figure 50-20-10
P-85662
Using a strap and a hoist remove the cab from the loader
[Figure 50-20-10].

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Removal And Installation Figure 50-30-2
Figure 50-30-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail bolts (Item 1) [Figure 50-30-2].

Remove the four nuts (Item 1) [Figure 50-30-1] and
washers from the operator seat mounting studs. Figure 50-30-3
Lower the operator cab. (See Raising on Page 10-30-2.)
Remove the seat.

2
NOTE: With the seat removed, the cab may raise.
P-85770
Remove the two slide rail bolts (Item 1) [Figure 50-30-3].
Remove the slide rail (Item 2) [Figure 50-30-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONTD) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-30-6
Figure 50-30-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-30-6].
Remove the nut (Item 1) [Figure 50-30-4] from the seat
belt mount.

Figure 50-30-5
P-85772
Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONTD) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-30-9
Figure 50-30-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
30-7]. the seat back to the upright position.

Figure 50-30-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-30-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONTD) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-30-10
Figure 50-30-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) Remove the nut (Item 1) [Figure 50-30-11].

Remove the seat shock clips (Item 1) [Figure 50-30-10]. Remove the end release buckle (Item 2) [Figure 50-30-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-30-10]. Figure 50-30-12
P-85784
Remove the nut (Item 1) [Figure 50-30-12].
Remove the seat belt retractor (Item 2) [Figure 50-30-

12].

OPERATOR SEAT (SUSPENSION) (CONTD) Figure 50-30-15
3-Point Seat Belt Removal And Installation (Contd)

2
Figure 50-30-13
1 3
1
P-85788

P-85786
Remove the shoulder harness guide, bushing (Item 2)
and hardened washer (Item 3) [Figure 50-30-15].

Figure 50-30-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].


BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
Figure 50-40-1
P-85649

1
Figure 50-40-3

P-85554
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm (3.0 in)) under each side of the 1
Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

P-31402
Remove the snap ring (Item 1) [Figure 50-40-3] from
Installation: Tighten the nut to 48 - 54 Nm (35 - 40 ft-lb) both sides of the Bob-Tach pivot pin grease plug.
torque.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-6
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from both of
P-31404 the Bob-Tach pivot pin bolts.
Figure 50-40-7
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)

[Figure 50-40-4].
Figure 50-40-5
P-31406
1
Remove the bolt (Item 1) [Figure 50-40-7] from the Bob-
Tach pin.
P-31405
Installation: Tighten the bolt and nut to 446 Nm (330 ft-
lb) torque.

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Figure 50-40-8
1 P-85664
P-31407
Using a 22,2 mm (0.875 in) punch (Item 1) [Figure 50- Installation: Tighten the nut to 48 - 54 Nm (35 - 40 ft-lb)
40-8] and a hammer, drive the pivot pin out of the lift arm torque.

and Bob-Tach.
Figure 50-40-10
NOTE: MEL1685 - Pivot Point Tapered Reamer is
available to ream out tapered bore if
necessary.
2
P-85665
Remove the washer, spring, (Item 1) and the lever

assembly (Item 2) [Figure 50-40-10].

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd) 4
Figure 50-40-11
1 3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.
Remove the bolt and replace the damaged parts as

Remove the roll pin (Item 1) [Figure 50-40-11] from the needed.

Bob-Tach wedge and spring clevis.
Assembly: Clean threads and apply Loctite 242 to the
Remove the spring clevis assembly (Item 2) [Figure 50- bolt (Item 1) [Figure 50-40-13]. Torque to 88 - 95 Nm
40-11]. (65 - 70 ft-lb).
Figure 50-40-12
P-85667
Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach.
Always replace bent or broken wedges.

BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-14
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Remove the seal (Item 1) [Figure 50-40-14] from the
Bob-Tach.
Remove the bushing (Item 2) [Figure 50-40-14] from the

Bob-Tach.
Figure 50-40-15
1
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-40-15].


BOB-TACH (POWER) Mark and remove the hoses (Item 1) [Figure 50-41-1].
Description Remove the bolts (Item 2) [Figure 50-41-1], washers and

nuts.
The Bob-Tach is the section of the loader lift arm that
attachments mount to. The Power Bob-Tach option uses Installation: Tighten the bolts to 48 - 54 Nm (35 - 40 ft-
two hydraulically operated, spring assisted, locking lb) torque.
wedge and lever assemblies to secure the attachment to
the Bob-Tach. Remove the cylinder from the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
lever assemblies by pressing a switch on the right switch
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the

gear pump.
IMPORTANT

damage the system.
I-2003-0888
Figure 50-41-1
1
2 2
P-85570
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm (3.0 in)) under each side of the
Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] from

P-85554 both sides of the Bob-Tach pivot pin grease plug.
Figure 50-41-5
Remove the bolt (Item 1) [Figure 50-41-2] and nut from

Installation: Tighten the bolt to 48 - 54 Nm (35 - 40 ft-lb)
torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5].
P-85649

BOB-TACH (POWER) (CONTD) Figure 50-41-8
Figure 50-41-6
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the nut and bolt (Item 1) [Figure

Remove the O-ring (Item 1) [Figure 50-41-6]. 50-41-7] and [Figure 50-41-8] to 446 Nm (330 ft-lb)
torque.

Figure 50-41-7
Figure 50-41-9
1
P-31403
P-31407
Remove the nut (Item 1) [Figure 50-41-7] from both of

the Bob-Tach pivot pin retaining bolts. With a 22 mm (0.875 in) punch (Item 1) [Figure 50-41-9]
and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.
NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

BOB-TACH (POWER) (CONT'D) Figure 50-41-12
Lever And Wedge Disassembly And Assembly
Figure 50-41-10
1 1 2
P-85665
Remove the washer, spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-12].
Figure 50-41-13
Remove the bolts (Item 1) [Figure 50-41-10], washers
and nuts.

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

1
Figure 50-41-11
P-85666
1 Remove the roll pin (Item 1) [Figure 50-41-13] from the

Bob-Tach wedge and spring clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
P-85664
Installation: Tighten the nut to 48 - 54 Nm (35 - 40 ft-lb)

torque.

BOB-TACH (POWER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Remove the Power Bob-Tach. (See Removal And
(Cont'd) Installation on Page 50-41-1.)
Figure 50-41-14 Figure 50-41-16
2 1
P-85667 P-85669
Remove the wedge (Item 1) [Figure 50-41-14] out the Remove the seal (Item 1) [Figure 50-41-16] from the

bottom of the Bob-Tach. Bob-Tach.
Always replace bent or broken wedges. Remove the bushing (Item 2) [Figure 50-41-16] from the
Bob-Tach.
Figure 50-41-15
Figure 50-41-17
4 3
1 2
3 2
P-85668 1
NA5472
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-15] are damaged, put the Installation: The seal (Item 1) needs to be seated in the
assembly in a vise. Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-41-17].
Remove the bolt and replace the damaged parts as
needed.
Assembly: Clear the threads and apply Loctite 242 to

the bolt (Item 1) [Figure 50-41-15]. Torque to 88 - 95
Nm (65 - 70 ft-lb).


LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
1 P-90591
2
With a slide hammer, remove the rear lift arm stabilizer

pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4

P-90592

the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from

both ends of the stabilizer bar.
P-90593

stabilizer bar rear pivot pin at the lift arm.

LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P100217 both sides of the lift arm link pivot pin.
Figure 50-50-8
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].

Figure 50-50-6
P90598
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

P100218 from both sides of the lift arm link.
Remove the bolt (Item 1) and washer [Figure 50-50-6]

from both sides of the lift arm pivot pin.

LIFT ARMS (CONT'D)
Link Removal And Installation (Contd)
Figure 50-50-9
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] from both sides of the loader.

Remove the lift arm link from the loader.

Put jackstands under the rear corners of the loader.
Drain the hydraulic reservoir. (See Removing And 1

IMPORTANT
P100263

At the base of the left side upright disconnect the two
auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
damage the system.
I-2003-0888
NOTE: Mark the hoses for proper installation.
Figure 50-50-12

Figure 50-50-10
4
3
1
2
P100265
1 P100262
At the left side upright disconnect the auxiliary hydraulic

At the right side upright disconnect the two tilt cylinder hose (Item 1) [Figure 50-50-12].
hoses (Item 1) [Figure 50-50-10].
At the right side upright disconnect the power Bob-Tach
hoses (Item 2) [Figure 50-50-10].(If equipped.)
Remove hose clamp bolt (Item 3) [Figure 50-50-10].
Remove Bob-Tach hose clamp bolt (Item 4) [Figure 50-

50-10] (If equipped).

Figure 50-50-13
P101724

P100264 the pin on the rod end of both lift cylinders.

At the left side upright remove the auxiliary hose clamp torque.
bolts (Item 1) [Figure 50-50-13].

Figure 50-50-16
Figure 50-50-14
P101723
P100225
Remove the pin (Item 1) [Figure 50-50-16] from the rod

Disconnect the electrical controls harness (Item 1) end of both lift cylinders.
[Figure 50-50-14]. (If equipped.)

Figure 50-50-17
1
1
1 P-90605
Position the front sling (Item 1) [Figure 50-50-19] in the

P100220 middle of the Bob-Tach as shown.
Figure 50-50-20
Install slings (Item 1) [Figure 50-50-17] on the lift arms
and connect to a chain hoist.

Figure 50-50-18
1
2
P100216

P100219 both of the lift arm pivot pins.

NOTE: The slings (Item 1) [Figure 50-50-18] must be torque.
in a position to balance the lift arms when
removing the lift arms from the loader. Remove the pin (Item 2) [Figure 50-50-20] from both
sides of the loader.
Remove the lift arms from the loader.

REAR GRILLE Installing
Removing Figure 50-60-3
Figure 50-60-1
P100808G
P100807
P100808D
Align the tabs of the two side covers into the slots in the
loader frame and lower [Figure 50-60-3].
(Earlier Models) - Flip the lockable handle (Inset)
[Figure 50-60-1] up and turn the handle 90 Figure 50-60-4

counterclockwise. Lift and pull the rear grille backward to
remove from the loader.
OR
(Later Models) - Remove the clamping knob (Item 1). Lift

using the handle (Item 2) [Figure 50-60-1] and pull the
rear grille backward to remove from the loader.
Figure 50-60-2
P109170
1
Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
(Earlier Models) - Turn the lockable handle 90

clockwise and fold the handle down (Inset) [Figure 50-
60-1].
OR
P107186A
(Later Models) - Install the clamping knob (Item 1)

Lift and remove the two side covers (Item 1) [Figure 50- [Figure 50-60-1].
60-2].

REAR GRILLE (CONTD)
Shield Removal And Installation
Figure 50-60-5
1 1
2
P109057
Remove the two bolts (Item 1) and remove the shield

(Item 2) [Figure 50-60-5].

REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
2 2
1
P-85695
Remove the top and bottom door hinge bolts and nuts
P101519 (Item 1) [Figure 50-70-3].
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 main frame harness. hinge as shown.

Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the bolts and nuts to 34 - 38 Nm
the door. (See Rear Removal And Installation on Page (25 - 28 ft-lb) torque.
60-60-2.)
Remove the door from the loader frame.
Figure 50-70-2
2
1 1
P-90584
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONTD) Striker Adjusting
Striker Removal And Installation

1 AVOID INJURY OR DEATH
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
P-85698B
Remove the two striker bolts (Item 1) [Figure 50-70-4].

Remove the striker assembly from the loader.
Striker Disassembly And Assembly 1

P-85698B
Figure 50-70-5
5 Loosen the striker assembly bolts (Item 1) [Figure 50-70-

6].
Align the striker assembly in the center of the mounting

3 4 holes.
2 1
NOTE: Tighten the top striker assembly bolt only,
until it will hold the striker assembly in the
center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
P106584 Open the door.
Tighten both bolts (Item 1) [Figure 50-70-6] to 125 - 135

Remove the lock nut (Item 1) [Figure 50-70-5]. Nm (90 - 100 ft-lb) torque.
Remove the bolt (Item 2), spacer (Item 3) and roller (Item Close the rear door.
4) from the bracket (Item 5) [Figure 50-70-5].

REAR DOOR (TAILGATE) (CONTD) Figure 50-70-9
Latch Removal And Installation (Early Models)
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7].

the latch.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

REAR DOOR (TAILGATE) (CONTD) Figure 50-70-12
Latch Removal And Installation (Later Models)
Figure 50-70-10
1
2
1
P109094
Remove the door handle (Item 1) [Figure 50-70-12] from

P109092 the rear door.
Check the parts for wear and replace as needed.

Remove the bolt (Item 1) and nut (Item 2) [Figure 50-70-
10] from the latch.

Installation: Tighten the bolt (Item 1) and nut (Item 2) to
34 - 38 Nm (25 - 28 ft-lb) torque.
Figure 50-70-11
P109093

latch.

FUEL TANK Figure 50-80-2
WARNING 1

explosion or fire.
W-2103-0508
P-85713
1.)
Remove the drain plug (Item 1) [Figure 50-80-2].
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on Drain the fuel into a container.
Page 70-10-10.)
NOTE: Later models may not be equipped with a fuel
Figure 50-80-1 drain plug.

Figure 50-80-3
1
1
1
P-85714
P106480
Remove the three mount bolts (Item 1) [Figure 50-80-1]
from the access cover at the rear of the loader frame.
Disconnect the two fuel lines (Item 1) [Figure 50-80-3].
Remove the access cover.
NOTE: Mark the fuel lines for correct installation.

50-80-3] from the fuel level sender.

FUEL TANK (CONT'D) Figure 50-80-6
Figure 50-80-4
2
2 P106483
Remove the bolt (Item 1) and bracket (Item 2) [Figure

P106481 50-80-6].
Lift the fuel tank and remove it from the loader frame.
Remove the two mounting bolts (Item 1) and remove the
bracket (Item 2) [Figure 50-80-4]. NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
Figure 50-80-5 damage.
P106482

battery hold down plate.
Remove the hold down plate from the loader.

FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation NOTE: The fuel filter is removed for photo clarity.
Remove the engine / hydrostatic pump assembly from Figure 50-80-9

the loader. (See Engine Removal And Installation on
Page 70-10-10.)
Figure 50-80-7
1
1
P106420
Remove the hose / clamp (Item 1) [Figure 50-80-9] from

P106480 the filler neck.

Figure 50-80-10
50-80-7] from the fuel level sender.
1
Remove the fuel level sender.
Figure 50-80-8
P106421
P-85716
Inspect the fuel level sender and replace if worn or

damaged [Figure 50-80-8].

FUEL TANK (CONT'D)
Fuel Fill Screen Removal And Installation (Contd)
Figure 50-80-11
P106422

hose (Item 2) [Figure 50-80-11] from the tank.

Figure 50-80-12
P106536
Remove the fuel fill screen (Item 1) [Figure 50-80-12].
Inspect and replace as needed.

FLOOR PAN

on Page 50-100-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-1
1
1

P-85859 P-85860
Figure 50-90-2
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-1] and [Figure

50-90-2] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-2].


CONTROL PANEL Figure 50-100-1
Description 1
The control panel is connected to the lower main frame

and wraps around the operator seat.
WARNING 1

P-85879
W-2017-0286
Remove the three bolts (Item 1) [Figure 50-100-1] that
secure the controller.
Figure 50-100-2

1
1
2
P-90328 1
AVOID DEATH
Keep out of this area when lift arms are raised 1 3 1
support. Replace if damaged. P-85881
D-1009-0409
Remove the ten panel bolts (Item 1) [Figure 50-100-2].
Remove the lift arm bypass knob and rubber washer

WARNING (Item 2) [Figure 50-100-2].
Remove the control panel (Item 3) [Figure 50-100-2].

W-2059-0598



JOYSTICK CONTROL
Description
The operators seat has two joysticks attached that

control the drive, steering, lift and tilt functions. There are
no mechanical connections to the hydrostatic pumps or
the control valve.
Joystick Testing
Refer to Service Analyzer help to check function.

JOYSTICK CONTROL (CONT'D) Figure 50-110-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-1.) 1
Figure 50-110-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

110-3] from the wire harness.
P-85890

Lift the rubber boot (Item 1) [Figure 50-110-1].
Figure 50-110-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-110-2] and

lift the joystick from the base.
Installation: Tighten the screws to 4 - 4,5 Nm (35 - 40

in-lb) torque.

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
4
1
2
1
P101581
P101523
Remove the two nuts (Item 1) and remove the foot rest
(Item 2) [Figure 50-120-3].
Remove the two nuts (Item 1) and remove the foot rest
(Item 2) [Figure 50-120-1]. Loosen the bolt (Item 3) and remove the engine speed

control pedal (Item 4) [Figure 50-120-3].
Figure 50-120-2
Figure 50-120-4
1
1
1 1
1
1
1
2 1
P101522
2
P101584
Remove the bolts (Item 1), and remove the inside left
access panel (Item 2) [Figure 50-120-2]. Remove the bolts (Item 1) and tilt the right access panel
(Item 2) [Figure 50-120-4] towards the center of the
loader.

ACCESS PANEL (INSIDE) (CONTD)
Removal And Installation (Right) (Contd)
Figure 50-120-5
P107707
Disconnect the wire harness (Item 1) from the engine

speed control (Item 2) [Figure 50-120-5].

Remove panel assembly from the loader.

WINDOW (REAR) Removal (Rubber Cord)
Rear Window Identification

Latches Rubber Cord
2 When fluids are under pressure.
Flying debris or loose material is present.
1 Engine is running.
P-85309B P-64994D W-2019-0907
Figure 50-130-2
There are two different procedures for removing the rear

window from your machine:
1. This window is equipped with latches (Item1) [Figure

50-130-1].

2. This window is equipped with a rubber cord and tag
(Item 2) [Figure 50-130-1].
P-64994C
Pull on the tag on the top of the rear window to remove

the rubber cord [Figure 50-130-2].
Push the rear window out of the rear of the operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.

WINDOW (REAR) (CONTD) Figure 50-130-5
Installation (Rubber Cord)
Clean the area before installing the rear window

assembly.
Figure 50-130-3
P109581
Install the rear window assembly from the outside of the

operator cab into the window frame.
Install a lower corner of the rear window assembly into

1
P109560 the corner of the window frame (Item 1) [Figure 50-130-
5].

Install the rubber molding (Item 1) [Figure 50-130-3] Work the window assembly downward until the window is
around the edge of the rear window. fully seated in the lower portion of the window frame.
Figure 50-130-4 Figure 50-130-6
P-85228 P109582
Apply liquid soap to the rubber molding (Item 1) [Figure Apply light pressure to the outside of the widow assembly
50-130-4] to make installation easier. holding it tight up against the window frame.
NOTE: Install the window assembly with the narrow Use a multipurpose tool (Item 1) [Figure 50-130-6] under
edge (Item 2) [Figure 50-130-4] toward the the molding lip to guide the window assembly into the
inside of the loader. window frame.
NOTE: Tapping the window with a rubber hammer

will help seat the window assembly in the
window frame.

WINDOW (REAR) (CONTD)
Installation (Rubber Cord) (Contd)
Figure 50-130-7
P109583A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-7]

with the safety tag into the molding on the inside of the
operator cab.
NOTE: Verify the safety tag is located in the top

center of the window.

WINDOW (REAR) (CONTD) Disassembly And Assembly (Latches)
Removal And Installation (Latches) Figure 50-130-9
WARNING
1
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
W-2019-0907
P-85705
Figure 50-130-8
Remove the screw (Item 1) from the latch [Figure 50-

130-9].
Installation: Tighten the screw (Item 1) [Figure 50-130-

9] to 21 - 23 Nm (180 - 200 in-lb) torque.
1 1
Figure 50-130-10
7
6
1
P-85706
5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-8] in until they disengage
from the window frame.
2
3
Push the rear window out the rear of the operator cab. 4
P-85704
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. The items listed below refer to [Figure 50-130-10].
Clean the area before installing the rear window 1. Latch

assembly.
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal
Inspect and replace any damaged parts.

WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].

Figure 50-131-4
Figure 50-131-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONTD)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].

Tighten the nuts (Item 1) [Figure 50-131-5] to 9 - 10 Nm
(80 - 90 in-lb) torque.
NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

Figure 50-132-1
1 1 2 3
P-85819
Remove the spring (Item 1), knob (Item 2), and sleeve
(Item 3) [Figure 50-132-3] from the window assembly.
Figure 50-132-4
P-85314A

Remove the plastic cap (Item 1) [Figure 50-132-1].
Figure 50-132-2 1 1
1
1
1
2 1
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-4].
P-85821 Installation: Tighten the bolts to 9 - 10 Nm (80 - 90 in-

lb) torque.
Remove the nut (Item 1) [Figure 50-132-2]. Remove the window assembly.
Installation: Tighten the nut flush to the end of the bolt.


CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Open the cab door.
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4

1 2
P-85781A
Disconnect the wire harness (Item 1) and washer fluid

Figure 50-140-2
3
2
1 2
1
P-85837
P-85588A P-85589A
Remove the bolts (Item 1) [Figure 50-140-4] and nuts

Rotate and pull the clip (Item 1) out of the gas spring from the cab.
socket. Pull the gas spring socket (Item 2) straight off the
ball stud fitting (Item 3) [Figure 50-140-2]. Remove the hinges (Item 2) [Figure 50-140-4] from the
cab.
Installation: Tighten the bolts to 9,6 - 10,7 Nm (85 - 90

in-lb) torque.

CAB DOOR (CONTD) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].

2
Installation: Tighten the nut (Item 1) to 20 - 24 Nm (177
- 212 in-lb) torque. Tighten the nut (Item 2) to 9 - 11 Nm 1
(80 - 97 in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 Nm (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), latch (Item 2), and spring (Item
3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts to 31 - 34 Nm (270 - 300

in-lb) torque.
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONTD) Aligning
Disassembly And Assembly (Contd) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4 1
P106481
3
4
P-85836
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
Remove the bolt (Item 1), latch (Item 2), and spring (Item door and the cab or the striker and the latch.
3) [Figure 50-140-9].

Adjust as needed. (See Adjusting on Page 50-140-4.)
9]. Figure 50-140-12
Installation: Tighten the nuts to 31 - 34 Nm (270 - 300 CORRECT CORRECT

in-lb) torque.
Figure 50-140-10
1 1
P106482
2 When the striker or latch is adjusted properly there will be

2 no gap (Item 1) [Figure 50-140-12] between the door
P106380 and the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Disconnect the wire harness (Item 1) [Figure 50-140- Checking Operation on Page 50-140-4.)
10].
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONTD) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
2
1
P-85413E
P-85830
Sit in operators seat. Turn the key ON, lower the seat bar
and close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P106587
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch inspect the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837

Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONTD) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.

P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the Joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8

1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

Figure 50-150-9
3 1 1
2 2
1 P-90844
Remove the two nuts (Item 1) and the slide rail (Item 2)
P100825 [Figure 50-150-11] from the armrest mount.
Repeat for the other side.

Figure 50-150-10

7 4
6 3
5 2
1
P100824
Remove the nut (Item 1), washer (Item 2) and spring

(Item 3) [Figure 50-150-9] and [Figure 50-150-10].
Remove the spacer (Item 4), washer (Item 5), plastic

washer (Item 6) and the bolt (Item 7)[Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 Nm (180 - 200 in-

lb) torque.

LEFT SIDE LOWER PANEL Figure 50-160-3
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4
Remove the five plastic rivets (Item 1) [Figure 50-160-1].

Remove the seat. (See Removal And Installation on
Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1
30-4.)
Lower the operators cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONTD) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].

Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONTD) Disassembly And Assembly
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11

1
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONTD)
Figure 50-160-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.

Figure 50-160-13
P-90864

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operators cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4

Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.) 2
Lower the operators cab.

1
Figure 50-170-2
1
1 P106595
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONTD) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.

NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new lock washer when it has been
side of the cab far enough to access the wire removed.
harness.
Figure 50-170-8
Figure 50-170-6
2 1
1
2 P-90877
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove

Disconnect the wire harnesses (Item 1) and the antenna the radio from the right side lower panel.
(Item 2) [Figure 50-170-6] (if equipped with radio).
Installation: Insert a screwdriver into the slot (Item 2)
NOTE: Install the right side lower panel with the radio [Figure 50-170-8] to lock the tab into place.
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONTD)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.

Remove the input from the right side lower panel.
Figure 50-170-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.


HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if

P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation (Early Models) on Page 60-60-
2) [Figure 50-180-1] (if equipped). 2.)

NOTE: The rear shelf has two panel clips on the Figure 50-180-4
underneath side, lift vertically to disengage.
Installation: Tighten the screws to 20 in.-lb. (2,3 Nm)

torque.
Figure 50-180-2 1
1
1
1
2
1
P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
P-90894 Installation: Route the cab light wire harness in the

groove on the topside of the headliner (if equipped with
HVAC).
Remove the air duct (Item 1) [Figure 50-180-2] (if
equipped). NOTE: Replace the retainers if needed.


ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Cab Harness Connectors (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Cab Harness Connectors (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
All-wheel Steer Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (DRIVE PLUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
WHEEL POSITION SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Wheel Alignment (Field Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-5
Wheel Alignment (Field Adjustment With Service Analyzer) . . . . . . . . . . . . . . . . . . 60-90-7
Wheel Alignment (Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-11
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT) . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Viewing Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting The BICS (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting Deactivation Of Lift And Tilt Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Bobcat Interlock Control System (BICS) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-130-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-3
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Connecting Diagmaster (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-2
Connecting Remote Parked Regeneration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-2
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Lift And Tilt Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-4
Hydrostatic Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-6
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-200-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

CONNECTOR ASSIGNMENTS
HARNESS PART NUMBER
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET LF MFR CTRL 7218334 (S/N ATDW11001 - ATDW11754)
PINS PINS PINS
(S/N ATDZ11001 & ABOVE)
C100 WATER IN FUEL SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 18
C103 TAILGATE 8 7,15,16,18 C412 LEFT HANDLE 2 WAY 2 18 7226814 (S/N ATDW11755 & ABOVE)
C105 HYD CHARGE PRESSURE 3 12 C415 HIGH FLOW SOLENOID 2 18 FRC1 FUSE RELAY CENTER 112 5,6,9,16,17 DLX CAB 7207730
C108 HYD TEMPERATURE SENDER 2 12 C418 FRONT ROD 2 12 DLX FUEL 7184255
C110 ALTERNATOR 2 9 C419 FRONT BASE 2 12 J1A GATEWAY CONTROLLER 34 ENGINE 7211660
C111 MFR-BCT ENG HARN CONN 3 9 C420 HYD LOCK 2 12 J1B GATEWAY CONTOLLER 26 STARTER 7206494
C112 HYD OIL FILTER SWITCH 2 12 C421 TILT SPOOL LOCK 3 15 J2A AUX CONTROLLER 34 TAILGATE DOM 7175271 or 7217484
C113 ENG-MFR HARN CONN 10 6,7,8, 9 C422 LIFT SPOOL LOCK 3 15 J2B AUX CONTROLLER 26
C114 HAND THROTTLE 6 9 C423 BUCKET POSITION 2 18 SUSP JSTK 7163706
C115 FOOT THROTTLE 6 9 C425 BRAKE SOLENOID 3 18 J7A ENGINE ECU CONTROLLER 80 BRAKE ADAPTER 7159366
C116 FOOT THROTTLE INTDM WHL 2 SPD ADP 7159366
C126 HORN 2 18 C426 CAN (Remote Start Tool, ACD) 7 8 J7B ENGINE ECU CONTROLLER 80 THROTTLE 7217683
C129 CAB ACCESSORY 3 14 C427 ENGINE CAN SERVICE TOOL 4 8
C428 CAB-MFR HARN CONN (LT GRY) 14
C130 FEED PUMP 2 9 C434-1 LEFT WORKLIGHT 1 2 16 SW1 BRAKE SWITCH 6 13
C131 EGR VALVE 4 8 C434-2 LEFT WORKLIGHT 2 2 16 SW2 BEACON SWITCH 6 18
C132 INJECTOR 8 11 C435-1 RIGHT WORKLIGHT 1 2 16 SW3 HAZARD SWITCH 6 18
C133 AIR FLOW SENSOR 5 10 C435-2 RIGHT WORKLIGHT 2 2 16 SW4 HAND/FOOT, H/ISO SWITCH 6 15
C134 DPF INTDM HARNESS C437 TWO SPEED MAKEUP 2 18 SW5 POWER BOBTACH SWITCH 6 18
C135 DIFF PRESSURE SENSOR C438 CAB-MFR HARN CONN (DK GRY) 14
C136 DPF EXHAUST TEMP SENSOR 2 11 C441 TWO SPEED 2 18 SW6 BUCKET POSITION SWITCH 6 18
C137 DPF EXHAUST TEMP SENSOR 2 11 C446 HYDRAULIC FAN 2 12 SW9 TRAVEL CONTROL SWITCH 6 13
C138 DPF EXHAUST TEMP SENSOR 2 11 C449 LEFT JOYSTICK (CAB HARN) 4 8,15 SW10 BLOWER SWITCH 5 17
C139 INTK THROTTLE VALVE MOTOR 5 10 C450 RIGHT JOYSTICK (CAB HARN) 4 8,15 SW11
Dealer AC for
Copy -- Not SWITCH
Resale 3 17
C140 CRANKSHAFT ANGLE SENSOR 3 11 C479 LEFT PANEL(BLACK) 12 8,13 SW12 DPF SWITCH 10 13
C142 CAMSHAFT ANGLE SENSOR 3 11 C480 LEFT PANEL(GRAY) 12 13
C143 EXT AIR TEMP SENSOR 2 11 C482 SEATBAR SENSOR 3 14 T1 BATT GROUND 1 7
C144 RAIL PRESSURE SENSOR 3 11 C483 TEMP CONTROL SWITCH 3 17 T2 BUZZER GROUND 1 13
C145 FUEL TEMP SENSOR 2 11 C486 AC COMPRESSOR 2 17 T3 FLASHER 2 18
C146 SUPPLY PUMP SCV 2 11 C489 MFR ACCESSORY 2 6, 7 T6 BATT GROUND 1 7
C147 COOLANT TEMP SENSOR 2 11 C492 ACS/SJC/AWS-MFR HARN 8 6,7,14 T8 BATT GROUND 1 7
C148 BOOST SENSOR 3 11 C493 ACS/SJC/AWS-MFR HARN 4 5,7 T10 ENGINE SYSTEM GROUND 1 7
C209 DOME LIGHT 3 14 C497 SJC HORN/BLINKER 3 18 T13 BUZZER POWER 1 13
C212 POWER SOCKET 2 14 C499 PTOL 4 13 T14 PRE HEATER 1 10
C252 WASHER 2 14 C500 RH KEY SWITCH 6 13 T15 RIGHT REAR WORK LIGHT(+) 1 16
C277 AIR RIDE SEAT 6 18 C503 RH DLX PANEL 6 8,13 T16 RIGHT REAR WORK LIGHT(-) 1 16 Printable Version Click Here
C278 RIGHT SPEAKER 2 18 C602 LEFT REAR TAIL LIGHT 2 16 T17 LEFT REAR WORK LIGHT (+) 1 16
C279
C308
LEFT SPEAKER
BRAKE SOLENOID
2
2
18
12
C603
C606
RIGHT REAR TAIL LIGHT
POWER BOBTACH OPEN
2
2
16
18
T18 LEFT REAR WORK LIGHT (-) 1
1
16
15
WIRING SCHEMATIC
T19 BACKUP ALARM
C350
C355
AC EVAPORATOR SWITCH
DLX or STD FUEL HARNESS
2
6
17
9,17,18
C607
C610
POWER BOBTACH CLOSE
HVAC DUCT FAN
2
2
18
17
T20
T24
BACKUP ALARM (GND)
OIL PRESSURE SW
1
1
15
10
(AWS)
C404 BU ALARM-MFR HARN 2 6,15 C611 BLOWER MOTOR 4 17 A770 (S/N ATDW11001 - ATDW11965)
C405 AIR FILTER SWITCH 2 9 C630 THERMOSTAT 3 17
C406 FUEL SENDER 2 9 C635 HEATER VALVE 6 17 A770 (S/N ATDY11001 AND ABOVE)
C408 CAB-MFR HARN CONN (BLK) 14 C667 DOOR 6 14
C409 RIGHT HANDLE 10 15 C670 EXTERIOR BEACON 6 18 Sheet 1 of 19
C410 LEFT HANDLE 10 15 C676 RADIO 6 18
Printed In U.S.A.
7207725 (E)
565 of 1010
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 ENGINE ECU A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-11 AC SENSE B-11 SEAT BAR A-11 B-11
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 REAR LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17
A-18 FAN 2 RETURN B-18 A-18 FRONT AUX (M) RETURN B-18
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE RUN KEY A-21 B-21
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 B-22 SWITCHED POWER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 WATER IN FUEL B-25 TWO SPEED MAKEUP Dealer
A-25 Copy -- Not for Resale B-25 HYDRAULIC BOOST
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED MAKE-UP RETURN A-27 HYDRAULIC BOOST RETURN
A-28 REAR LIGHT 2 RELAY FDBK A-28
A-29 A-29
A-30 FUEL PULL RELAY FDBK A-30
A-31 FRONT WORK LIGHT 1 RELAY FDBK A-31
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
WIRING SCHEMATIC
(AWS)
Sheet 2 of 19
Printed In U.S.A. 7207725 (E)
566 of 1010
J7A CONNECTOR ASSIGNMENT (CN1 ENGINE ECU) J7B CONNECTOR ASSIGNMENT (CN2 ENGINE ECU)
A-1 A-41 INJ4 DRV TWV4 (CYL #2) B-1 +BF B-41
A-2 A-42 INJ2 DRV TWV2 (CYL #3) B-2 B-42
A-3 A-GND6 (RAIL PRESSURE) A-43 INJ COMMON (INJECTOR COMMON 2) B-3 MAIN RELAY B-43
A-4 A-GND4 (BOOST PRESSURE SENSOR) A-44 B-4 B-44
A-5 A-GND2 (COOLANT TEMP SENSOR) A-45 INJ3 DRV TWV3 (CYL #4) B-5 B-45 GND - INTAKE AIR TEMP (AFS)
A-6 NE-GND (CRANKSHAFT ANGLE SENSOR (NE A-46 INJ1 DRV TWV1 (CYL #1) (IN AIR FLOW SENSOR)
SENSOR)) B-6 B-46
A-7 A-47 INJ COMMON (INJECTOR COMMON 1) B-7 B-47
A-8 G-SIG (CAMSHAFT ANGLE SENSOR (G A-48 A-VCC2 (BOOST SENSOR) B-8 B-48 INTAKE THROTTLE SENSOR (INTAKE
SENSOR SIGNAL)) THROTTLE POSITION SENSOR ,SIGNAL)
A-9 NE(12)-GND (CRANKSHAFT ANGLE SENSOR A-49 B-9 B-49 PWR - INTAKE AIR TEMP (AFS)
(NE SENSOR)) (IN AIR FLOW SENSOR)
A-10 A-50 B-10 B-50
A-11 A-51 SCV - (SUPPLY PUMP) B-11 B-51
A-12 AFS-SIG (AIR FLOW SENSOR SIGNAL) A-52 SCV + (SUPPLY PUMP) B-12 ST-SW (KEY SWITCH (ST), TERMINAL 50) B-52
A-13 PFUEL1 (RAIL PRESSURE SENSOR SIGNAL) A-53 B-13 IG-SW B-53
A-14 BOOST SENSOR (BOOST SENSOR SIGNAL) A-54 B-14 B-54
A-15 COOLANT TAMP (COOLANT TAMP SENSOR A-55 B-15 B-55
SIGNAL) B-16 CAN1-L (FOR SERVICE TOOL) B-56
A-16 A-56 B-17 CAN2-L (FOR VEHICLE) B-57
A-17 A-57 B-18 +BP B-58 +BP
A-18 OUTLET DOC (DPF EXHAUST TEMP. A-58 B-19 B-59 POWER GND
SENSOR T1) B-20 CASE-GND B-60 SIGNAL-GND
A-19 A-59 B-21 +BP B-61
A-20 A-60 INTAKE THROTTLE VALVE MOTOR (-) B-22 B-62
A-21 A-61 INJ4 DRV TWV4 (CYL #2) B-23 MAIN RELAY B-63
A-22 A-62 INJ2 DRV TWV2 (CYL #3) B-24 HEATER RLY (INTAKE HEATER RELAY) B-64
A-23 A-GND5 (FUEL TEMP. SENSOR) A-63 INJ COMMON (INJECTOR COMMON 2) B-25 B-65 A-GND11 (DIFFERENTIAL PRESSURE SENSOR,
A-24 A-GND3 (DPF EXHAUST TEMP SENSOR T0, A-64
Dealer Copy -- Not for Resale INTAKE THROTTLE POSITION SENSOR)
T1, T2) B-26 B-66
A-25 A-GND1 (INTAKE AIR TEMP SENSOR) A-65 INJ3 DRV TWV3 (CYL #4) B-27 B-67
A-27 G-GND (CAMSHAFT ANGLE SENSOR (G A-67 INJ COMMON (INJECTOR COMMON 1) B-29 OIL-SW B-69
SENSOR))
A-28 G-VCC (CAMSHAFT ANGLE SENSOR (G A-68 A-VCC1 (RAIL PRESSURE SENSOR, B-30 B-70
SENSOR)) CRANKSHAFT ANGLE SENSOR (NE SENSOR))
B-31 B-71 A-VCC12 (DIFFERENTIAL PRESSURE SENSOR)
A-29 NE(12)-SIG (CRANKSHAFT ANGLE SENSOR A-69
B-32 B-72
(NE SENSOR SIGNAL))
B-33 IG-SW B-73
A-30 A-70
B-34 B-74
A-31 A-71 SCV - (SUPPLY PUMP)
B-35 B-75
A-32 PFUEL2 (RAIL PRESSURE SENSOR SIGNAL) A-72 SCV + (SUPPLY PUMP)
B-36 CAN1-H (FOR SERVICE TOOL) B-76
A-33 FUEL TEMP (FUEL TEMP SENSOR SIGNAL) A-73
B-37 CAN2-L (FOR VEHICLE) B-77
A-34 INTAKE AIR TEMP SENSOR (INTAKE AIR A-74
TEMP SENSOR SIGNAL) B-38 +BP B-78 +BP
A-35 A-75 B-39 POWER GND B-79 GND
A-36 DIFFERENTIAL PRESSURE SENSOR SIGNAL A-76 B-40 SIGNAL-GND B-80 GND
A-37 INLET DOC (DPF EXHAUST TEMP. SENSOR A-77
T0) WIRING SCHEMATIC
A-38 OUTLET DPF (DPF EXHAUST TEMP. SENSOR A-78
T2) (AWS)
A-39 A-79
A-40 A-80 INTAKE THROTTLE VALVE MOTOR (+) A770 (S/N ATDW11001 - ATDW11965)
A770 (S/N ATDY11001 AND ABOVE)
Sheet 3 of 19
Printed In U.S.A.
567 of 1010 7207725 (E)
M SCHEMATIC INDEX LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3 PARTIAL CONNECTOR
UNSWITCHED
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-11
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 12 CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 13
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
BATT POWER
CAB PAGE 14
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 15
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 16 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 17
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 18
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C408
(BLACK)
SHEET 13
CAB-MFR HARN CONN 1
SHEET 14
FRC1 FUSE RELAY CENTER

SHEET 13
J1B
GWY CTRLR SHEET 13
J2B
AUX CTRLR
C493 Dealer Copy -- Not for Resale

ACS/SJC/AWS-MFR HARN
(4 PIN)
SHEET 8
SHEET 8
SHEET 9
SHEET 7
SHEET 18
SHEET 18
SHEET 14
SHEET 5
SHEET 17 Printable Version Click Here
SHEET 12
WIRING SCHEMATIC
SHEET 16
(AWS)
SHEET 16
A770 (S/N ATDW11001 - ATDW11965)
SHEET 5 A770 (S/N ATDY11001 AND ABOVE)
SHEET 8 Sheet 4 of 19
Printed In U.S.A. 7207725 (E)
568 of 1010
SWITCHED
POWER
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 14
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS PAGE 15
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
ACS (IF EQUIPPED) PAGE 19
SJC (IF EQUIPPED) PAGE 20
AWS (IF EQUIPPED) PAGE 19
SHEET 9
C113
ENG-MFR HARN CONN
+12V
PWR
SHEET 4
SHEET 8
J7B (CN2)
ECU CNTRLR
SHEET 10
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
C489
MFR ACCESSORY
SHEET 14
SHEET 13
SHEET 13
SHEET 18 SHEET 13
SHEET 13
SHEET 15
SHEET 13
SHEET 15 SHEET 13
C428
J2B (LT GRAY) SHEET 13
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 14
SHEET 13
SHEET 13
SHEET 7
SHEET 14 SHEET 8
+12V
PWR
SHEET 8
SHEET 4 WIRING SCHEMATIC
GND
SHEET 6 J1A
GWY CTRLR
C428
(AWS)
(LT GRAY)
CAB-MFR HARN CONN 2 A770 (S/N ATDW11001 - ATDW11965)
SHEET 7
C492
ACS/SJC/AWS-MFR HARN SHEET 7
(8 PIN) Sheet 5 of 19
Printed In U.S.A.
569 of 1010 7207725 (E) Printable Version Click Here
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8-11 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 12
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
CAB DISPLAY PAGE 13
CAB PAGE 14
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS SHEET 12
LIGHTS PAGE 16
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 17 J1B
ENGINE 8000 THROUGH 8999 TAN TAN SHEET 14 GWY CTRLR
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 18
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS (IF EQUIPPED) PAGE 19
SJC (IF EQUIPPED) PAGE 20 SHEET 12
SHEET 9 AWS (IF EQUIPPED) PAGE 19
SHEET 12
SHEET 9
SHEET 8
SHEET 11
SHEET 8
SHEET 8
C113
J7B (CN2)
ENG-MFR HARN CONN
ECU CNTRLR SHEET 8
SHEET 10
SHEET 16
SHEET 9 C493 SHEET 17
SHEET 7 (4 PIN) T8
T6 SHEET 14 BATT GND
SHEET 7 C408 BATT GND
(BLACK) SHEET 18
CAB-MFR HARN CONN 1 Dealer Copy -- Not for Resale
SHEET 13
SHEET 14
SHEET 13
SHEET 13
J1B
GWY CTRLR
SHEET 13
C428
SHEET 13 (LT GRAY)
CAB-MFR HARN CONN 2 J2B
SHEET 13 AUX CTRLR
SHEET 18
T10
SHEET 18 SHEET 8 ENGINE
SHEET 13
SHEET 18 GROUND
SHEET 18
SHEET 7
T35
ENGINE ECU
CASE GND SHEET 8
T1
SHEET 16 C103 BATT GND Printable Version Click Here
TAILGATE HARN C489
SHEET 15 MFR ACCESSORY
WIRING SCHEMATIC
SHEET 16
SHEET 12 (AWS)
SHEET 16 SHEET 8 SHEET 18
A770 (S/N ATDW11001 - ATDW11965)
SHEET 16 SHEET 15
SHEET 16
SHEET 16
SHEET 15
Sheet 6 of 19
SHEET 12
SHEET 5
570 of 1010 Printed In U.S.A. SHEET 17 7207725 (E)

LEGEND
CAN BUS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-11 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 15 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 16 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 17 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 18
C408
J7B (CN2) C113 (BLACK)
ECU CNTRLR ENG-MFR HARN CONN CAB-MFR HARN CONN 1
CAN LO
Dealer Copy -- Not for Resale C479
CAN HI LEFT PANEL (BLACK)
ECU CNTRLR CONTAINS

120 OHM RESISTOR
C503
J2B RIGHT DELUXE PANEL
AUX CTRLR
J1B
GWY CTRLR SHEET 5 C450
SHEET 6 RIGHT JOYSTICK
C492 SHEET 10
(8 PIN)
SHEET 5 C449
SHEET 6 LEFT JOYSTICK
SHEET 10
WIRING SCHEMATIC
J1B C426
GWY CTRLR Remote Run Tool, ACD (AWS)
CAN HI
CAN LO
A770 (S/N ATDW11001 - ATDW11965)
REMOTE RUN KEY
SWITCHED POWER
SHEET 8 SHEET 5
SHEET 4 UNSWITCHED POWER
GROUND
Sheet 7 of 19
SHEET 6
Printed In U.S.A.
571 of 1010 7207725 (E)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
ENGINE 1/4
PARTIAL CONNECTOR
OPTIONS PAGE 18
+12V C111
PWR MFR - BCT ENG HARN STARTER
SHEET 4 S B SHEET 4
M
GND
R
SHEET 6 SHEET 5
C110
B
ALTERNATOR G
J1A C405 EXCITATION

GWY CTRLR
GND SHEET 6
SHEET 6
SIG
C100
SIG SENSOR
(AIR/DIESEL: 82K OHMS)
SHEET 14 +5V PWR (WATER:SENSOR
60K OHMS)
(AIR/DIESEL: 82K OHMS)
C116 (WATER: 60K OHMS)
FOOT THROTTLE C115
INTDM ENGINE SPEED CONTROL
+5V PWR
SHEET 14
Dealer
SIG Copy -- Not for Resale
GND
SHEET 6
C113 J7B (CN2)
ENG-MFR HARN CONN ECU CNTRLR
FOOT THROTTLE
J1B ADAPTER HARNESS
GWY CTRLR 7217683
C355
FUEL HARN
C406
SIG
GND
SHEET 6
C428
(LT GRAY)
CAB-MFR HARN CONN 2 C114
ENGINE SPEED CONTROL
SHEET 14 +5V PWR
SIG
GND
SHEET 6

C130
ELECTRIC
FUEL PUMP
WIRING SCHEMATIC
SHEET 5
SHEET 6
+12V PWR
GND
C430
DIESEL PARTICULATE FILTER (DPF)
(AWS)
REGENERATION

A770 (S/N ATDW11001 - ATDW11965)
SHEET 13
J1A SHEET 6
START
GND
GWY CTRLR SHEET 7 REMOTE RUN
SHEET 5 SWITCHED POWER Sheet 8 of 19
REMOTE REGEN
NOTE: SEE THE ADDITIONAL OPTIONS (PRINTED AUGUST 2015)
PAGE (1 of 4)FOR PARKED REGEN KIT
572 of 1010 Printed In U.S.A. 7207725 (E)
LEGEND
ENGINE 2/4
PARTIAL CONNECTOR
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY PAGE 13
%WIRE COLORS IN SHIELDED CABLE
CAB PAGE 14
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 15
PAGE 16
WIRE BREAK
(TWO WIRE BREAKS
DO NOT FOLLOW CHART. WIRE NUMBERS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 17
PAGE 18
JOIN ONE WIRE)
ARE FOR REFERENCE ONLY.
AWS (IF EQUIPPED) PAGE 19 C134
J7A (CN1)
DPF INTDM
ECU CNTRLR HARNESS
C136
SIG
DOC INLET
GND TEMP SENSOR (T-0)
C137
GND
DPF INLET
SIG TEMP SENSOR (T-1)
C138
GND
DPF OUTLET
SIG TEMP SENSOR (T-2)
C133
MASS AIR FLOW SENSOR
CONNECTOR
SHEET 5 PWR
SHEET 6 GND
SIG
AIR TEMP +
AIR TEMP - C135
DIFFERENTIAL
PRESSURE SENSOR
SIG
GND
Dealer Copy -- Not for Resale +5V PWR
+12V T14
PWR INTAKE HEATER
SHEET 4 SHEET 11
GND
SHEET 6
C132 J7B (CN2)

SHEET 6 INJECTOR INTDM ECU CNTRLR
HARNESS
%
INJECTOR 1
INJECTOR 4
% WIRING SCHEMATIC
(AWS)
INJECTOR 2
A770 (S/N ATDW11001 - ATDW11965)
INJECTOR 3 A770 (S/N ATDY11001 AND ABOVE)
SHIELDED CABLE
Sheet 9 of 19
USED GROUNDED C149
THROUGH PIN 6 INJECTOR (PRINTED AUGUST 2015)
CONNECTOR
Printed In U.S.A.
573 of 1010 7207725 (E)
LEGEND
ENGINE 3/4
HYDRAULICS PAGE 12
CAB DISPLAY PAGE 13
CAB PAGE 14
MANUAL CONTROLS PAGE 15 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
AWS (IF EQUIPPED) PAGE 19 C147
C153 COOLANT
J7A (CN1)
ECU INTDM TEMPERATURE SENSOR
ECU CNTRLR
HARNESS
SIG
GND
C148
INTAKE MANIFOLD
PRESSURE SENSOR
GRD
SIG
+5V PWR
C145
FUEL TEMP SENSOR
GND
SIG
C146
SUCTION CONTROL
VALVE (SCV)
C143
INTAKE MANIFOLD
TEMPERATURE SENSOR
SIG
GND
C427
ENGINE CAN SERVICE
NOTE: DISCONNECT C427 FOR
+12V CONNECTING DIAGMASTER
GND C131
EGR VALVE
J7B (CN2)
ECU CNTRLR SHEET 5 +12V
SHEET 6 GND
CAN LO CAN LO
CAN HI CAN HI
WIRING SCHEMATIC
(AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 10 of 19
Printed In U.S.A.
7207725 (E)
574 of 1010
LEGEND
ENGINE 4/4
%
HYDRAULICS
CAB DISPLAY
PAGE 12
PAGE 13 WIRE COLORS IN SHIELDED CABLE
CAB PAGE 14
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS PAGE 15 WIRE BREAK DO NOT FOLLOW CHART. WIRE NUMBERS
LIGHTS PAGE 16 (TWO WIRE BREAKS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC PAGE 17 JOIN ONE WIRE) ARE FOR REFERENCE ONLY.
OPTIONS PAGE 18
C153
ECU INTDM
HARNESS SHIELDED CABLE USED
GROUNDED THROUGH PIN 1
J7A (CN1)
C140
ECU CNTRLR
CRANKSHAFT POSITION
SENSOR (NE)
%
GND
SIG
+5V PWR
SHEET 6 C144
FUEL RAIL
PRESSURE SENSOR
%
+5V PWR
SIG
GND
Dealer Copy -- Not for Resale C142

CAMSHAFT POSITION
% SENSOR (G)
GND
SIG
+5V PWR
C139
INTAKE THROTTLE
VALVE
M2 +
M1 -
%
SHEET 9 GND
+5V PWR
SIG
T24
ENGINE OIL
PRESSURE SWITCH OPENS WITH LOW OIL PRESSURE
OPEN = NORMAL
CLOSED = LOW OIL PRESSURE;
BELOW 50 kPa (7 PSI)
J7B (CN2)
WIRING SCHEMATIC
ECU CNTRLR
(AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 11 of 19
Printed In U.S.A.
575 of 1010
7207725 (E)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
CONTROLLER GROUND/RETURN
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
CONNECTOR
WIRE BREAK
HYDRAULICS
OPTIONS PAGE 18
C425
+12V C308
PWR
SHEET 4 TRACK 2 SPEED
ADAPTER (SEE
SHEET 6 ADDITIONAL
GND
SHEET 6 OPTIONS SHEET)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
C108
HYDRAULIC
GND
SHEET 6 TEMPERATURE
SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A SIG HYDRAULIC OIL
GWY CTRLR SHEET 6 GND FILTER SWITCH (NC)
C446
GND
SIG
C420
GND
SIG
C105
GND
SHEET 6
SIG
+8V PWR
J1B +8V
GWY CTRLR
C418 Printable Version Click Here

J2A GND
AUX CTRLR
SIG
WIRING SCHEMATIC
C419
GND (AWS)
SIG
A770 (S/N ATDW11001 - ATDW11965)
J2B
Sheet 12 of 19
AUX CTRLR
Printed In U.S.A.
7207725 (E)
576 of 1010
LEGEND
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 6
PAGE 7
PAGE 8-11
PAGE 12
PAGE 13
PAGE 14
CONNECTOR CAB DISPLAY
LIGHTS 6000 THROUGH 6999 PINK PNK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC PAGE 17 JOIN ONE WIRE)
OPTIONS PAGE 18
T13
BUZZER (+)
SHEET 5 C499
LEFT PANEL
BUZZER Press To Operate Loader
C479 (PTOL)
T2
LEFT PANEL (BLACK)
BUZZER (-) SHEET 5 SWITCHED POWER
BUZZER C408 SHEET 6 GROUND
(BLACK)
SHEET 6 GROUND CAB-MFR HARN CONN 1
SHEET 5 SHEET 4 UNSWITCHED POWER

PTOL OUTPUT
SHEET 5 SWITCHED POWER
PTOL LED
J1A
SHEET 18 LEFT BLINKER INPUT
GWY CTRLR
C500
SHEET 18 RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
TRAVEL CONTROL INPUT
SHEET 6 START
PARK BRAKE INPUT Dealer Copy -- Not for Resale
SHEET 8
SHEET 5
C480 J1B
SHEET 6 LEFT PANEL (GRAY) GWY CTRLR RUN/ENTER SWITCH
SHEET 14 DOOR SIGNAL
SHEET 6 GROUND
PARK BRAKE OUTPUT
SW12
DIESEL PARTICULATE FILTER C503
INHIBIT SWITCH (OPTIONAL) RIGHT PANEL DELUXE DISPLAY
SHEET 5 DPF LAMP

SHEET 5 DPF INHIBIT LAMP
DPF OVERRIDE
SHEET 6
DPF INHIBIT REGEN SHEET 6 GROUND
SW12
DIESEL PARTICULATE DERATE
WIRING SCHEMATIC
SWITCH (STANDARD)
(AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 13 of 19
Printed In U.S.A.
LEGEND
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB
GROUND PAGE 6
ENGINE PAGE 8-11 CONNECTOR
HYDRAULICS PAGE 12
CAB DISPLAY PAGE 13
CAB PAGE 14
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
* DLX CAB HARN 7207730 ONLY
HVAC PAGE 17
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 18 (NOT IN STD CAB HARN)
*
SHEET 5
C492 C438 SHEET 14
ACS/SJC/AWS-MFR HARN (DK GRAY)
(8 PIN) SHEET 15 CAB-MFR HARN CONN 3
SHEET 15
SHEET 5 *C212
POWER
SOCKET
GND
+12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1 * C209
GND
SHEET 4 +12V PWR
DOOR SIG
C129
CAB ACCESSORY Dealer Copy -- Not for Resale
+12V BATT PWR
+12V SW PWR
SHEET 5
GND
SHEET 18
SHEET 18
SHEET 18
SHEET 6 SHEET 18
SHEET 14
C428
(LT GRAY)
CAB-MFR HARN CONN 2
* C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
SHEET 6
WIPER SWITCH, MOTOR SWITCHED POWER
SHEET 13 DOOR SIGNAL
C482 SHEET 4 DOOR UNSW PWR
J1B
GWY CTRLR SHEET 6
WIPER MOTOR GROUND
WASHER SIGNAL
+5V
SHEET 6 * C252 WIRING SCHEMATIC
SHEET 6
SHEET 6 (AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 14 of 19
Printed In U.S.A.
LEGEND
MANUAL
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 12
CAB DISPLAY PAGE 13
CAB PAGE 14
CONTROLS
HVAC PAGE 17
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 18
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A SHEET 6
AUX CTRLR
C404 SHEET 14
C103 SHEET 5
BU ALARM-MFR HARN
TAILGATE HARN
T19 TERMINAL (+)
(SEE ADDITIONAL
OPTIONS SHEET) BACK UP
ALARM
SHEET 6
T20 TERMINAL (-)
C410
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR
J1A
GWY CTRLR
C422
SHEET 5
SHEET 14
SHEET 6
J1B
GWY CTRLR WIRING SCHEMATIC
(AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 15 of 19
Printed In U.S.A.
7207725 (E)
579 of 1010 Printable Version Click Here
LEGEND
LIGHTS
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
SJC (IF EQUIPPED) PAGE 20 C434-1
AWS (IF EQUIPPED) PAGE 19 GND
C408
(BLACK) SIG
CAB-MFR HARN CONN 1
C434-2
GND
SHEET 6
SIG
C435-1
SIG
GND
C435-2
SIG
GND
C103
C603
+12V Dealer Copy -- Not TAILGATE
for Resale
HARN
PWR GND
SHEET 4 SHEET 6
SIG
GND
C602
SHEET 6
SIG
GND
SHEET 6
J1A
GWY CTRLR
T16 TERMINAL (-)

GND
SHEET 6
SIG
T15 TERMINAL (+)

+12V
PWR T17 TERMINAL (+)
SHEET 4 SIG
GND SHEET 6 GND

SHEET 6 T18 TERMINAL (-)
WIRING SCHEMATIC
(AWS)
A770 (S/N ATDW11001 - ATDW11965)
Sheet 16 of 19
Printed In U.S.A. Printable Version Click Here
580 of 1010 7207725 (E)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
CONNECTOR
HVAC
WIRE BREAK
#
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS
HVAC
PAGE 16
PAGE 17
(TWO WIRE BREAKS
JOIN ONE WIRE)
DLX FUEL HARN 7184255 ONLY
OPTIONS
ACS (IF EQUIPPED)
PAGE 18
PAGE 19
(NOT IN STD FUEL HARN 7149219)
* C610
*
HVAC DUCT
DLX CAB HARN 7207730 ONLY
FAN
(NOT IN STD CAB HARN)
* C483
C635
*
C438
(DK GRAY)
Dealer Copy -- Not for Resale *
+12V CAB-MFR HARN CONN 3
PWR
SHEET 4
GND
SHEET 6
* C611
J1A SHEET 6
*
GWY CTRLR
C630
* Printable Version Click Here
C350
WIRING SCHEMATIC
C355
FUEL HARN # C486
SIG
(AWS)
GND
A770 (S/N ATDW11001 - ATDW11965)
SHEET 18
D4
Sheet 17 of 19
Printed In U.S.A.
581 of 1010 7207725 (E)
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1-3
OPTIONS
GROUND PAGE 6
HYDRAULICS PAGE 12
CAB DISPLAY PAGE 13
CAB PAGE 14
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
HVAC
OPTIONS
PAGE 17
PAGE 18
JOIN ONE WIRE) #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C428
(LT GRAY)
C355
FUEL HARN CAB-MFR HARN CONN 2
# C607
SIG
GND
SHEET 6
SHEET 17 (NOT IN STD CAB HARN)
#
*
C606
GND
SIG
SHEET 5
C438
(DK GRAY)
C411 CAB-MFR HARN CONN 3
LEFT HANDLE
(FLASHER) 5 WAY
SHEET 4
D1
* T3
FLASHER
(SEE ADDITIONAL
SHEET 13 CONN
*
OPTIONS SHEET) D2
C103
SHEET 13
*
TAILGATE HARN
(PINS 3 & 6
Dealer Copy -- Not for Resale INTERNALLY
EURO TAIL LIGHTS
(SEE ADDITIONAL INSULATED) * C670
OPTIONS SHEET)
SHEET 6 BEACON/FLASHER
C423 EXTERIOR HARNESS
(SEE ADDITIONAL
SIG D3
* OPTIONS SHEET)
GND
SHEET 6 SHEET 6
C408
(BLACK)
CAB-MFR HARN CONN 1 SHEET 6
C126
* C279 * C676
RADIO CONN
LEFT HANDLE C412 GND +
(HORN) 2 WAY SIG HORN C277
(SEE ADDITIONAL SHEET 4

- *
OPTIONS SHEET)
C497 * -
C278
SJC PWR
HORN/BLINKER + SHEET 14
GND
(SEE ADDITIONAL SHEET 14 SHEET 14
J2A OPTIONS SHEET) SHEET 14
AUX CTRLR
C415
GND
SIG
J2B
AUX CTRLR WIRING SCHEMATIC
C437 (AWS)
GND
J1A
SIG TRACK 2 SPEED
ADAPTER
A770 (S/N ATDW11001 - ATDW11965)
GWY CTRLR C441
GND
(SEE ADDITIONAL
OPTIONS SHEET) A770 (S/N ATDY11001 AND ABOVE)
SIG
Sheet 18 of 19
J1B
GWY CTRLR
Printed In U.S.A.
7207725 (E)
582 of 1010
J5 DRIVE PLUS CONTROLLER
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE PIN FUNCTION
LEGEND ACS CONTROLLER
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE 1 SAFETY IN
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT PIN FUNCTION PIN FUNCTION PIN FUNCTION 2 TWO SPEED SWITCH
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 3 SPARE DIGITAL INPUT 2
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 4 H PAT SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 5 ISO PAT SWITCH
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 6 ISO LITE
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 7 L SWASH PLATE ANGLE
LIGHTS 6000 THROUGH 6999 PINK PNK 8 R SWASH PLATE ANGLE
WIRE BREAK F F LIFT HANDLE F LIFT MOTOR 1
(TWO WIRE BREAKS G GROUND G TILT HANDLE G PEDAL ENABLE 9 SPARE ANALOG 4
CONNECTOR ASSIGNMENTS JOIN ONE WIRE) 10 SPARE ANALOG 5
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
NUM OF COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 11 L FWD RETURN
CONN DESCRIPTION J LIFT PEDAL J GROUND
PINS 12 CAN HIGH
K TILT PEDAL K TILT MOTOR 2
C536 RIGHT SWASHPLATE 4
13 LF ANGLE
C537 LEFT SWASHPLATE 4
HARNESS PART NUMBER 14 RF ANGLE
C428 TILT ACTUATOR 8
LF AWS 7210507 15 LR ANGLE
C429 LIFT ACTUATOR 8
LF AWS 7182311 16 H PAT LITE
C440 RF BASE 2
A22 PUMP 7188448 17 RR ANGLE
C442 LF BASE 2
SUSP JSTK 7163706 18 L JOYSTICK X
C443 LF ROD 2
J5 - DRIVE PLUS
AWS
19 L JOYSTICK Y
C444 RR BASE 2
20 R JOYSTICK X
C445
C447
RR ROD
LR ROD
2
2
CONTROLLER C458
C460
+12V PWR
21 L FWD DRIVE
SIG C450 GND 22 CAN LOW
C448 PRESSURE CONTROL 2 GND RIGHT JOYSTICK CAN LO 23 R QUAD A DRIVE
C452 LR BASE 2 +5V PWR (CONNECTS TO
24 R QUAD B DRIVE
CONTROLS
C453 RIGHT QUAD A DRIVE 4 DLX CAB HARNESS)
C457 CAN HI 25 TWO SPEED 1
C454 LEFT QUAD DIRVE 4
SIG 26 BRAKE LIGHT OUTPUT
C455 R FRT WHEEL POS SENSOR 3 GND C459 27 GROUND
C456 R REAR WHEEL POS SENSOR 3 +5V PWR +12V PWR
# 28 GROUND
C457
C458
L FRT WHEEL POS SENSOR
L REAR WHEEL POS SENSOR
3
3 +5V
C456 HARNESS 7182311 ONLY C449
LEFT JOYSTICK
GND 29 SENSOR GROUND
+5V PWR 30 SENSOR SUPPLY 2 +5V
(CONNECTS TO CAN LO
C461 RF ROD 2 SIG DLX CAB HARNESS)
C429 31 L REV DRIVE
C474 BRAKE LIGHT 1 GND CAN HI
32 CAN SHIELD
C492 MAINFRAME HARN 1 8 C455 SUSP SEAT JOYSTICK HARNESS 33 L QUAD A DRIVE
C493 MAINFRAME HARN 2 4 +5V PWR
34 L QUAD B DRIVE
C501 A22 PUMP HARNESS 8 SIG GND 35 SAFETY OUT
C544 LEFT FORWARD DRIVE 2 GND
36 BACKUP ALARM
C545 LEFT REVERSE DRIVE 2 # C454 SIG
37 R JOYSTICK Y
C546 RIGHT FORWARD DRIVE 2 GND
+5V PWR 38 SPARE ANALOG 1
C547 RIGHT REVERSE DRIVE 2 +5V PWR
SIG
39 SPARE PWM COIL 7
C542 LEFT SWASHPLATE 3 C428
SIG 40 SENSOR SUPPLY 1 +5V
C543 RIGHT SWASHPLATE 3 +5V PWR 41 L REV RETURN
C707 OBW STOP BRAKE LIGHT 3 +5V # C453
R FWD RETURN
+5V PWR 42
SIG
43 R FWD DRIVE
J1-ACS ACS CONTROLLER 8
GND
SIG GND
J6 - DRIVE PLUS 44 R REV DRIVE
J2-ACS ACS CONTROLLER 10 STEERING
SIG 45 R REV RETURN
C536
SOLENOIDS CONTROLLER 46 TWO SPEED 2
J5 DRIVE PLUS CONTROLLER 50 A22 PUMP HARNESS C448
C543 47 UNSWITCHED BATTERY
J6 DRIVE PLUS CONTROLLER 50
GND 48 UNSWITCHED BATTERY
SIG 49 SPARE PWN COIL 6
+12V PWR
C442 50 SWITCHED BATTERY
J2-ACS
C537
C542
GND
Dealer Copy -- Not for Resale PIN
FUNCTION
SIG C447 1 STEER MODE 3
+12V PWR
2 PRESSURE CONTROL
C501 C546 3 RR LEFT (BASE)
RIGHT FORWARD DRIVE 4 RR RIGHT (ROD)
C452
ACS CONTROLLER
5 LR RIGHT (BASE)
6 RF RIGHT (ROD)
C547
7 LF RIGHT (BASE)
RIGHT REVERSE DRIVE +5V C443 8 RR ROD RET
J1-ACS
9 LR ROD RET
C545 10 LR BASE RET
C461
11 STEER MODE 2
LEFT REVERSE DRIVE
12 STEER MODE 1
13
C544
14
LEFT FORWARD DRIVE C445 15 LR LEFT (R0D)
16 RF LEFT (BASE)
17 LF LEFT (ROD)
C474 TO SJC BRAKE
HARNESS C444 18 PRESSURE CONTROL RET
J3-ACS
(SEE ADDITIONAL OPTIONS 19 RR BASE RET
SHEET) 20 RF ROD RET
C492 21
C440
22
23 NOT USED
24 NOT USED
25 NOT USED
26 GND
27
MAINFRAME
28
HARNESS 29 RF BASE RET
C493
30 LF BASE RET
31
32
33 NOT USED
34 GND
35 SPARE AN/DIG IN 4
36 GND
Printable Version Click Here 37 STEER MODE SELECT 3
38
WIRING SCHEMATIC 39
40 LF ROD RET
(AWS) 41
42 SPARE PWM OUTPUT COIL
A770 (S/N ATDW11001 - ATDW11965) 43
44
UNSWITCHED BATTERY
UNSWITCHED BATTERY
A770 (S/N ATDY11001 AND ABOVE) 45
46
NOT USED
C404
(CONNECTS TO BACKUP
Sheet 19 of 19 47 STEER MODE SELECT 1
48
ALARM C404 ON MFR
HARNESS) (PRINTED AUGUST 2015) 49 STEER MODE SELECT 2
50
Printed
583 ofIn1010
U.S.A. 7207725 (E)
CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C100 WATER IN FUEL SENSOR 2 8 C422 LIFT SPOOL LOCK 3 15 HARNESS PART NUMBER
C103 TAILGATE 8 6,15,16,18 C423 BUCKET POSITION 2 18 LF MFR CTRL 7226814
C105 HYD CHARGE PRESSURE 3 12 C425 BRAKE SOLENOID 3 12 FRC1 FUSE RELAY CENTER 112 4,5,8,12,16, DLX CAB 7234736
17 DLX FUEL 7184255
C108 HYD TEMPERATURE SENDER 2 12 C426 CAN (Remote Start Tool, ACD) 7 7 ENGINE 7211660
C110 ALTERNATOR 2 8 C428 CAB-MFR HARN CONN (LT GRY) 14 5,6,8,14,18 J1A GATEWAY CONTROLLER 34 STARTER 7206494
C111 MFR-BCT ENG HARN CONN 3 8 C430 DIESEL PARTICULATE REGEN 6 8 J1B GATEWAY CONTOLLER 26 TAILGATE DOM 7217484
C112 HYD OIL FILTER SWITCH 2 12 C434-1 LEFT WORKLIGHT 1 2 16 J2A AUX CONTROLLER 34 SUSP JSTK 7163706
C113 ENG-MFR HARN CONN 10 5,6,7,8 C434-2 LEFT WORKLIGHT 2 2 16 J2B AUX CONTROLLER 26 BRAKE ADAPTER 7165061
C114 HAND THROTTLE 6 8 C435-1 RIGHT WORKLIGHT 1 2 16 WHL 2 SPD ADP 7159366
C115 FOOT THROTTLE 6 8 C435-2 RIGHT WORKLIGHT 2 2 16 THROTTLE 7217683
C116 FOOT THROTTLE INTDM 3 8 C437 TWO SPEED MAKEUP 2 18 J7A ENGINE ECU CONTROLLER 80
C126 HORN 2 18 C438 CAB-MFR HARN CONN (DK GRY) 14 14,16,18 J7B ENGINE ECU CONTROLLER 80
17
C129 CAB ACCESSORY 3 14 C441 TWO SPEED 2 18
C130 FEED PUMP 2 8 C446 HYDRAULIC FAN 2 12
C132 INJECTOR INTDM HARNESS 12 9 C449 LEFT JOYSTICK (CAB HARN) 4 7 SW1 BRAKE SWITCH 6 13
C133 AIR FLOW SENSOR 5 9 C450 RIGHT JOYSTICK (CAB HARN) 4 7 SW2 BEACON SWITCH 6 18
C134 DPF INTDM HARNESS 16 9 C479 LEFT PANEL(BLACK) 12 7,13 SW3 HAZARD SWITCH 6 18
C153 ECU INTDM HARNESS 42 10,11 C480 LEFT PANEL(GRAY) 12 13 SW4 HAND/FOOT, H/ISO SWITCH 6 15
C212 POWER SOCKET 2 14 C482 SEATBAR SENSOR 3 14 SW5 POWER BOBTACH SWITCH 6 18
C252 WASHER 2 14 C483 TEMP CONTROL SWITCH 3 17 SW6 BUCKET POSITION SWITCH 6 18
C277 AIR RIDE SEAT 6 18 C486 AC COMPRESSOR 2 17 SW9 TRAVEL CONTROL SWITCH 6 13
C278 RIGHT SPEAKER 2 18 C489 MFR ACCESSORY 2 5,6 Dealer
SW10 CopyBLOWER
-- Not for Resale
SWITCH 5 17
C279 LEFT SPEAKER 2 18 C492 ACS/SJC/AWS-MFR HARN 8 5,7,14 SW11 AC SWITCH 3 17
C308 BRAKE SOLENOID 2 12 C493 ACS/SJC/AWS-MFR HARN 4 4,6 SW12 DPF SWITCH 10 13
C350 AC EVAPORATOR SWITCH 2 17 C497 SJC HORN/BLINKER 3 18
C355 DLX or STD FUEL HARNESS 6 8,17,18 C499 PTOL 4 13
C404 BU ALARM-MFR HARN 2 5,15 C500 RH KEY SWITCH 6 13 T1 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C503 RH DLX PANEL 6 7,13 T2 BUZZER GROUND 1 13
C406 FUEL SENDER 2 8 C602 LEFT REAR TAIL LIGHT 2 16 T3 FLASHER 2 18
C408 CAB-MFR HARN CONN (BLK) 14 4,6,7,13, C603 RIGHT REAR TAIL LIGHT 2 16
T6 BATT GROUND 1 6
14,16
C409 RIGHT HANDLE 10 15 C606 POWER BOBTACH OPEN 2 18 1 6
T8 BATT GROUND
C410 LEFT HANDLE 10 15 C607 POWER BOBTACH CLOSE 2 18 T10 ENGINE SYSTEM GROUND 1 6 Printable Version Click Here
C411 LEFT HANDLE 5 WAY 5 18 C610 HVAC DUCT FAN 2 17 T13 BUZZER POWER 1 13
C412
C415
LEFT HANDLE 2 WAY
HIGH FLOW SOLENOID
2
2
18
18
C611
C630
BLOWER MOTOR
THERMOSTAT
4
3
17
17
T14 PRE HEATER
RIGHT REAR WORK LIGHT(+)
1 9 WIRING SCHEMATIC
T15 1 16
C418 FRONT ROD 2 12 C635 HEATER VALVE 6 17 T16 RIGHT REAR WORK LIGHT(-) 1 16 (AWS)
C419 FRONT BASE 2 12 C667 DOOR 6 14 T17 LEFT REAR WORK LIGHT (+) 1 16
C420 HYD LOCK 2 12 C670 EXTERIOR BEACON 6 18 T18 LEFT REAR WORK LIGHT (-) 1 16 A770 (S/N ATDW11966 AND ABOVE)
C421 TILT SPOOL LOCK 3 15 C676 RADIO 6 18 T19 BACKUP ALARM 1 15
C421 TILT SPOOL LOCK 3 15 T20 BACKUP ALARM (GND) 1 15
T35 ENGINE ECU CASE GND 1 6
T36 DOMELIGHT (-) 1 14 Sheet 1 of 19
T37 DOMELIGHT (+) 1 14
Printed In U.S.A. P
7233063 (B)
584 of 1010
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 HVAC RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER RELAY B-4 ENGINE ECU A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 FRONT WORK LIGHT RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE A-10 REAR AUX (M) RETURN B-10
A-11 AC SENSE B-11 SEAT BAR A-11 SIDE SHIFT B-11
A-12 B-12 FUEL LEVEL A-12 SIDE SHIFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 HYD LOCK HOLD A-13 TWO SPEED B-13 FRONT AUX (F)
A-14 REMOTE REGEN B-14 CAN HI 2 A-14 B-14
A-15 B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 REAR LIGHT RELAY B-17 GROUND P3, SENSOR A-17 B-17 PWM LOW
A-18 FAN RETURN B-18 A-18 FRONT AUX (M) RETURN B-18 PWM SIGNAL
A-19 PTOL LED B-19 FAN OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 FLOAT B-20
A-21 SWITCHED POWER RELAY FDBK B-21 REMOTE RUN KEY A-21 B-21 DETENT
A-22 STARTER RELAY FDBK B-22 RUN/ENTER A-22 SKI CTRL B-22 SWITCHED POWER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 PWM HIGH
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 WATER IN FUEL B-25 TWO SPEED MAKEUP
Dealer
A-25
Copy -- Not for Resale B-25
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED MAKE-UP RETURN A-27
A-28 REAR LIGHT RELAY FDBK A-28 SKI CTRL
A-29 A-29
A-30 HVAC RELAY RDBK A-30 SKI CTRL
A-31 FRONT WORK LIGHT RELAY FDBK A-31 SKI CTRL
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 FOOT THROTTLE SIGNAL A-33
A-34 HYD OIL FILTER SW1 A-34
WIRING SCHEMATIC
(AWS)
Sheet 2 of 19
Printed In U.S.A. 7233063 (B)

585 of 1010
J7A CONNECTOR ASSIGNMENT (CN1 ENGINE ECU) J7B CONNECTOR ASSIGNMENT (CN2 ENGINE ECU)
A-1 A-41 INJ4 DRV TWV4 (CYL #2) B-1 +BF B-41
A-3 A-GND6 (RAIL PRESSURE) A-43 INJ COMMON (INJECTOR COMMON 2) B-3 MAIN RELAY B-43
A-4 A-GND4 (BOOST PRESSURE SENSOR) A-44 B-4 B-44
A-5 A-GND2 (COOLANT TEMP SENSOR) A-45 INJ3 DRV TWV3 (CYL #4) B-5 B-45 A-GND10 (AIR FLOW SENSOR)
A-6 NE-GND (CRANKSHAFT ANGLE SENSOR (NE A-46 INJ1 DRV TWV1 (CYL #1) B-6 B-46
SENSOR)) B-7 B-47
A-7 A-47 INJ COMMON (INJECTOR COMMON 1) B-8 B-48 INTAKE THROTTLE SENSOR (INTAKE
A-8 G-SIG (CAMSHAFT ANGLE SENSOR (G A-48 A-VCC2 (BOOST SENSOR) THROTTLE POSITION SENSOR ,SIGNAL)
SENSOR SIGNAL)) B-9 B-49 INTAKE AIR TEMP (AFS)(INTAKE TEMP
A-9 NE(12)-GND (CRANKSHAFT ANGLE SENSOR A-49 SENSOR (IN AIR FLOW SENSOR))
(NE SENSOR)) B-10 B-50
A-10 A-50 B-11 B-51
A-11 A-51 SCV - (SUPPLY PUMP) B-12 ST-SW (KEY SWITCH (ST), TERMINAL 50) B-52
A-12 AFS-SIG (AIR FLOW SENSOR SIGNAL) A-52 SCV + (SUPPLY PUMP) B-13 IG-SW B-53
A-13 PFUEL1 (RAIL PRESSURE SENSOR SIGNAL) A-53 B-14 B-54
A-14 BOOST SENSOR (BOOST SENSOR SIGNAL) A-54 B-15 B-55
A-15 COOLANT TAMP (COOLANT TAMP SENSOR A-55 B-16 CAN1-L (FOR SERVICE TOOL) B-56
SIGNAL) B-17 CAN2-L (FOR VEHICLE) B-57
A-16 A-56 B-18 +BP B-58 +BP
A-17 A-57 B-19 B-59 POWER GND
A-18 OUTLET DOC (DPF EXHAUST TEMP. A-58 B-20 CASE-GND B-60 SIGNAL-GND
SENSOR T1)
B-21 +BP B-61
A-19 A-59
B-22 B-62
A-20 A-60 INTAKE THROTTLE VALVE MOTOR (-)
B-23 MAIN RELAY B-63
A-21 A-61 INJ4 DRV TWV4 (CYL #2)
B-24 HEATER RLY (INTAKE HEATER RELAY) B-64
B-25 B-65 A-GND11 (DIFFERENTIAL PRESSURE SENSOR,
A-23 A-GND5 (FUEL TEMP. SENSOR) A-63 INJ COMMON (INJECTOR COMMON 2) INTAKE THROTTLE POSITION SENSOR)
A-24 A-GND3 (DPF EXHAUST TEMP SENSOR T0, A-64 Dealer Copy
B-26 -- Not for Resale B-66
T1, T2)
B-27 B-67
A-25 A-GND1 (INTAKE AIR TEMP SENSOR) A-65 INJ3 DRV TWV3 (CYL #4)
B-28 B-68
B-29 OIL-SW B-69
A-27 G-GND (CAMSHAFT ANGLE SENSOR (G A-67 INJ COMMON (INJECTOR COMMON 1)
SENSOR))
B-30 B-70
A-28 G-VCC (CAMSHAFT ANGLE SENSOR (G A-68 A-VCC1 (RAIL PRESSURE SENSOR,
B-31 B-71 A-VCC12 (DIFFERENTIAL PRESSURE SENSOR)
SENSOR)) CRANKSHAFT ANGLE SENSOR (NE SENSOR))
B-32 B-72
A-29 NE(12)-SIG (CRANKSHAFT ANGLE SENSOR A-69
(NE SENSOR SIGNAL)) B-33 IG-SW B-73
A-30 A-70 B-34 B-74
A-31 A-71 SCV - (SUPPLY PUMP) B-35 B-75
A-32 PFUEL2 (RAIL PRESSURE SENSOR SIGNAL) A-72 SCV + (SUPPLY PUMP) B-36 CAN1-H (FOR SERVICE TOOL) B-76
A-33 FUEL TEMP (FUEL TEMP SENSOR SIGNAL) A-73 B-37 CAN2-L (FOR VEHICLE) B-77
A-34 INTAKE AIR TEMP SENSOR (INTAKE AIR A-74 B-38 +BP B-78
TEMP SENSOR SIGNAL) B-39 POWER GND B-79
A-35 A-75 B-40 SIGNAL-GND B-80
A-36 DIFFERENTIAL PRESSURE SENSOR SIGNAL A-76
A-37 INLET DOC (DPF EXHAUST TEMP. SENSOR A-77
T0) WIRING SCHEMATIC
A-38 OUTLET DPF (DPF EXHAUST TEMP. SENSOR A-78
T2) (AWS)
A-39 A-79
A-40 A-80 INTAKE THROTTLE VALVE MOTOR (+) A770 (S/N ATDW11966 AND ABOVE)
Sheet 3 of 19
Printed In U.S.A.
586 of 1010 7233063 (B)
UNSWITCHED
BATT POWER
CAB PAGE 14
LIGHTS PAGE 16
OPTIONS PAGE 18
C408
(BLACK)
CAB-MFR HARN CONN 1
J1B
GWY CTRLR
J2B
AUX CTRLR
C493 Dealer Copy -- Not for Resale

(4 PIN)
WIRING SCHEMATIC
(AWS)
Sheet 4 of 19
587 of 1010
SWITCHED
POWER
LIGHTS PAGE 16
OPTIONS PAGE 18
C113
ENG-MFR HARN CONN
+12V
PWR
J7B (CN2)
ECU CNTRLR
C404
BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
C489
MFR ACCESSORY
C428
J2B (LT GRAY)
AUX CTRLR CAB-MFR HARN CONN 2
+12V
PWR WIRING SCHEMATIC
GND
(AWS)
J1A
GWY CTRLR
C428
(LT GRAY) A770 (S/N ATDW11966 AND ABOVE)
CAB-MFR HARN CONN 2
C492
ACS/SJC/AWS-MFR HARN Sheet 5 of 19
(8 PIN)

588 of 1010
LEGEND
GROUND
CAB PAGE 14
LIGHTS PAGE 16
HVAC PAGE 17 J1B
OPTIONS PAGE 18 GWY CTRLR
C113
J7B (CN2)
ENG-MFR HARN CONN
ECU CNTRLR
C493
(4 PIN) T8
T6 BATT GND
C408 BATT GND
(BLACK)
CAB-MFR HARN CONN 1 Dealer Copy -- Not for Resale
J1B
GWY CTRLR
C428
(LT GRAY)
CAB-MFR HARN CONN 2 J2B
AUX CTRLR
T10
ENGINE
GROUND
T35
ENGINE ECU
CASE GND
T1
C103 BATT GND
TAILGATE HARN C489
MFR ACCESSORY
WIRING SCHEMATIC
(AWS)
Sheet 6 of 19
7233063 (B)
Printed In U.S.A.
589 of 1010
LEGEND
CAN BUS
CAB PAGE 14
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
C408
J7B (CN2) C113 (BLACK)
ECU CNTRLR ENG-MFR HARN CONN CAB-MFR HARN CONN 1
CAN LO C479
CAN HI LEFT PANEL (BLACK)
ECU CNTRLR CONTAINS

120 OHM RESISTOR
C503
J2B RIGHT DELUXE PANEL
AUX CTRLR
J1B
GWY CTRLR C450
RIGHT JOYSTICK
C492 SHEET 10
(8 PIN)
C449
LEFT JOYSTICK
SHEET 10
WIRING SCHEMATIC
J1B C426
(AWS)
GWY CTRLR Remote Run Tool, ACD
CAN HI
CAN LO
REMOTE RUN KEY
SWITCHED POWER
UNSWITCHED POWER
Sheet 7 of 19
GROUND
Printed In U.S.A.
590 of 1010 7233063 (B)
LEGEND
ENGINE 1/4
PARTIAL CONNECTOR
CAB PAGE 14
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
+12V C111
PWR MFR - BCT ENG HARN STARTER
S M
B
GND
R
C110
B
ALTERNATOR G
J1A C405 EXCITATION

GWY CTRLR
GND
SIG
C100
WATER IN FUEL
SIG SENSOR
+5V PWR (AIR/DIESEL: 82 K OHMS)
(WATER: 60K OHMS)
C116
FOOT THROTTLE C115
INTDM FOOT THROTTLE
+5V PWR
Dealer
SIG Copy -- Not for Resale
GND
C113 J7B (CN2)
ENG-MFR HARN CONN ECU CNTRLR
FOOT THROTTLE
J1B ADAPTER HARNESS
GWY CTRLR 7217683
C355
FUEL HARN
C406
SIG
GND
C428
(LT GRAY)
CAB-MFR HARN CONN 2 C114
HAND THROTTLE
+5V PWR
SIG
GND
C130
FUEL FEED
PUMP WIRING SCHEMATIC
+12V PWR C430
GND DIESEL PARTICULATE FILTER (DPF)
REGENERATION
(AWS)
UNSWITCHED POWER A770 (S/N ATDW11966 AND ABOVE)
START
J1A GND Printable Version Click Here
GWY CTRLR REMOTE RUN
SWITCHED POWER
REMOTE REGEN
Sheet 8 of 19
Printed In U.S.A.
591 of 1010
7233063 (B)
LEGEND
ENGINE 2/4
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
HYDRAULICS
CAB DISPLAY
PAGE 12
PAGE 13
%WIRE COLORS IN SHIELDED CABLE
CAB PAGE 14
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
(TWO WIRE BREAKS
DO NOT FOLLOW CHART. WIRE NUMBERS
LIGHTS PAGE 16
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 17
PAGE 18
JOIN ONE WIRE)
ARE FOR REFERENCE ONLY.
C134
J7A (CN1) DPF INTDM
ECU CNTRLR HARNESS
C133
MASS AIR FLOW SENSOR
CONNECTOR
PWR
GND
SIG
AIR TEMP +
AIR TEMP -

+12V T14
PWR INTAKE HEATER
GND
C132 J7B (CN2)

INJECTOR INTDM ECU CNTRLR
HARNESS
WIRING SCHEMATIC
%
(AWS)
Sheet 9 of 19
Printed In U.S.A.
7233063 (B)
592 of 1010
LEGEND
ENGINE 3/4
PARTIAL CONNECTOR
CAB DISPLAY PAGE 13
CAB PAGE 14
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
C153
J7A (CN1)
ECU INTDM
ECU CNTRLR
HARNESS
J7B (CN2)
ECU CNTRLR
CAN LO
CAN HI
WIRING SCHEMATIC
(AWS)
Sheet 10 of 19

593 of 1010
LEGEND
ENGINE 4/4
PARTIAL CONNECTOR
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
HYDRAULICS
CAB DISPLAY
PAGE 12
PAGE 13
%
WIRE COLORS IN SHIELDED CABLE
CAB PAGE 14
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS PAGE 15 WIRE BREAK DO NOT FOLLOW CHART. WIRE NUMBERS
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC PAGE 17 JOIN ONE WIRE) ARE FOR REFERENCE ONLY.
OPTIONS PAGE 18
C153
ECU INTDM
HARNESS
J7A (CN1)
ECU CNTRLR
WIRING SCHEMATIC
J7B (CN2)
ECU CNTRLR (AWS)
Sheet 11 of 19
Printed In U.S.A.
594 of 1010
7233063 (B)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-11
PAGE 12
PAGE 13
PAGE 14
PAGE 15
CONNECTOR
WIRE BREAK
HYDRAULICS
HVAC PAGE 17
OPTIONS PAGE 18
C425
+12V C308
PWR
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
GND
OPTIONS SHEET)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
C108
HYDRAULIC
GND
TEMPERATURE
SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A SIG HYDRAULIC OIL
GWY CTRLR GND FILTER SWITCH (NC)
C446
GND
SIG
C420
GND
SIG
C105
GND
SIG
+8V PWR
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
GND
SIG
WIRING SCHEMATIC
C419
(AWS)
GND
SIG A770 (S/N ATDW11966 AND ABOVE)
Sheet 12 of 19
J2B
AUX CTRLR (PRINTED AUGUST 2015)
Printed In U.S.A.
7233063 (B)
595 of 1010
LEGEND
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 6
PAGE 7
PAGE 8-11
PAGE 12
PAGE 13
PAGE 14
CONNECTOR CAB DISPLAY
OPTIONS PAGE 18
T13
BUZZER (+)
LEFT PANEL C499

BUZZER Press To Operate Loader
C479 (PTOL)
T2
LEFT PANEL (BLACK)
BUZZER (-) SWITCHED POWER
BUZZER C408 GROUND
(BLACK)
GROUND CAB-MFR HARN CONN 1
UNSWITCHED POWER
PTOL OUTPUT
SWITCHED POWER
PTOL LED
LEFT BLINKER INPUT J1A
GWY CTRLR
C500
RIGHT BLINKER INPUT
Dealer Copy -- Not for Resale RIGHT PANEL - KEY SWITCH
TRAVEL CONTROL INPUT START
PARK BRAKE INPUT
C480 J1B
LEFT PANEL (GRAY) GWY CTRLR RUN/ENTER SWITCH
DOOR SIGNAL
SWITCHED POWER
UNSWITCHED POWER
GROUND
PARK BRAKE OUTPUT
SW12
DIESEL PARTICULATE C503
DERATE OVERIDE SWITCH RIGHT PANEL DELUXE DISPLAY
DPF LAMP
SWITCHED POWER
DPF INHIBIT LAMP
UNSWITCHED POWER
DPF OVERRIDE
GROUND
DPF INHIBIT REGEN
(OPT KIT)
WIRING SCHEMATIC
DIESEL PARTICULATE
FILTER INHIBIT SWITCH (AWS)
Sheet 13 of 19
Printed In U.S.A.
596 of 1010 7233063 (B)

LEGEND
PARTIAL CONNECTOR
CAB
GROUND PAGE 6
HYDRAULICS PAGE 12
CAB DISPLAY PAGE 13
CAB PAGE 14
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
HVAC PAGE 17
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 18 (NOT IN STD CAB HARN)
*
C492 C438
ACS/SJC/AWS-MFR HARN (DK GRAY)
(8 PIN) CAB-MFR HARN CONN 3
*C212
POWER
SOCKET
GND
C408 +12V PWR

(BLACK)
CAB-MFR HARN CONN 1
* T37
DOME LIGHT (+)
C129
CAB ACCESSORY Dealer Copy -- Not for Resale T38
+12V BATT PWR
+12V SW PWR * DOME LIGHT (-)
GND
C428
(LT GRAY)
CAB-MFR HARN CONN 2
*C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
WIPER SWITCH, MOTOR SWITCHED POWER

DOOR SIGNAL
C482 DOOR UNSW PWR
J1B
GWY CTRLR WIPER MOTOR GROUND
WASHER SIGNAL
+5V
WIRING SCHEMATIC
* C252
(AWS)
Sheet 14 of 19

597 of 1010
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 12
CAB PAGE 14
CONTROLS
HVAC PAGE 17
OPTIONS PAGE 18
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
AUX CTRLR
C404
C103
BU ALARM-MFR HARN
TAILGATE HARN
T19 TERMINAL (+)
(SEE ADDITIONAL
OPTIONS SHEET) BACK UP
ALARM
T20 TERMINAL (-)
C410
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR
J1A
GWY CTRLR
C422
J1B
WIRING SCHEMATIC
GWY CTRLR
(AWS)
Sheet 15 of 19
Printed In U.S.A.
598 of 1010 7233063 (B)
LEGEND
LIGHTS
CAB PAGE 14
LIGHTS PAGE 16
HVAC PAGE 17
OPTIONS PAGE 18
C434-1
GND
C408
(BLACK) SIG
CAB-MFR HARN CONN 1
C434-2
GND
SIG
C435-1
SIG
GND
C438 C435-2
(DK GRAY) SIG
CAB-MFR HARN CONN 3
GND
+12V
forC103
Dealer Copy -- NotTAILGATE
Resale
HARN C603
PWR GND
SIG
GND
C602
SIG
GND
J1A
GWY CTRLR
T16 TERMINAL (-)

GND
SIG
T15 TERMINAL (+)

+12V
PWR T17 TERMINAL (+)
SIG
GND GND
T18 TERMINAL (-)
WIRING SCHEMATIC
(AWS)
Sheet 16 of 19
Printed In U.S.A.
599 of 1010 7233063 (B) Printable Version Click Here
LEGEND
PARTIAL CONNECTOR
HVAC
GROUND PAGE 6
HYDRAULICS PAGE 12
CAB PAGE 14
#
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS
HVAC
PAGE 16
PAGE 17
(TWO WIRE BREAKS
JOIN ONE WIRE)
OPTIONS PAGE 18
* C610
*
HVAC DUCT
DLX CAB HARN 7234736 ONLY
FAN
* C483
C635
*
C438
(DK GRAY)
Dealer Copy -- Not for Resale *
+12V CAB-MFR HARN CONN 3
PWR
GND
* C611
J1A *
GWY CTRLR
C630
*
C350
WIRING SCHEMATIC
C355
FUEL HARN #
(AWS)
C486
SIG
GND
D4
Sheet 17 of 19
7233063 (B) Printable Version Click Here

Printed In U.S.A.
600 of 1010
LEGEND
OVERVIEW PAGE 1-3
OPTIONS
GROUND PAGE 6
HYDRAULICS PAGE 12
#
HVAC
OPTIONS
PAGE 17
PAGE 18
JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C428
(LT GRAY)
C355
FUEL HARN CAB-MFR HARN CONN 2
# C607
SIG
GND
#
*
C606
GND
SIG
C438
(DK GRAY)
C411 CAB-MFR HARN CONN 3
LEFT HANDLE
(FLASHER) 5 WAY D1
* T3
FLASHER
(SEE ADDITIONAL
CONN
*
OPTIONS SHEET) D2
C103 *
TAILGATE HARN
Dealer Copy -- Not for Resale (PINS 3 & 6
INTERNALLY
EURO TAIL LIGHTS
(SEE ADDITIONAL INSULATED) * C670
OPTIONS SHEET)
BEACON/FLASHER
C423 EXTERIOR HARNESS
(SEE ADDITIONAL
SIG D3
* OPTIONS SHEET)
GND
C408
(BLACK)
CAB-MFR HARN CONN 1
C126
* C279 * C676
RADIO CONN
LEFT HANDLE C412 GND +
(HORN) 2 WAY SIG HORN C277
(SEE ADDITIONAL
- *
OPTIONS SHEET)
C497 * -
C278
SJC PWR
HORN/BLINKER +
(SEE ADDITIONAL GND
J2A OPTIONS SHEET)
AUX CTRLR
C415
GND
SIG
J2B
WIRING SCHEMATIC
AUX CTRLR
(AWS)
C437
GND A770 (S/N ATDW11966 AND ABOVE)
SIG TRACK 2 SPEED
J1A ADAPTER Printable Version Click Here
GWY CTRLR C441 (SEE ADDITIONAL
OPTIONS SHEET)
GND
SIG
Sheet 18 of 19
J1B
Printed In U.S.A. GWY CTRLR 7233063 (B)
601 of 1010
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE PIN FUNCTION
LEGEND ACS CONTROLLER
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE 1 SAFETY IN
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT PIN FUNCTION PIN FUNCTION PIN FUNCTION 2 TWO SPEED SWITCH
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 3 SPARE DIGITAL INPUT 2
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 4 H PAT SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 5 ISO PAT SWITCH
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 6 ISO LITE
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 7 L SWASH PLATE ANGLE
LIGHTS 6000 THROUGH 6999 PINK PNK 8 R SWASH PLATE ANGLE
WIRE BREAK F F LIFT HANDLE F LIFT MOTOR 1
(TWO WIRE BREAKS G GROUND G TILT HANDLE G PEDAL ENABLE 9 SPARE ANALOG 4
CONNECTOR ASSIGNMENTS JOIN ONE WIRE) 10 SPARE ANALOG 5
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
NUM OF COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT J LIFT PEDAL J GROUND 11 L FWD RETURN
CONN DESCRIPTION
PINS 12 CAN HIGH
4 K TILT PEDAL K TILT MOTOR 2
C536 RIGHT SWASHPLATE 13 LF ANGLE
C537 LEFT SWASHPLATE 4
HARNESS PART NUMBER 14 RF ANGLE
C428 TILT ACTUATOR 8
LF AWS 7210507 15 LR ANGLE
C429 LIFT ACTUATOR 8
LF AWS 7182311 16 H PAT LITE
C440 RF BASE 2
A22 PUMP 7188448 17 RR ANGLE
C442 LF BASE 2
SUSP JSTK 7163706 18 L JOYSTICK X
C443 LF ROD 2
J5 - DRIVE PLUS
AWS
19 L JOYSTICK Y
C444 RR BASE 2
20 R JOYSTICK X
C445
C447
RR ROD
LR ROD
2
2
CONTROLLER C458
C460
+12V PWR
21 L FWD DRIVE
SIG C450 GND 22 CAN LOW
C448 PRESSURE CONTROL 2 GND RIGHT JOYSTICK CAN LO 23 R QUAD A DRIVE
C452 LR BASE 2 +5V PWR (CONNECTS TO
24 R QUAD B DRIVE
CONTROLS
C453 RIGHT QUAD A DRIVE 4 DLX CAB HARNESS)
C457 CAN HI 25 TWO SPEED 1
C454 LEFT QUAD DIRVE 4
SIG 26 BRAKE LIGHT OUTPUT
C455 R FRT WHEEL POS SENSOR 3 GND C459 27 GROUND
C456 R REAR WHEEL POS SENSOR 3 +5V PWR +12V PWR
# 28 GROUND
C457
C458
L FRT WHEEL POS SENSOR
L REAR WHEEL POS SENSOR
3
3 +5V
C456 HARNESS 7182311 ONLY C449
LEFT JOYSTICK
GND 29 SENSOR GROUND
+5V PWR 30 SENSOR SUPPLY 2 +5V
(CONNECTS TO CAN LO
C461 RF ROD 2 SIG DLX CAB HARNESS)
C429 31 L REV DRIVE
C474 BRAKE LIGHT 1 GND CAN HI
32 CAN SHIELD
C492 MAINFRAME HARN 1 8 C455 SUSP SEAT JOYSTICK HARNESS 33 L QUAD A DRIVE
C493 MAINFRAME HARN 2 4 +5V PWR
34 L QUAD B DRIVE
C501 A22 PUMP HARNESS 8 SIG
GND 35 SAFETY OUT
C544 LEFT FORWARD DRIVE 2 GND
36 BACKUP ALARM
C545 LEFT REVERSE DRIVE 2 SIG
# C454
37 R JOYSTICK Y
C546 RIGHT FORWARD DRIVE 2 GND
+5V PWR +5V PWR 38 SPARE ANALOG 1
C547 RIGHT REVERSE DRIVE 2
SIG
39 SPARE PWM COIL 7
C542 LEFT SWASHPLATE 3 C428
SIG 40 SENSOR SUPPLY 1 +5V
C543 RIGHT SWASHPLATE 3 +5V PWR 41 L REV RETURN
C707 OBW STOP BRAKE LIGHT 3 +5V # C453
+5V PWR 42 R FWD RETURN
SIG
43 R FWD DRIVE
GND
SIG GND
J6 - DRIVE PLUS 44 R REV DRIVE
J2-ACS ACS CONTROLLER 10 STEERING
SIG 45 R REV RETURN
C536
SOLENOIDS CONTROLLER 46 TWO SPEED 2
J5 DRIVE PLUS CONTROLLER 50 A22 PUMP HARNESS C448
C543 47 UNSWITCHED BATTERY
J6 DRIVE PLUS CONTROLLER 50
GND 48 UNSWITCHED BATTERY
SIG 49 SPARE PWN COIL 6
+12V PWR
C442 50 SWITCHED BATTERY
J2-ACS
C537
C542
GND
Dealer Copy -- Not for Resale J6 DRIVE PLUS CONTROLLER
PIN FUNCTION
SIG C447 1 STEER MODE 3
+12V PWR 2 PRESSURE CONTROL
C501 C546 3 RR LEFT (BASE)
RIGHT FORWARD DRIVE
4 RR RIGHT (ROD)
C452
ACS CONTROLLER
5 LR RIGHT (BASE)
6 RF RIGHT (ROD)
C547
7 LF RIGHT (BASE)
RIGHT REVERSE DRIVE +5V C443 8 RR ROD RET
J1-ACS
9 LR ROD RET
C545 10 LR BASE RET
11 STEER MODE 2
LEFT REVERSE DRIVE C461
12 STEER MODE 1
13
C544
14
LEFT FORWARD DRIVE C445 15 LR LEFT (R0D)
16 RF LEFT (BASE)
17 LF LEFT (ROD)
C474 TO SJC BRAKE
HARNESS C444 18 PRESSURE CONTROL RET
J3-ACS
(SEE ADDITIONAL OPTIONS 19 RR BASE RET
SHEET) 20 RF ROD RET
C492 21
C440
22
23 NOT USED
24 NOT USED
25 NOT USED
26 GND
27
MAINFRAME
28
HARNESS 29 RF BASE RET
C493
30 LF BASE RET
31
32
33 NOT USED
34 GND
35 SPARE AN/DIG IN 4
36 GND
37 STEER MODE SELECT 3
38
WIRING SCHEMATIC 39
40 LF ROD RET
(AWS) 41
42 SPARE PWM OUTPUT COIL
A770 (S/N ATDW11966 AND ABOVE) 43
44
UNSWITCHED BATTERY
UNSWITCHED BATTERY
Printable Version Click Here 45 NOT USED
46
C404
(CONNECTS TO BACKUP
Sheet 19 of 19 47 STEER MODE SELECT 1
48
ALARM C404 ON MFR
HARNESS) (PRINTED AUGUST 2015) 49 STEER MODE SELECT 2
50
Printed
602 of In U.S.A.
1010 7233063 (B)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CONNECTOR SSL 7-PIN
C426 To Mainframe
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CAN CONNECTOR D F C E A B G
Harness

9800
1160
9700
1710
9500
9600
2710
WIRE BREAK KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
(TWO WIRE BREAKS UNSW POWER F 1160 RED/WHT 2720 H GROUND

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
JOIN ONE WIRE) SW POWER E 1730 RNG 9 1720 B SW POWER ACD
ENGINE 8000 THROUGH 8999 TAN TAN 9 Machine
SHEET # CAN LOW B 9620 PUR
14
9610 E CAN LOW
Connector to
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR CAN HIGH A 9520 PUR 9510 D CAN HIGH Engine
GROUND G 2730 BLK 13 C OPEN Compartment
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT Connector 7-PIN A OPEN
on Loader C666 ATTACHMENT
CONNECTOR G OPEN
C430 C431 DPF KEY SSL 7-PIN Boom
J
CAN CONNECTOR
DPF REGEN DPF SWITCH SWITCH N
BOOM-MOUNTED
ACD CONNECTORS
KEY "RUN" D 9800 D SW POWER K 1740
1 1166 RED/WHT 1 UNSWITCHED POWER GROUND B 2740 C703 J2 - 10-PIN BLACK
UNSW POWER 2 1160 F
TO ENGINE 2 8135 TAN 2 START CAN SHIELD C 9700 C
E OUTPUT E 5100 5100 C E OUTPUT
F OUTPUT F 5350 5350 H F OUTPUT
HARNESS 3 3 SW POWER 1 1710 E G OUTPUT G 5400 5400 J G OUTPUT
ACD
(IT4 MACHINES 4 3095 TAN 8066 TAN 4 RUN/ENTER CAN LOW B 9600 A H OUTPUT H 5050 5050 B H OUTPUT
Output
SWITCH C OUTPUT C 5300 5300 G C OUTPUT
ONLY) CAN HIGH A 9500 B Connector to
5 5 D OUTPUT D 5150 5150 D D OUTPUT
Engine
GROUND 3 2700 G A OUTPUT A 5250 5250 F A OUTPUT Compartment
6 8065 TAN 6 Connector
7-PIN M OUTPUT M 5200 5200 E B OUTPUT
on Loader C666 C426
ATTACHMENT
CONNECTOR
ID (K TO L)
ID (K TO P)
L
P
5910
5510
12
5000
5450
A J OUTPUT
K K OUTPUT
Boom
11
CONTROL HARNESS - 7175321 C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
Connector CONNECTOR
on Loader 5900 J ID #1
7218446 PARKED REGEN HARNESS Boom 5500 A ID #2
B ID #3 ACD
C ID #4 Input
D ID #0 Connector to
C667 SW7 DELUXE ATTACHMENT E OPEN
Engine
Compartment
DOOR HARN C250 SENSOR SHOWN F OPEN
REAR CONTROL HARNESS - G OPEN
4 3630 LBL 1 SIG WITH DOOR OPEN C129 WIPER 6732730 H OPEN
5 1400 RED/WHT 2 PWR DOOR SENSOR A SWITCH K OPEN
TO CAB B
TO DLX CAB 6 1865 RNG/WHT 1 2
HARNESS
HARNESS 1 C 2820 BLK 3
3 4 5 7230 WHT T6 1
6 REAR
2 Dealer CopyWIPER
-- Not for Resale
MOTOR C667
7170531 SPECIAL APPS DOOR HARNESS DOOR HARN C250 SENSOR SHOWN
4 3630 LBL 1 SIG WITH DOOR OPEN
7180207 REAR WIPER HARNESS 5 1400 RED/WHT 2 PWR DOOR SENSOR
C251
6 7330 WHT C PARK
R2
CAB 1570 RNG/WHT
C667 750 OHM RESISTOR E
DOOR HARN C250 HARNESS
1W 5%
5 1400 RED/WHT 1 1400 RED/WHT 1 1850 RNG/WHT 3 7300 WHT A LOW
WIPER
1410 RED/WHT
1 2
3 7310 WHT 6 1860 RNG/WHT D SW PWR MOTOR
4 5
R1
300 OHM RESISTOR SW8
0.5W 5% C251 FRONT WIPER
SENSOR SHOWN SWITCH
4 3630 LBL 2 3630 LBL 3635 LBL 2 SIG WITH DOOR OPEN 2 2840 BLK B GND
2860 BLK 3 2860 BLK 1 GND DOOR SENSOR

6
7155024 DOOR HARNESS
7195485 DOOR SENSOR HARNESS
TO DLX
CAB HARNESS
C251
SW8
7330 WHT
1570 RNG/WHT
C PARK
WIRING SCHEMATIC
E
FRONT WIPER
1 1850 RNG/WHT SWITCH
3 7300 WHT A LOW
(KIT AND OPTION HARNESS)
1 2 WIPER
3 7310 WHT 6
4 5
1860 RNG/WHT D SW PWR MOTOR ALL MODELS
2 2840 BLK 2850 BLK B GND
Sheet 1 of 4
7171105 FORESTRY DOOR HARNESS
(PRINTED JUNE 2012)
Printed In U.S.A. 7195572 Printable Version Click Here

603 of 1010
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR C425
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED TO B C427
BRAKE
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT MAINFRAME A 4200 LGN 1 SOLENOID
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT HARNESS C 2200 BLK 2 9.8 OHM
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 12 V
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR C437 C428
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL TO
2 2360 BRN 2 GND TWO SPEED
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN MAINFRAME MAKEUP SOLENOID
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL HARNESS 1 4360 LGN 1 SIG
8.8 OHM 12V
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS C441 C429
TO
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE) MAINFRAME 2 2350 BRN 2 GND TWO SPEED
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET # HARNESS 1 4350 LGN 1 SIG SOLENOID
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 5.1 OHM 12 V
EXMF, LF: 7177692 2 SPD TRACK ADAPTER

EXLF: 7190709 2 SPD TRACK ADAPTER
7110 WHT
BACK-UP ALARM
SWITCHES
C404
TO A 7100 WHT
MAINFRAME B 1720 RNG/WHT
HARNESS
7175017 BACK-UP ALARM HARNESS
C362 C414
A 4440 LGN 1 SIG
REAR BASE (M) C411 TO
B 2440 BLK 2 GND 7.5 OHM 12V MAINFRAME
WHITE TIE STRAP A C E B D HARNESS
C413 (5 WAY LH)
C 4430 LGN 1
6000 PNK
SIG
REAR ROD (F)
D 2430 BLK 2 GND 7.5 OHM 12V
BROWN TIE STRAP C497 6510 PNK
TO
MAINFRAME C416 Dealer Copy -- Not for Resale B 6415 PNK 2780 BLK
HARNESS E 4450 LGN 1 SIG REAR ROD LOCK 86 85
6410 PNK
F 2450 BLK 2 GND 7.5 OHM 30
87
12 V TO A 6515 PNK 2790 BLK
YELLOW TIE STRAP MAINFRAME
C417 86 85
HARNESS
G 4480 LGN 1 SIG 30 6010 PNK 6020 PNK
REAR BASE LOCK 87
H 2480 BLK 2 GND
9.8 OHM
GREEN TIE STRAP 12 V C 7200 WHT 2770 BLK
86 85
7173271 REAR AUX HARNESS C412 30
TO 87
B 2785 BLK
MAINFRAME
HARNESS A 1420 RED/WHT
(2 WAY LH)
TO C489-1 C489-2
ADDITIONAL
MAINFRAME B B
2720 BLK 2740 BLK ACCESSORY
HARNESS
C414 A 1720 RNG A POWER
(ACCESSORY
4440 LGN 1 SIG CONNECTOR
REAR BASE POWER)
AUX CTRLR J2B PIN 5
2440 BRN 2 GND 7.5 OHM 12V 7151940 SJC/AWS/SCPA HRN/BLKR HARNESS
AUX CTRLR J2A PIN 2
WHITE TIE STRAP
C413
AUX CTRLR J2B PIN 7 4430 LGN 1 SIG
REAR ROD
2430 BRN 2 GND 7.5 OHM 12V
AUX CTRLR J2A PIN 10 Printable Version Click Here
BROWN TIE STRAP
C416
TO
MAINFRAME
C489-1
J2B PIN 4
4450 LGN 1 SIG
REAR ROD LOCK
WIRING SCHEMATIC
B 2720 BLK 2450 BLK 2 GND
HARNESS 7.5 OHM
(ACCESSORY
POWER)
A 1780 RNG/WHT 2725 BLK YELLOW TIE STRAP
C417
12 V (KIT AND OPTION HARNESS)
C489-2 4480 LGN 1
ADDITIONAL
ACCESSORY A 2480 BLK 2
SIG
GND REAR BASE LOCK ALL MODELS
POWER B J2B PIN 6 9.8 OHM
CONNECTOR
GREEN TIE STRAP 12 V
Sheet 2 of 4
7191339 or 7201414 REAR AUX HARNESS (PRINTED JUNE 2012)
Printed
604 of 1010 In U.S.A. 7195572
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C129
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB ACCESSORY
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK POWER CONN
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS A 1410 RED/WHT 1200 RED/WHT
JOIN ONE WIRE)
SHEET # 1430 RED/WHT X T3
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B FLASHER CONN
TO STANDARD SW2
CAB HARNESS
L
BEACON
SWITCH
C 2780 BLK
2725 BLK 6
SW3 5
4
4 WAY FLASHER 1 2
SWITCH
3
6570 PNK 1
C670 C609 2 2780 BLK
3 C670
E 6700 PNK 1 C669 (PINS 3 & 6 4
STD CAB: STROBE 5 2850 BLK 6700 PNK E
D 2780 BLK 2775 BLK 2 INTERNALLY
TO ACC HARNESS BEACON 1 6440 PNK RIGHT 6 D
C INSULATED) 2420 BLK
FLASHER TO EXTERIOR
A 2785 BLK 2 2785 BLK 2795 BLK C
DLX CAB: LIGHT CAB HARNESS
TO DLX CAB HARNESS F 6440 PNK 2790 BLK A
B 3 LEFT 6440 PNK F
6540 PNK 6540 PNK
FLASHER 6540 PNK B
7169130 ACC HARNESS
LIGHT
(STD CAB HARNESS ONLY)
6718872 EXTERIOR CAB HARNESS
7169753 4 WAY FLASHER HARNESS
C800
6340 PNK A Dealer
6340 PNK Copy -- Not for Resale
REGISTRATION
2670 BLK B 2670 BLK (LICENSE PLATE)
LAMP
7153090 HARNESS LICENSE LIGHT
TO EURO
TAILGATE C603
HARNESS E Taillight Right
C103 F 7104670
D 6510 PNK 6510 PNK A BLU
C407-A C407-B 6610 PNK C RED
H 6200 PNK 6320 PNK A A 6430 PNK B YEL
B 2600 BLK 2610 BLK D BLK
BREAK CONNECTION
FOR ROADLIGHT KIT 2620 BLK -
6210 PNK +
Backup Alarm
6660294
WITH ROADLIGHT KIT: C 2650 BLK
7100 WHT + -
TO ROADLIGHT KIT C602
HARNESS G 6600 PNK Taillight Left
E Printable Version Click Here
F 7104671
WITHOUT ROADLIGHT E 6410 PNK 6410 PNK A BLU
KIT: TO MAINFRAME
HARNESS
6620 PNK C RED WIRING SCHEMATIC
6330 PNK B YEL
F
2640 BLK D BLK
(KIT AND OPTION HARNESS)
2630 BLK
6210 PNK
-
+
ALL MODELS
A 6310 PNK 6310 PNK
Sheet 3 of 4
(PRINTED JUNE 2012)
Printed In U.S.A. 7195572

605 of 1010
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT F 1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK E 3
7210 WHT A 6330 WHT 2
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN 2310 BLK B 2120 BLK 6
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C 6120 LGN 5 Front Turn Light
7230 WHT
7270 WHT D 6340 RED 4
Position Light
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
C407-B
TO EURO
6430 PNK
TAILGATE F F
HARNESS Relay1
Right Side Lights 6420 PNK A 7210 WHT E
87 6410 PNK 6440 PNK D 7250 WHT 7260 WHT B

1020 RED 1410 RED/WHT
6510 PNK E 7200 WHT C Brake Light
10.0 Amps 30 7200 WHT
6400 PNK 6220 PNK C 7220 WHT 7240 WHT A
85 86 2020 BLK
2110 BLK B 2300 BLK 2320 BLK D Rear Turn Light
T01
Relay2
Left Side Lights
87 6310 PNK
1010 RED 1400 RED/WHT
10.0 Amps 30
T02
6300 PNK 85 86 2030 BLK
2120 BLK B 2300 BLK E

ADDITIONAL
1510 RNG A
ACCESSORY 6330 PNK A 7210 WHT F
B POWER
2210 BLK
CONNECTOR
Dealer Copy
6120 PNK -- NotCfor7220
Resale
WHT 7240 WHT A
6340 PNK D 7250 WHT 7260 WHT B Rear Position Light
1730 RNG A 1520 RNG 1500 RNG A 6520 PNK E 7200 WHT C
2730 BLK C 2200 BLK B HARNESS F 2320 BLK D Brake Light
2230 BLK
87
6600 PNK B 6500 PNK
30
87A
85 86
TO
SJC/AWS/SCPA A 6330 WHT 2
4210 LGN 1 7210 WHT
CONTROLS HARNESS
(1 PIN CONN) 7270 WHT D 6340 RED 4 Position Light
7175581 - SJC BRAKE HARNESS

E 3
(ONLY FOR SJC OPTION) 7230 WHT C 6120 LGN 5
2310 BLK B 2120 BLK 6
F 1
H 6010 PNK 6320 PNK H
6530 PNK G
B 2000 BLK 2010 BLK B Printable Version Click Here
D 6210 PNK 6230 PNK D
E 6110 PNK 6130 PNK E HARNESS WIRING SCHEMATIC
HARNESS F F
G (KIT AND OPTION HARNESS)
A 6000 PNK 6000 PNK A
C 7100 WHT 7100 WHT C ALL MODELS
Sheet 4 of 4
(PRINTED JUNE 2012)
606 ofPrinted
1010 In U.S.A. 7195572
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONTD)
Glossary Of Electrical Symbols (Contd)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710 SPLICE () - Used to show when

3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Contd)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A
SPEED SENSOR - magnetic pickup -
detects rpm.
B

Cab Harness Connectors (Early Models)
C209
C479 C434-1
C670 C480 C434-2
T2
T13

C482
C499
SW1
SW3
C503 SW2
C500 C435-1 SW6
C435-2
C630 C611 SW4 T3
SW5
SW9
C667
C252
C635
SW12
C408 C114
C428
C438 SW10 C126
C129 SW11
C277
C483
C449
C450
C279
C278
C676
C212
NA5824

Cab Harness Connectors (Later Models)
NA9086

Mainframe Harness Connectors
C430
C103 C426 C405
C113
C112
C350
C355
C446

C130
C111
T1 C105
T6 J2A
T8 C408 J2B J1A
C438 J1B
C108 C497
C498
C423 C428
C100 C415 C419
C420 C441
C425
C418 C409 C404

C421 C437 FRC1
C422
C410
C411
C492 C412
C116 C493
NA5820

All-wheel Steer Harness Connectors
C544

C545
C542 C458
C546 C536 C452
C547 C474 C442 DRIVE
C443
C543 C447
C501 J5 C448
C537 C404
C457
C456 J2
J1
C440 J6
ACS C444
C445
J3 C461
C428
C429
C492
C493 C455
NA5822

Engine Harness Connectors
T0 C133
T1
C148
T2 C138 C137 C143
C153 C135
C136
C132 T31

T28 J7A
C134
T29 J7B
T5
C113
C131
C139
C144
C149 C148
C427 C147
C111
T24 C142
T10
C145
C146
T7
T11 C140
T9 T21
C110
T12
NA5821

Description
Figure 60-10-1
P100958A
P107198
The loader has a 12 volt, negative ground, alternator

charging system.

The electrical system is protected by fuses located in the
operator cab and a 100 ampere master fuse (Inset)
[Figure 60-10-1] located above the battery in the engine
compartment.
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operators
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONTD) Figure 60-10-4
Fuse And Relay Location / Identification 1
Figure 60-10-2
1
P107514
1
Line up the clips on the back of the fuse panel cover with
P100414
the slots (Item 1) [Figure 60-10-4] in the fuse panel and
push the cover into position when finished.
The fuse / relay panel is located behind an access panel Line up the clips on the back of the access panel with the
near the left footrest. Pull the panel at each end (Item 1) slots provided and push the panel into position [Figure

[Figure 60-10-2] to remove. 60-10-2]. A locating pin prevents the panel from being
installed upside down.
Figure 60-10-3
A table is provided with details on amperage ratings and
the circuits affected by each fuse and relay [Figure 60-
10-5].
1
P107513
The electrical system is protected from overload by fuses

located behind the fuse panel cover (Item 1) [Figure 60-
10-3]. Remove the fuse panel cover by pulling at each
end.
A decal located inside the fuse panel cover indicates fuse

/ relay location and fuse amperage ratings.

Fuse And Relay Location / Identification (Contd)
Figure 60-10-5
23 31
1 5
24 32
9 12 17 20
25 33
2 6
26 34
3 7 10 13 18 21 27 35
28 36
4 8 11 14 19 22 29 37
15 16 30 38
NA5694
Fuse location and amperage ratings are shown in the table below and on the decal [Figure 60-10-5]. Relays are identified
by the letter R in the AMP column.
REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 Rear Lights 15 14 Front Lights R 27 ACS Controller 25

2 Front Lights 20 15 Not Used -- 28 Engine Controller 15
Drive Controller
3 Traction 30 16 Not Used -- 29 25
Back-up Alarm
4 Heater / HVAC 25 17 Not Used -- 30 Attachments 25
Switched Power
5 25 18 Engine Controller R 31 Not Used --
Back-up Alarm
Exhaust Gas
6 Wiper / Washer 25 19 Not Used -- 32 5
Recirculation
7 Switched Power 25 20 Traction R 33 Not Used --
Cab Switched Accessories and

8 25 21 Not Used -- 34 25
Power Front Horn
9 Switched Power R 22 Heater / HVAC R 35 Alternator 15
Cab Accessories
10 Rear Lights R 23 Bobcat Controller 25 36 25
Power Port
11 Not Used -- 24 Bucket Position 15 37 Not Used --
Auxiliary
12 Starter R 25 25 38 Not Used --
Controller
Cab Switched
13 Not Used -- 26 5
Power

Solenoid Testing
Figure 60-10-6
P9175
Use a test meter to measure coil resistance [Figure 60-

10-6]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.


BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15 P100959 P100960
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807
metal parts with the battery terminals.

Open the rear door. Connect the negative (-) cable last to prevent sparks.
Figure 60-20-1 Connect and tighten the battery cables.
Install and tighten the battery hold down clamp.

3
Put Bobcat Battery Saver or grease on the batter
terminals and cable ends to prevent corrosion.
1 Close the rear door.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
P107200 SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
Disconnect the negative (-) cable (Item 1) [Figure 60-20-
make final connection (negative) at machine frame.
1].
Do not jump start or charge a frozen or damaged
Remove the battery hold down clamp (Item 2) [Figure
battery. Warm battery to 16C (60F) before
60-20-1].
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Disconnect the positive (+) cable (Item 3) [Figure 60-20-
lean over battery while boosting, testing or charging.
1] from the battery.
W-2066-0910
Remove the battery from the loader.

BATTERY (CONTD)
Servicing
Figure 60-20-3
P100959 P100960
The battery cables must be clean and tight [Figure 60-

20-3]. Check electrolyte level in the battery. Add distilled

water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
WARNING
contact. Wear goggles, protective clothing and

and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONTD) Connect the end of the second cable (Item 3) to the
negative (-) terminal of the booster battery. Connect the
Using A Booster Battery (Jump Starting) other end of the same cable (Item 4) [Figure 60-20-4] to
the engine.
If the engine will not start without using a booster battery,
BE CAREFUL! There must be one person in the Keep cables away from moving parts. Start the engine.
operators seat and one person to connect and (See the Operation And Maintenance Manual.)
disconnect the battery cables.
After the engine has started, remove the negative (-)
The key switch must be in the STOP position. The cable (Item 4) first. Remove the cable from the positive
booster battery must be 12 volt. (+) terminal (Item 2) [Figure 60-20-4].
Remove the cables from the booster battery.
WARNING Close the rear door.
BATTERY GAS CAN EXPLODE AND CAUSE

SERIOUS INJURY OR DEATH
IMPORTANT
make final connection (negative) at machine frame. Damage to the alternator can occur if:
Engine is operated with battery cables
Do not jump start or charge a frozen or damaged disconnected.

battery. Warm battery to 16C (60F) before Battery cables are connected when using a fast
connecting to a charger. Unplug charger before charger or when welding on the loader. (Remove
connecting or disconnecting cables to battery. Never both cables from the battery.)
lean over battery while boosting, testing or charging. Extra battery cables (booster cables) are
W-2066-0910 connected wrong.
I-2023-1285
Open the rear door.
Figure 60-20-4
3 1
P107199
Connect the end of the first cable (Item 1) to the positive

(+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-4] to the
positive (+) terminal on the engine starter.


ALTERNATOR Move the alternator toward the engine fully and remove
the belt from the pulleys.
Belt Adjustment
Inspect the pulleys for wear.
The alternator belt is a special maintenance free type
that is pretensioned over the pulleys. This belt eliminates Install new belt.
the need for a tensioning device and does not require
periodic adjustment. Contact your dealer for replacement Figure 60-30-3
parts.
Belt Replacement
Figure 60-30-1
2 1
P107204
1

3 Use a prybar (Item 1) [Figure 60-30-3] to move the
alternator until the bottom alternator mounting bolt (Item
2) [Figure 60-30-2] can be installed.
P109404
Tighten the top alternator mounting nut (Item 1) and
bottom alternator mounting bolt (Item 2) [Figure 60-30-
2].
Remove the fuel hose clamp nut and bolt (Item 3).
Remove the belt shield mounting nuts and bolts (Item 1). Install the air conditioning belt. (See Belt Replacement on
Remove the belt shield (Item 2) [Figure 60-30-1]. Page 80-20-2.)
Remove the air conditioning belt. (See Belt Replacement Install the belt shield, the belt shield mounting nuts and
on Page 60-30-1.) bolts, and the fuel hose clamp nut [Figure 60-30-3].
Figure 60-30-2 Close the rear door.
2
P107203
Remove the bottom alternator mounting bolt (Item 2) and

loosen the top alternator mounting nut (Item 1) [Figure
60-30-2].

ALTERNATOR (CONTD) Figure 60-30-4
Charging System Inspection 1
WARNING
contact. Wear goggles, protective clothing and 1

P106610
and wash eye with clean, cool water for at least 15
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get Check the condition and tension of the alternator belt.
prompt medical attention. (See Belt Adjustment on Page 60-30-1.) Replace belt if
W-2065-0807 worn or deteriorated.
Inspect the alternator wiring harness and connectors

(Item 1) [Figure 60-30-4] at alternator. Harness and
connectors must be clean and tight.
WARNING Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair / replace. If fuse is in
BATTERY GAS CAN EXPLODE AND CAUSE doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)
make final connection (negative) at machine frame.
Verify the charge of the battery. Make sure battery is fully
Do not jump start or charge a frozen or damaged charged.
battery. Warm battery to 16C (60F) before
connecting to a charger. Unplug charger before Disconnect the battery cables (negative first, then
connecting or disconnecting cables to battery. Never positive). Inspect the cable clamps and battery posts for
lean over battery while boosting, testing or charging. corrosion. Remove acid or corrosion from the battery and
W-2066-0910 cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR (CONTD) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-6
Figure 60-30-5
P106610
P106611
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.

TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE Figure 60-30-7
10-61-1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21,1C (70 F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test.
2
If the voltage is lower than 13.5 volts, run the engine at 1
high idle and recheck voltage. If voltage is still below 13.5 P106612
volts, proceed with the following low voltage test.
Check the voltage across the L terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

ALTERNATOR (CONTD) Removal And Installation
High Voltage Testing Remove the air conditioning belt. (See Belt Replacement
on Page 80-20-2.)
Figure 60-30-8
2
IMPORTANT
Damage to the alternator can occur if:
1 Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P106613
Figure 60-30-9
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.

1
Check the continuity between the S terminal (Item 1)
[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21,1C (70F)

(Alternator Temperature), then remove alternator for 2
replacement or repair.
P106610
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-30-9] from

the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2)

[Figure 60-30-9] from the alternator.

ALTERNATOR (CONT'D) Figure 60-30-12
Figure 60-30-10
1
P106617
Remove the top alternator mounting bolt (Item 1) and the

P106615 bottom alternator mounting bolt / ground cable (Item 2)
[Figure 60-30-12].
Remove the fuel hose clamp nut and bolt (Item 1) Remove the belt and alternator from the loader.
[Figure 60-30-10].

Figure 60-30-11
1 2
1
P106616
Remove the belt shield mounting nuts and bolts (Item 1)

and remove the belt shield (Item 2) [Figure 60-30-11].

ALTERNATOR (CONTD)
1. Nut
2. Washer
3. Pulley
4. Spacer
6
5. Bolt
6. Case Half 5
7. Bearing
8. Retainer
9. Rotor
10. Stator 3
11. Case Half
12. Sleeve
13. Regulator 5
1 4
14. Rectifier
15. Cover
16. Spacer 11 12
2
10 5

7
9
8
7
15 1
14
16
13
C-3529

STARTER Removal And Installation
Testing Open the rear door.
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
The battery must be at full charge. Figure 60-40-3

The cable connections on the battery must be clean and
tight.
3
Figure 60-40-1
2 1
Bat
S
M
Cranking 3
Motor P107329

Disconnect the positive (+) cable (Item 1) [Figure 60-40-
3] from the starter solenoid.
A-1992
Installation: Tighten the nut to 14,7 - 16,7 Nm (10.8 -

12.3 ft-lb) torque.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
Disconnect the wire connector (Item 2) [Figure 60-40-3]
If the starter turns but does not turn the engine, the from the two solenoid wires.
starter drive has a defect.
Remove the three bolts (Item 3) [Figure 60-40-3].
Figure 60-40-2
Remove the starter from the engine.
Bat
S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT'D)
1. Bolt
2. O-ring
3. Bracket
4. Snap Ring 12
5. Stop
6. Gear 14
7. Spring 13
8. Holder 11
9. Lever
10. Plate 8
3
11. Lever 10
7
12. Switch 7
13. Washer
14. Nut 2
1 9
15. Shaft 17
16. Ball
17. Armature 3
18. Bearing 2
7 18
19. Boot
6 6

20. Yoke 5
21. Holder 4
16
6
4 1
13
6
15 1
2
19
13 3
2 21
2
20
B-19824

INSTRUMENT PANELS
Left Panel
Figure 60-50-1
2 3 12
13
1 7
4 14 17
6 8 9 10 11 16
5 15
18 21
19 20

22 23
24
P-90726G
The left panel [Figure 60-50-1] is the same for all machines regardless of options and accessories.
REF. NO. DESCRIPTION FUNCTION / OPERATION

1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT AND TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.

INSTRUMENT PANELS (CONTD)
Left Panel (Contd)
REF. NO. DESCRIPTION FUNCTION / OPERATION

12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
13 DIESEL PARTICULATE FILTER Diesel particulate filter requires service when flashing. (See DIESEL
(DPF) / DIESEL EXHAUST FLUID PARTICULATE FILTER (DPF) SYSTEM in this manual.)
(DEF)
14 SHOULDER BELT Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
15 HYDRAULIC SYSTEM Hydraulic system malfunction or failure. (See Service Codes*)
MALFUNCTION
16 FUEL Fuel level low or sensor error.
17 FUEL GAUGE Shows the amount of fuel in the tank.
18 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green
LED lights.) Press a second time to add REAR work lights. (Left and
right green LEDs light.) Press a third time to turn all lights off. (Left and
right green LEDs off.)
Press and hold 5 seconds to display software version in display screen.
19 AUTO IDLE Press once to engage auto idle. (Left green LED lights.) Press a

second time to disengage. (See AUTO IDLE in this manual.)
Move cursor to the left inside the DISPLAY SCREEN when using
certain INFORMATION button menus.
20 AUXILIARY HYDRAULICS without Press once to activate the auxiliary hydraulic system. (Left green LED
high-flow option lights.) Press a second time to deactivate the system.
AUXILIARY HYDRAULICS with Press once to activate the auxiliary hydraulic system. (Left green LED
high-flow option lights.) Press a second time to engage the HIGH-FLOW auxiliary
hydraulics. (Left and right green LEDs light.) Press a third time to
deactivate auxiliary hydraulics. (Left and right green LEDs off.)
Move cursor to the right inside the DISPLAY SCREEN when using
certain INFORMATION button menus.
21 INFORMATION Cycles through (after each button press):
Hourmeter (On startup)
Engine rpm
Battery voltage
Drive response menu
Steering drift compensation menu
Maintenance clock (Press and hold 7 seconds when displayed to
reset the maintenance clock.)
Service codes*
22 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the left joystick to
move the loader forward or backward when using the backhoe
attachment. (See TRACTION LOCK OVERRIDE in this manual.) Press
a second time to lock the brakes.
23 PRESS TO OPERATE LOADER Press to activate the BICS when the seat bar is down and operator is
seated in operating position. Button will light.
24 PARKING BRAKE (Standard on all Press the top to engage the Parking Brake. Press the bottom to
loaders) disengage. (See PARKING BRAKE in this manual.)
* This manual contains a table with Service Code descriptions. (See DIAGNOSTIC SERVICE CODES on Page 60-100-1.)

INSTRUMENT PANELS (CONTD) Right Panel (Standard Key Panel)
Display Screen Figure 60-50-3
The display screen can display the following information:
Operating hours
Engine rpm
Battery voltage
Drive response setting
Steering drift compensation setting
Maintenance clock countdown
Service codes
Speed management setting
Figure 60-50-2

2
3 4 5 6 7
NA3071
P-85285D
The display screen is shown in [Figure 60-50-2]. The

This machine may be equipped with a Standard Key
data display will show operating hours upon startup.
Panel [Figure 60-50-3].
1. Data Display
1. Key Switch: Used to turn the loaders electrical
system on and off, and to start and stop the engine.
2. Hourmeter
2. All-Wheel Steer / Skid-Steer Switch: Press the top
3. Speed Management
to select All-Wheel Steer Mode; bottom to select Skid-
Steer Mode.
4. Engine Preheat
5. Engine RPM
6. Battery / Charging Voltage
7. Service

INSTRUMENT PANELS (CONTD) 5. All-Wheel Steer / Skid-Steer Switch: Press the top
to select All-Wheel Steer Mode; bottom to select Skid-
Right Panel (Keyless Start Panel) Steer Mode.
Figure 60-50-4
2 3

5
P-90819K
This machine may be equipped with a Keyless Start

1. Keypad (keys 1 through 0): Used to enter a number

code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
2. LOCK Key: Used to lock keypad. The lock key will

display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-200-2.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-200-2.)
4. Key Switch: Used to turn the loaders electrical


INSTRUMENT PANEL IDENTIFICATION (CONTD) 5. Key Switch: Used to turn the loaders electrical
Right Panel (Deluxe Instrumentation Panel)
6. All-Wheel Steer / Skid-Steer Switch: Press the top
Figure 60-50-5 to select All-Wheel Steer Mode; bottom to select Skid-
Steer Mode.

6
P-90212L
This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].
1. Keypad (1 through 0): The keypad has two

functions:
- To enter a number code (password) to allow starting

the engine.
- To enter a number as directed for further use of the

display screen.
2. Display Screen: The display screen is where all

system setup, monitoring, and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen

choices.
4. ENTER Button: Used to make selections on the

display screen.

INSTRUMENT PANEL IDENTIFICATION (CONTD) Change Language:
Right Panel (Deluxe Instrumentation Panel) (Contd) Press the left or right scroll button to cycle through the
languages. The language that is stopped on becomes
Figure 60-50-6 the default language used for the Deluxe Instrumentation
The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-190-1.)
Enter The Password:
Use the numbers on the keypad to enter the password,

then press the [ENTER] button. A symbol will appear on
the display screen for each number entered. The left
scroll button can be used to backspace if an incorrect
number is entered.
If the correct password is not entered, [INVALID

NA3187 PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
The first screen you will see on your new loader is shown See CONTROL PANEL SETUP for further description of
in [Figure 60-50-6]. screens to set up the system for your use. (See

CONTROL PANEL SETUP on Page 60-190-1.)
When this screen is on the display you can enter the
password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See Changing The Owner
Password on Page 60-200-1.) Keep your
password in a safe location for future needs.

INSTRUMENT PANEL IDENTIFICATION (CONTD) Right Switch Panel
Left Switch Panel Figure 60-50-8
Figure 60-50-7
2
3

4 OR 5
3
NA3157
NA5693
NA3092
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
NO.
DESCRIPTION FUNCTION / OPERATION 1 POWER Press and hold the up arrow to
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
3 NOT USED ---
(Option)
4 DERATE Press the top to override
3 HYDRAULIC Press the top to engage
OVERRIDE engine derate. See DIESEL
BUCKET Hydraulic Bucket Positioning;
PARTICULATE FILTER (DPF)
POSITIONING bottom to disengage.
SYSTEM in this manual.
(Option)
5 DIESEL Press the top to override
PARTICULATE engine derate; bottom to inhibit
FILTER (DPF) DPF regeneration. See
INHIBIT (Option) DIESEL PARTICULATE
FILTER (DPF) SYSTEM in this
manual.

INSTRUMENT PANEL IDENTIFICATION (CONTD) Right Side Lower Panel
Left Side Lower Panel Figure 60-50-10
Figure 60-50-9 1
2
3
1 2 4
P-85267D
P-85282
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER PORT Provides a 12 volt

NO.
receptacle for accessories.
1 FAN MOTOR Turn clockwise to increase
2 RADIO (Option) See Radio in this manual.
(Option) fan speed;
counterclockwise to 3 HEADPHONE JACK Used to connect
decrease. There are four (Option) headphones to the optional
positions; OFF-1-2-3. radio output. Automatically
silences speakers when
2 AIR CONDITIONING Press top of switch to start;
used.
/ DEFROST SWITCH bottom to stop. Switch will
(Option) light when started. Fan 4 SPEAKER (Option) Right speaker used with
Motor (Item 1) must be ON optional radio.
for air conditioning to
operate.
3 TEMPERATURE Turn clockwise to increase
CONTROL (Option) the temperature;
counterclockwise to
decrease.
4 SPEAKER (Option) Left speaker used with
optional radio.

INSTRUMENT PANEL (CONTD) Right Panel Removal And Installation
Left Panel Removal And Installation Figure 60-50-13
Figure 60-50-11
1 1
2
1 1
2 P-85929
P-85928
Remove the two bolts (Item 1) and the fastener (Item 2)
[Figure 60-50-13].
Remove the two bolts (Item 1) and the fastener (Item 2)
[Figure 60-50-11]. Installation: Do not overtighten the instrument panel

bolts. Stripping of the threaded holes in the panels can
Installation: Do not overtighten the instrument panel occur.
bolts. Stripping of the threaded holes in the panels can
occur. Figure 60-50-14
Figure 60-50-12
1
1
1
P-85931
1
P-85930
Pull the right instrument panel down and disconnect the
wire harness (Item 1) [Figure 60-50-14].
Pull the right instrument panel down and disconnect the
wire harness (Item 1) [Figure 60-50-12] from the panel. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONTD) Alarm Disassembly And Assembly
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Remove the right instrument panel. (See Right Switch
Panel Removal And Installation on Page 60-50-11.) Figure 60-50-16
Figure 60-50-15
1
1
P-85947
P-85948

loader alarm.
Remove the key (Item 1) from the switch. Remove the nut
(Item 2) [Figure 60-50-15]. Remove the alarm from the loader instrument panel.
Remove the switch from the control panel.

INSTRUMENT PANELS (CONTD) Right Switch Panel Removal And Installation
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel Removal And
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-9.) Figure 60-50-19
Figure 60-50-17
P107695
1
P-85945
Remove the two fasteners (Item 1) [Figure 60-50-19].

Remove the two fasteners (Item 1) [Figure 60-50-17]. Figure 60-50-20
Figure 60-50-18
1
1
2
2
P-85944
P-85946
Remove the fastener (Item 1) and the left side panel
(Item 2) [Figure 60-50-20].
Remove the fastener (Item 1) and the left side panel
(Item 2) [Figure 60-50-18].


LIGHTS Figure 60-60-3
Front Removal And Installation 1
Disconnect the negative(-) cable from the battery. (See

Figure 60-60-1
1
P-85436
1
Remove the two bulbs (Item 1) [Figure 60-60-3] from the
housing by turning the bulb 1/4 turn.
Figure 60-60-4
P-85433

Figure 60-60-2
P-85435
NOTE: Two different light bulbs are used. Note the

location of each bulb [Figure 60-60-4].
P-85434
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness.

LIGHTS (CONTD) Cab Light Removal And Installation (Early Models)
Rear Removal And Installation Figure 60-60-7
Figure 60-60-5
1
1 2
3
2
P-85586A
P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning the bulb NOTE: Do not pull the cab light to far away from the

assembly 1/4 turn. headliner to prevent damage to the wires.
P-85437 P-85783
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8] from
[Figure 60-60-6]. the wire harness.

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)
Description
The Gateway controller is the main controller. It provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
The Gateway and Auxiliary controller are located under

the cab, on the left side of the loader frame.

AUXILIARY) (CONTD)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

AUXILIARY) (CONTD)
Connector Identification (Contd)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BROWN HYD LOCK VALVE SOLENOID GROUND
2 2680 BROWN LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 3380 LBL SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2670 BROWN TILT SPOOL LOCK SOLENOID GROUND
11 7021 WHITE AC SIGNAL MONITOR

12 OPEN NA NA
13 3430 LBL TRACTION LOCK RELAY FEEDBACK
14 3420 LBL GLOW PLUG RELAY FEEDBACK
15 3160 LBL ENGINE SPEED SENSOR SIGNAL
16 3150 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BROWN HYDRAULIC FAN GROUND
19 2380 BROWN PTOL LED
20 3030 LBL PTOL SWITCH
21 3450 LBL SWITCHED POWER RELAY FEEDBACK
22 3560 LBL STARTER RELAY FEEDBACK
23 OPEN NA NA
24 8130 TAN START ENGINE
25 3140 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BRN TWO SPEED GROUND
27 2360 BRN TWO SPEED MAKEUP GROUND
28 3440 LBL REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 3410 LBL FUEL RELAY FEEDBACK
31 3460 LBL MRKR LIGHT PWR RELAY FEEDBACK
32 3220 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3320 LBL HYD FILTER DIFF PRESS

AUXILIARY) (CONTD)
J1B
WIRE
NUMBER
1 3190 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4680 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4670 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9200 PUR CAN LO 0
9 9100 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3370 LBL SEATBAR SENSOR SIGNAL

12 3180 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 2230 BROWN SENSOR GROUND
18 3170 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN CONN
20 9600 PURPLE CAN LOW 1
21 3090 LBL REMOTE ATTACHMENT SIGNAL
22 3040 LBL RUN / ENTER
23 5190 YEL HYDRAULIC CHARGE PRESSURE
24 5100 YEL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL

AUXILIARY) (CONTD)
Auxiliary Controller
1 1
34 26
J2A J2B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

AUXILIARY) (CONTD)
J2A
WIRE
NUMBER
1 2340 BROWN FRONT BASE SOLENOID GROUND
2 OPEN NA NA
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 OPEN NA NA
11 4810 LGN LEFT HANDLE PADDLE RIGHT

12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BROWN FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BROWN HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

AUXILIARY) (CONTD)
J2B
WIRE
NUMBER
1 OPEN NA NA
4 OPEN NA NA
5 OPEN NA NA
6 OPEN NA NA
7 OPEN NA NA
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LGN RIGHT HANDLE PWM LOW
18 4320 LGN RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG/WHT SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLERS (GATEWAY AND Figure 60-70-2
AUXILIARY) (CONTD)

1.)
Figure 60-70-1
P101568
2 1 Remove the bolts (Item 1) [Figure 60-70-2] from the left

fender.

lb) torque.

Remove the Gateway and Auxiliary controllers from the
loader.
2
1
P106605

from the gateway controller.

from the auxiliary controller.
NOTE: The connectors are keyed and will only plug

in one way.

BOBCAT CONTROLLER (ACS)
Description
The ACS controller processes information for the lift and

tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.

BOBCAT CONTROLLER (ACS) (CONTD)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2

P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONTD) Figure 60-71-2


1.)
Figure 60-71-1
1
P100291

controller.
1 Remove the controller from the loader.
Reverse procedure for installation.

when replacing a controller. (See Lift And Tilt
P-85903 Calibration on Page 60-170-4.)
NOTE: Before unplugging any controller the key

switch must be off.
Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.
NOTE: The connectors are keyed and will only plug

in one way.


BOBCAT CONTROLLER (DRIVE PLUS) The drive controller works along with the ACS controller
and communicates with the Gateway controller in an SJC
Description system. All these controllers are capable of software
upgrades.
This controller processes information for the drive
functions. The SJC system uses electronic joysticks to control the
workgroup functions (lift and tilt) and the drive functions
The drive controller is located underneath the operators of the loader. The control can be switched from ISO and
cab, attached to the control panel. H-Pattern drive control layouts.
The drive controller monitors the position of the joysticks, The workgroup actuators are the same as those used on
pump swash plate angles and the position of the AWS the ACS system.
switch.
DRIVE
CONTROL
ACS HYDRAULIC WHEEL

CONTROL MOTOR POSITION
SENSORS

RIGHT
HAND
PANEL LEFT/TILT TWO SPEED
ACTUATORS PARK BRAKE
GEAR ENGINE
PUMP
RIGHT
JOYSTICK
FWD/REF AND
SWASH PLATE
LEFT SENSORS
JOYSTICK
LEFT
HAND
PANEL
AUXILIARY DRIVE
CONTROL PUMP
EXTERNAL
CAN BUS ACD HYDRAULIC
CONTROL MOTOR
GATEWAY
CONTROL
NA5678

BOBCAT CONTROLLER (DRIVE PLUS) (CONTD)
Connector Identification
P-64295A

BOBCAT CONTROLLER (DRIVE PLUS) (CONTD)
Connector Identification (Cont'd)
P-68915

BOBCAT CONTROLLER (DRIVE PLUS) (CONTD) Figure 60-72-3
Figure 60-72-1
1
1
1
P-64325
Installation: Install the wire harness connectors so the

tab is aligned with the socket (Item 1) [Figure 60-72-3]
controller.
P101571

Remove the three bolts (Item 1) [Figure 60-72-1].

lb) torque.
Figure 60-72-2
J S
P-64324
Remove the screws and wire harness connectors (Item

1) [Figure 60-72-2].

35 in-lb) torque. DO NOT OVERTIGHTEN.
Remove the controller.

ENGINE CONTROL UNIT (ECU)
Description
The engine ECU controls the amount, timing, mixture

IMPORTANT
and pressure of fuel that is injected. The engine ECU
Avoid damage to the Engine Control Unit (ECU).
operates each kind of control based on the signals from
Water entering ECU atmospheric pressure sensor
each type of sensor.
will damage the ECU. Do not use high water pressure
around the ECU when cleaning the engine
The actuator for controlling the amount, timing and
compartment.
mixture of fuel injection is the injector, while the actuator I-2357-0512
for controlling fuel pressure is the supply pump.
The amount of fuel to be injected is determined using a

basic injection amount, which is calculated based on the
state of the engine and driving conditions, with
corrections added for parameters such as water
temperature, fuel temperature, intake pressure, etc.
The ECU controls the timing for starting to energize the

injectors, first determining the timing for the main
injection and then the of other injections, such as pilot
injections.

By conducting a pilot injection, the initial fuel mixture is
kept to a minimum, mitigating the explosive initial
combustion and reducing NOx and noise.
The ECU calculates the set fuel injection pressure based

on the engine load (last injection amount and engine
RPM) and controls the amount the supply pump supplies
and the fuel pressure inside the rail.
The ECU monitors the diesel particulate filter (DPF) and

determines when regeneration and level of regeneration
should occur.
Figure 60-80-1
P107449
The ECU is located in the engine compartment on the

right hand upright [Figure 60-80-1].

ENGINE CONTROL UNIT (ECU) (CONTD) Figure 60-80-4
Cleaning
NOTE: The ECU connectors must to be free of all dirt

and debris before removing connectors. 1
NOTE: ECU removed for photo quality.
Figure 60-80-2
1
2
P107614
Remove any residual dirt and debris from the connector

and slide area with a small brush (Item 1) [Figure 60-80-
4].
Repeat all steps until there is no visible evidence of dirt,

grit or other debris.

P107612
NOTE: Inspect the connector and repeat cleaning
Use a spray bottle (Item 1) to apply water around the process if debris remains on the connector
connector (Item 2) [Figure 60-80-2] to remove dirt and and ECU.
debris.
Figure 60-80-5
NOTE: Do not apply water when any connector is
removed. 3
2
Figure 60-80-3
2
1
P107611
1
Inspect the connector (Item 1) [Figure 60-80-5] for
damage and debris.
P107613
NOTE: To avoid getting debris in the terminal
openings, clean the connector facing the
Use air pressure to remove loose particles from the ECU ground.
head (Item 1) and the connector (Item 2) [Figure 60-80-
3]. Using a clean damp cloth or paper towel, not dripping
wet, brush off the heavy deposits on the housing (Item 2)
The connectors should be dry before disconnecting. but do not wipe on the terminal openings (Item 3) [Figure
60-80-5].

ENGINE CONTROL UNIT (ECU) (CONTD) Figure 60-80-8

2
1
3
IMPORTANT
Avoid damaging the Engine Control Unit (ECU) and
electrical connectors. Use care when removing or
installing the ECU connectors.
I-2356-0512
Clean the connectors before removal. (See Cleaning on

Page 60-80-2.) P107606
Figure 60-80-6
Press the latch (Item 1) to release the lever (Item 2) from
the connector (Item 3) [Figure 60-80-8].
2
Figure 60-80-9

1 1
2
1
P107530
Remove the connectors (Item 1) from the ECU (Item 2)

[Figure 60-80-6]. P107607
Figure 60-80-7
Lift the lever (Item 1) and push fully forward to remove
connector (Item 2) [Figure 60-80-9]. Pull connector
straight out to avoid damage.
NOTE: If resistance is encountered when opening the

1 lever, lock connector and repeat the cleaning
process.
P107605
Slide the lock (Item 1) forward [Figure 60-80-7].

ENGINE CONTROL UNIT (ECU) (CONTD)
Figure 60-80-10
P107615
Remove the connector (Item 1) from the head (Item 2)

[Figure 60-80-11]. Evenly pull straight out and away from
module.

NOTE: Removing or installing the connector at an
extreme angle will result in seal scooping,
creating an environment for fluid ingress.
Damage to the header or connector may
result if undue force is used.
Figure 60-80-11
1
1
P107531
Remove the retaining nuts (Item 1) and remove the ECU

(Item 2) [Figure 60-80-11].

WHEEL POSITION SENSORS Press the INFORMATION button (Item 3) to cycle the
DATA DISPLAY (Item 2) [Figure 60-90-2] until the
Description service code screen is displayed. If more than one
service code is present, the codes will scroll on the data
Figure 60-90-1 display. The service code(s) will identify the wheel(s) with
an error condition. (See Service Codes List on Page 60-
Cover Installed Cover Removed
100-2.)
NOTE: If more than one wheel is affected, the loader

will shut down.
Wheel alignment may need to be performed when any

steering components are replaced or repaired. There are
1 three different procedures for wheel alignment. Select the
best one for your circumstances.
Wheel Alignment (Field Adjustment)
The Field Adjustment can be used to align each wheel

P-24924 P-24925 with the wheels installed without Service Analyzer.
This procedure can be performed in the field after
service or part replacement to visually align the
There is a sensor on each wheel, located inside each wheels.
axle tube (Item 1) [Figure 60-90-1], to monitor the wheel

position. The sensors are associated with the selected Wheel Alignment (Field Adjustment With Service
steering mode (Skid-Steer, All-Wheel Steer). Analyzer)
If there is an electrical interruption to the wheel position The Field Adjustment with Service Analyzer can be
sensor(s) or other system problem: used to align each wheel with the wheels installed.
This procedure can be performed in the field or the
All-Wheel Steer Mode shop after service or part replacement when the
loader cannot be placed on jackstands.
Moving the joystick left or right will cause the affected
wheel to turn to the left or right at a set rate. Wheel Alignment (Calibration)
Skid-Steer Mode The Calibration procedure is used to set the zero

point of each axle hub using Service Analyzer without
The affected wheel will remain at its last position. It the wheels installed. This procedure needs to be
will not be automatically moved to point straight. performed in the shop after service or part
replacement. This procedure is the preferred method
Figure 60-90-2 of wheel calibration.
1
2
P-76460F
The general warning icon (Item 1) [Figure 60-90-2] will

come ON and the alarm will sound three beeps.

WHEEL POSITION SENSORS (CONT'D) Aligning the wheels:
Wheel Alignment (Field Adjustment) Sit in the operator's seat with the seat bar down and
start the engine. Press the PRESS TO OPERATE
Figure 60-90-3 LOADER button (Item 1) [Figure 60-90-3] and the
bottom of the two-speed switch on the left joystick
(Items 1) and [Figure 60-90-4] at the same time.
You will hear the alarm sound and FL-A will appear in the
2 hourmeter display (Item 2) [Figure 60-90-3].
Alignment Codes:
FL-A (Front Left Wheel)

FR-A (Front Right Wheel)
RL-A (Rear Left Wheel)
1 RR-A (Rear Right Wheel)
Move the left joystick to the left or right to align the
wheel.
P-85413C
When the wheel is aligned straight ahead, press the
PRESS TO OPERATE LOADER button (Item 1)
Figure 60-90-4 [Figure 60-90-3] to set the wheel position and the
alarm will sound two times.

Repeat the alignment procedure for the remaining
wheels. After all the wheels have been aligned DONE
will be displayed in the hourmeter (Item 3) [Figure 60-90-
2].
P-90135

WHEEL POSITION SENSORS (CONT'D) Figure 60-90-6
Testing
Figure 60-90-5
1
P-24924

P-28303 support device. (See Installing on Page 10-20-1.)

procedure: Connect the Remote Start Tool to the loader. (See

REMOTE START TOOL (SERVICE TOOL) KIT -
MEL1603-Wheel Angle Sensor Test Harness [Figure 60- 7217666 on Page 10-61-1.)
90-5].
MEL1563 or 7003031-Remote Start Tool Remove the two mount bolts (Item 1) [Figure 60-90-6]
Multimeter and remove the wheel position sensor / steering cylinder

Testing (Cont'd)
1
Figure 60-90-7
P-28305
1
With a multimeter, check the voltage on pins 2 (Item 1)

P-24925
and pins 3 (Item 2) [Figure 60-90-9] of the test harness.
The voltage should be 5 volts.

Disconnect the wheel position sensor wire connector
(Item 1) [Figure 60-90-7] from the loader harness. (See Service Codes List on Page 60-100-2.) for the

diagnostics codes that apply to the four wheel position
Figure 60-90-8 sensors.
2
1
P-28304
Connect one end of the test harness to the loader

harness (Item 1) [Figure 60-90-8].
Connect the other end of the test harness to the wheel

position sensor wiring harness (Item 2) [Figure 60-90-8].
Turn the remote start key to the RUN position without

starting the loader.

Sensor Removal And Installation
Remove the loader hub. (See Removal on Page 40-50-

1.) 1
Figure 60-90-10
1
P-24926
With a needle nose plier, remove the wedge (Item 1)

1
[Figure 60-90-12] from the wheel sensor wire connector.
Figure 60-90-13
P-28239

Remove the two mount bolts (Item 1) [Figure 60-90-10]
and remove the wheel position sensor / steering cylinder
cover form the loader.
Figure 60-90-11
P-24927
1
With a pointed screw driver lightly press in on the tabs
and remove the individual wires from the connector
[Figure 60-90-13].
Installation:
P-28238
Number of Connector Wire Color
1 Red
Disconnect the wheel sensor wire connector (Item 1)
[Figure 60-90-11] from the loader wiring harness. 2 Black
3 Blue

Sensor Removal And Installation (Cont'd)
Figure 60-90-14
1
P-34483
Lift the wheel sensor up and lightly pull on the sensor

P-24928
while pushing the wires (Item 1) [Figure 60-90-16]
through the face of the casting.
Remove the seal (Item 1) [Figure 60-90-14] from the Remove the wheel position sensor from the loader.
wires.

Figure 60-90-15
P-34482

the wheel sensor.
Installation: Tighten the bolts to 2,85 - 3,39 Nm (25 - 30

in-lb) torque.

Wheel Alignment (Field Adjustment With Service

Analyzer)

procedure:
1
Remote Start Tool (Service Tool)
or
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software)
Straight Edge 6 ft. long
P-76110
NOTE: This procedure must be performed with two

people. Select Diagnostics (Item 1) [Figure 60-90-18].
Connect the Remote Start Tool or Remote Start Tool Figure 60-90-19
(Service Tool) to the loader. (See REMOTE START

10-61-1.)
1
Connect the Service PC to the Remote Start Tool. (See
Connecting Remote Start Tool on Page 60-160-1.)
Turn on the Remote Start Tool (Service Tool).
Figure 60-90-17
P-76584
Select System Diagnostics (Item 1) [Figure 60-90-19].
Read and select OK on the jackstands warning message.
P-76110
Enter the Bobcat Service Analyzer screen [Figure 60-90-

17].

WHEEL POSITION SENSORS (CONTD) Figure 60-90-21

Analyzer) (Contd)
Figure 60-90-20
P-76582
The loader is now in calibration mode [Figure 60-90-21].
P-76581
The Diagnostic Screen will be displayed. [Figure 60-90-

20]
Turn the Remote Start Tool (Service Tool) to the STOP

position.
With an operator in the cab, seat bar down, start the

loader and press THE PRESS TO OPERATE LOADER
button.
Click the [Angle Sensor] button (Item 1) [Figure 60-90-

20].
NOTE: If at any time during the procedure, the power

to the loader is turned OFF before the wheels
are aligned, the complete procedure must be
repeated to insure correct alignment of the
wheels.
Audible beeps will sound to signal when the system is

ready to align.
NOTE: Code D7599 will be displayed by pressing the

info button four times.


Analyzer) (Cont'd)
Figure 60-90-22
P-85961
1
Move the left joystick [Figure 60-90-24] from side to side
to align the left front wheel.
P106145
Figure 60-90-25
With the All-Wheel Steer / Skid-Steer selector switch

(Item 1) [Figure 60-90-22] in the Skid-Steer Mode, the
left front wheel and left rear wheel can be aligned.
NOTE: The All-Wheel Steer / Skid-Steer selector

switch and the position of the left joystick
determine the side of the loader and the wheel
that is to be aligned.
Figure 60-90-23
P106145
Press the AWS switch (Item 1) [Figure 60-90-25] into the

AWS Mode, the right front wheel and right rear wheel can
be aligned.
P-85961
Move the left joystick [Figure 60-90-23] forward and

backward to align the left rear wheel.


Analyzer) (Cont'd)
Figure 60-90-26
P-76583
NOTE: Allow the joystick to go to neutral position

before clicking [OK].
Click OK on the service analyzer screen (Item 1) [Figure

P-85961
60-90-28] to complete the Wheel Alignment (Field
Adjustment).
Move the left joystick [Figure 60-90-26] forward and
The wheel sensors should display 0 on all wheels

backward to align the right rear wheel.
[Figure 60-90-28].
Figure 60-90-27 Figure 60-90-29
P-85961 P-28584
Use a straight edge along both tires to check the wheel

Move the left joystick [Figure 60-90-27] from side to side
alignment [Figure 60-90-29].
to align the right front wheel.
If the wheels are not aligned, check the sensors, linkages
or steering cylinders.
If one or both wheels need to be aligned, repeat the

complete procedure to insure correct alignment.
The procedure is completed for both sides of the loader.
Shut the loader off.
Remove the Service Analyzer and Remote Start Tool

(Service Tool).

Wheel Alignment (Calibration)
NOTE: A calibration procedure must be followed

when replacing a wheel position sensor, or
Drive Plus Controller. Failure to calibrate after
component replacement may result in poor
performance.

procedure:
Remote Start Tool (Service Tool)

or
MEL1563 or 6689779 - Remote Start Tool P-76110
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software) Enter the Bobcat Service Analyzer screen [Figure 60-90-
Straight Edge 6 ft. long 30] on the Service PC.
Figure 60-90-31
Connect the Remote Start Tool or Remote Start Tool
(Service Tool) to the loader. (See REMOTE START

10-61-1.)
1
10-10-1.)
Remove the four wheel / tire assemblies from the loader.

(See Mounting on Page 10-170-1.)
Remove the four steering cylinder pins at the hub. (See

Removal on Page 40-50-1.)
P-73668
Connect the Remote Start Tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.)
Select Diagnostics (Item 1) [Figure 60-90-31].
Connect the Service PC to the Remote Start Tool. (See
Connecting Remote Start Tool on Page 60-160-1.)
Turn on the Remote Start Tool (Service Tool).

WHEEL POSITION SENSORS (CONT'D) NOTE: If at any time during the procedure, the power
to the loader is turned OFF before the wheels
Wheel Alignment (Calibration) (Cont'd) are aligned, the complete procedure must be
repeated to insure correct alignment of the
Figure 60-90-32 wheels.
NOTE: Code D7599 will be displayed by pressing the

info button four times.
Figure 60-90-34
1
P-76110
Select System Diagnostics (Item 1) [Figure 60-90-32].

Read and click [OK] on the jackstands warning message.
P-76582
Figure 60-90-33
The loader is now in calibration mode and the Diagnostic
Screen [Figure 60-90-34] will be displayed.
Figure 60-90-35
P-76581
The Diagnostic Screen will be displayed. [Figure 60-90-

33]
P-28588
Turn off the Remote Start Tool (Service Tool).

With an operator in the cab, seat bar down, start the Place a straight edge along both hubs as shown in
loader and press the PRESS TO OPERATE LOADER [Figure 60-90-35].
button.
Use the straight edge as a reference to verify the two
Select Angle Sensor (Item 1) [Figure 60-90-33]. wheel hubs are in line with each other.
NOTE: The straight edge must contact the whole

surface of each hub.

WHEEL POSITION SENSORS (CONT'D) NOTE: When the steering cylinder pins are
reinstalled in the hub, the wheels may be out
Wheel Alignment (Calibration) (Cont'd) of alignment. This will be corrected as soon
as the loader is started, the PRESS TO
Figure 60-90-36 OPERATE LOADER button is pushed, and the
left joystick is moved.
Remove the Service Analyzer and Remote Start Tool

(Service Tool).
With an operator in the cab, seat bar down, start the

loader and press the PRESS TO OPERATE LOADER
button.
Move the left joystick and the four wheels will move into
alignment.
Shut the loader off.
P-28589 Install the four wheel / tire assemblies from the loader.
(See Mounting on Page 10-170-1.)
Move to the other side of the loader and place a straight Remove the loader from jackstands.
edge along both hubs, and place the hubs in alignment

[Figure 60-90-36].
Figure 60-90-37
P-76583
Select OK (Item 1) [Figure 60-90-37] on the service

analyzer screen to complete the Wheel Alignment
(Calibration).
The wheel sensors should display 0 on all wheels

[Figure 60-90-37].
The procedure is competed.
Install the steering cylinder pins in the hubs of the loader.


DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions that can damage your machine.
The last 40 codes stored in history can also be viewed
Figure 60-100-1 using the Deluxe Instrumentation Panel.
1
Press a scroll button (Item
1) repeatedly until the
Active Warnings screen
icon (Inset) is highlighted.
1 1
2 The ACTIVE WARNINGS

screen displays active
NA3181 service codes. Press [9]
to view the next service
Press the Information button (Item 2) to cycle the data code if more than one is
display (Item 1) [Figure 60-100-1] until the service code present. Press [4] to
screen is displayed. If more than one service code is display a history of service

present, the codes will scroll on the data display. codes.
The WARNINGS
When no service code is present, [NONE] is displayed HISTORY screen will list
[Figure 60-100-1]. the Service Code Number
(CODE), Hourmeter
NOTE: Corroded or loose grounds can cause reading when the error
multiple service codes and / or abnormal occurred (HOUR), and the
symptoms. All instrument panel lights User (USER) who was
flashing, alarm sounding, headlights and logged in to operate the
taillights flashing, can indicate a bad ground. machine when the error
The same symptoms can apply if the voltage occurred.
is low, such as loose or corroded battery Press [9] to view the next eight service codes.
cables. If you observe these symptoms, check
grounds and positive leads first. A total of 40 codes can be stored. When more than 40
codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.
Press the list number next

to the service code for
more detail.

Press the left scroll button
to back up one screen.

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-100-2 The following word errors may be displayed:
[REPLY] One or both instrument panel(s) not

1 2
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
NA3077 only.)
NA3084
NA3181
[SHTDN] A shutdown condition exists.
Service codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-100-2]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A0618 Wheel speed out of range A8403 ACD output E error OFF

A3623 ACD not programmed A8405 ACD output E short to battery
A4621 5 volt sensor supply out of range high A8406 ACD output E short to ground
A4622 5 volt sensor supply out of range low A8407 ACD output E open circuit
A4721 8 volt sensor supply out of range high A8432 ACD output E overcurrent
A4722 8 volt sensor supply out of range low A8502 ACD output F error ON
A7701 Machine key active A8503 ACD output F error OFF
A7901 E-Stop active A8505 ACD output F short to battery
A8002 ACD output A error ON A8506 ACD output F short to ground
A8003 ACD output A error OFF A8507 ACD output F open circuit
A8005 ACD output A short to battery A8532 ACD output F overcurrent
A8006 ACD output A short to ground A8602 ACD output G error ON
A8007 ACD output A open circuit A8603 ACD output G error OFF
A8032 ACD output A overcurrent A8605 ACD output G short to battery
A8102 ACD output B error ON A8606 ACD output G short to ground
A8103 ACD output B error OFF A8607 ACD output G open circuit
A8105 ACD output B short to battery A8702 ACD output H error ON
A8106 ACD output B short to ground A8703 ACD output H error OFF
A8107 ACD output B open circuit A8705 ACD output H short to battery
A8132 ACD output B overcurrent A8706 ACD output H short to ground
A8202 ACD output C error ON A8707 ACD output H open circuit
A8203 ACD output C error OFF A8802 Reverse solenoid error ON
A8205 ACD output C short to battery A8803 Reverse solenoid error OFF
A8206 ACD output C short to ground
A8207 ACD output C open circuit D3905 Left joystick X-axis not in neutral
A8232 ACD output C overcurrent D3907 Left joystick Y-axis not in neutral
A8302 ACD output D error ON D4007 Right joystick Y-axis not in neutral
A8303 ACD output D error OFF D7501 Drive CAN joystick information error
A8305 ACD output D short to battery D7504 Drive no communication from drive controller
A8306 ACD output D short to ground D7505 Drive left joystick X-axis not in neutral
A8307 ACD output D open circuit D7507 Drive left joystick Y-axis not in neutral
A8332 ACD output D overcurrent D7508 Drive right joystick Y-axis not in neutral
Drive operating mode switch short to ground or
A8402 ACD output E error ON D7509
battery

Service Codes List (Contd)

D7510 Drive improper joysticks installed D7555 Drive right forward drive solenoid error OFF
D7511 Drive left speed sensor not connected D7556 Drive right reverse drive solenoid error OFF
D7512 Drive right speed sensor not connected D7557 Drive right front steer extend short to ground
D7513 Drive right front wheel angle sensor stuck D7558 Drive right front steer retract short to ground
D7514 Drive left front wheel angle sensor stuck D7559 Drive left front steer extend short to ground
D7515 Drive right rear wheel angle sensor stuck D7560 Drive left front steer retract short to ground
D7516 Drive left rear wheel angle sensor stuck D7561 Drive right rear steer extend short to ground
D7517 Drive left swash plate not in neutral D7562 Drive right rear steer retract short to ground
D7518 Drive right swash plate not in neutral D7563 Drive left rear steer extend short to ground
D7519 Drive left joystick X-axis out of range high D7564 Drive left rear steer retract short to ground
D7521 Drive left joystick Y-axis out of range high D7565 Drive steer pressure short to ground
D7522 Drive right joystick Y-axis out of range high D7566 Drive back-up alarm error OFF
Drive right front wheel angle sensor out of range
D7523 D7567 Drive no communication from Bobcat controller
high
Drive left front wheel angle sensor out of range
D7524 D7568 Drive angle sensors not calibrated
high
Drive right rear wheel angle sensor out of range
D7525 D7569 Drive battery voltage out of range high
high

Drive left rear wheel angle sensor out of range Drive interrupted power (also occurs after
D7526 D7570
high software updates)
D7527 Drive left swash plate out of position D7571 Drive battery voltage out of range low
D7528 Drive right swash plate out of position D7572 Drive pump not calibrated
Drive operating mode switch flipped while
D7529 Drive left joystick X-axis out of range low D7573
operating
D7531 Drive left joystick Y-axis out of range low D7574 Drive right wheel speed uncommanded motion
D7532 Drive right joystick Y-axis out of range low D7575 Drive left wheel speed uncommanded motion
Drive right front wheel angle sensor out of range
D7533 D7576 Drive no communication from ACS controller
low
Drive left front wheel angle sensor out of range
D7534 D7577 Drive left speed sensor out of range high
low
Drive right rear wheel angle sensor out of range
D7535 D7578 Drive right speed sensor out of range high
low
Drive left rear wheel angle sensor out of range
D7536 D7579 Drive left speed sensor out of range low
low
D7537 Drive 5 volt sensor supply 1 out of range low D7580 Drive right speed sensor out of range low
D7538 Drive 5 volt sensor supply 2 out of range low D7581 Drive right front steer retract short to battery
D7539 Drive left swash plate sensor out of range high D7582 Drive left front steer retract short to battery
D7540 Drive left swash plate sensor out of range low D7583 Drive right rear steer retract short to battery
D7541 Drive right swash plate sensor out of range high D7584 Drive left rear steer retract short to battery
D7542 Drive right swash plate sensor out of range low D7585 Drive 5 volt sensor supply 1 out of range high
D7543 Drive left forward drive solenoid error ON D7586 Drive 5 volt sensor supply 2 out of range high
D7544 Drive left reverse drive solenoid error ON D7587 Drive software update required
D7545 Drive right forward drive solenoid error ON D7588 Drive switched power stuck ON
D7546 Drive right reverse drive solenoid error ON D7589 Drive switched power error OFF
D7547 Drive right front steer extend short to battery D7590 Drive calibration performed
D7548 Drive left front steer extend short to battery D7591 Drive left swash plate sensor reversed
D7549 Drive right rear steer extend short to battery D7592 Drive right swash plate sensor reversed
D7550 Drive left rear steer extend short to battery D7593 Drive unresponsive right speed sensor
D7551 Drive steer pressure short to battery D7594 Drive unresponsive left speed sensor
D7552 Drive back-up alarm error ON D7595 Drive left speed sensor reverse direction
D7553 Drive left forward drive solenoid error OFF D7596 Drive right speed sensor reverse direction
D7554 Drive left reverse drive solenoid error OFF D7597 Drive controller programmed


D7598 Drive controller in calibration mode E001485-02 ECU main relay fault
Drive AWS controller in wheel position
D7599 E003242-00 Exhaust temperature extremely high
calibration mode
E003242-03 Exhaust gas temperature sensor fault
E000029-03 Throttle position sensor fault E003242-04 Exhaust gas temperature sensor fault
E000029-04 Throttle position sensor fault E003242-16 Exhaust gas temperature sensor fault
E000091-02 Throttle position sensor fault E003246-00 Exhaust temperature extremely high
E000091-03 Throttle position sensor fault E003246-03 EGR temperature sensor fault
E000091-04 Throttle position sensor fault E003246-04 EGR temperature sensor fault
E000100-01 Engine oil pressure too low E003246-16 Exhaust gas temperature sensor fault
E000102-03 Intake air pressure sensor fault E003251-00 Differential pressure sensor fault
E000102-04 Intake air pressure sensor fault E003251-01 Differential pressure sensor fault
E000108-03 Barometric pressure fault E003251-03 EGR temperature sensor fault
E000108-04 Barometric pressure fault E003251-04 EGR temperature sensor fault
E000110-00 Engine temperature extremely high E003252-00 Exhaust temperature too high
E000110-03 Water temperature sensor fault E003509-03 Sensor supply voltage fault
E000110-04 Water temperature sensor fault E003509-04 Sensor supply voltage fault
E000132-01 Intake air volume fault E003510-03 Sensor supply voltage fault

E000132-03 MAF sensor fault E003510-04 Sensor supply voltage fault
E000132-04 MAF sensor fault E003701-00 Particulate matter extremely high
E000132-15 Boost pressure fault E003701-15 Particulate matter warning
E000157-00 Rail pressure fault E003701-16 Particulate matter too high
E000157-03 Rail pressure sensor fault E004765-00 Exhaust temperature extremely high
E000157-04 Rail pressure sensor fault E004765-03 Exhaust gas temperature sensor fault
E000168-03 System voltage too high E004765-04 Exhaust gas temperature sensor fault
E000168-04 System voltage too low E004765-18 Exhaust gas temperature sensor fault
E000171-03 MAF sensor fault E523523-02 Injector #1 and #4 fault
E000171-04 MAF sensor fault E523523-03 Injector #1 and #4 fault
E000172-00 Intake air temperature too high E523523-04 Injector #1 and #4 fault
E000172-03 Intake air temperature fault E523524-02 Injector #2 and #3 fault
E000172-04 Intake air temperature fault E523524-03 Injector #2 and #3 fault
E000174-00 Fuel temperature too high E523524-04 Injector #2 and #3 fault
E000174-03 Fuel temperature sensor fault E523525-01 Injector fault
E000174-04 Fuel temperature sensor fault E523527-02 ECU fault
E000190-00 Engine speed extremely high E523535-00 Injector fault
E000628-02 ECU fault E523536-02 EGR fault
E000633-07 Rail pressure fault E523537-02 EGR fault
E000636-02 Crank position sensor fault E523538-02 ECU fault
E000636-07 Cam or crank sensor fault E523538-07 ECU fault
E000636-08 Crank position sensor fault E523539-02 Fuel pump fault
E000651-03 Injector #1 fault E523540-02 Fuel pump fault
E000652-03 Injector #2 fault E523541-03 EGR fault
E000653-03 Injector #3 fault E523541-04 EGR fault
E000654-03 Injector #4 fault E523543-02 Throttle position sensor fault
E000723-02 Camshaft position sensor fault E523544-03 Intake heater fault
E000723-08 Camshaft position sensor fault E523544-04 Intake heater fault
E001077-02 ECU fault E523547-02 ECU communication error
E001239-01 High pressure fuel leak E523548-02 ECU communication error
E001347-03 High pressure pump fault E523572-04 EGR position sensor fault
E001347-04 High pressure pump fault E523573-04 EGR actuator fault
E001347-07 High pressure pump fault E523574-03 EGR actuator fault


E523574-04 EGR actuator fault H2632 Front base output overcurrent
E523575-07 EGR actuator fault H2705 Front rod output short to battery
E523576-02 EGR motor fault H2706 Front rod output short to ground
E523577-02 EGR temperature sensor fault H2707 Front rod output open circuit
E523578-02 EGR fault H2732 Front rod output overcurrent
E523580-02 Intake throttle fault H2805 Diverter short to battery
E523582-03 Intake throttle lift sensor fault H2806 Diverter short to ground
E523582-04 Intake throttle lift sensor fault H2807 Diverter open circuit
E523589-17 Low water temperature in parked regeneration H2905 High-flow short to battery
E523590-16 Parked regeneration time out H2906 High-flow short to ground
E523591-02 ECU communication fault H2907 High-flow open circuit
E523592-02 ECU communication fault H2932 High-flow overcurrent
E523593-02 ECU communication fault H3028 Controller memory failure
E523594-02 ECU communication fault H3128 Interrupted power failure
E523595-02 ECU communication fault H3648 Multiple ACD conflict error
E523596-02 ECU communication fault H3904 Left joystick in error
E523598-00 DOC failure H3912 Left joystick thumb switch not in neutral
E523598-02 ECU communication fault H3913 Left joystick grip no communication

E523599-00 Exhaust temperature sensor fault H3916 Left joystick no communication
E523600-00 Pump calibration error H3928 Left joystick internal failure
E523601-00 Exhaust gas temperature sensor fault H3948 Left joystick multiple
E523602-00 DPF fault H4004 Right joystick in error
E523603-15 Water temperature sensor fault H4012 Right joystick thumb switch not in neutral
E523604-02 ECU communication fault H4013 Right joystick grip no communication
E523700-13 ECU fault H4016 Right joystick no communication
H4028 Right joystick internal failure
H1221 Right thumb switch out of range high H4048 Right joystick multiple
H1222 Right thumb switch out of range low H4302 Horn error ON
H1224 Right thumb switch not in neutral H4303 Horn error OFF
H1321 Left thumb switch out of range high H4423 Auxiliary not programmed
H1322 Left thumb switch out of range low H4497 Auxiliary controller programmed
H1324 Left thumb switch not in neutral H4502 Right blinker error ON
H2005 Boost solenoid short to battery H4503 Right blinker error OFF
H2006 Boost solenoid short to ground H4602 Left blinker error ON
H2007 Boost solenoid open circuit H4603 Left blinker error OFF
H2032 Boost solenoid overcurrent H4721 8 volt sensor supply out of range high
H2305 Rear base output short to battery H4722 8 volt sensor supply out of range low
H2306 Rear base output short to ground H7404 Main controller no communication
H2307 Rear base output open circuit
H2332 Rear base output overcurrent L0102 Lights button error ON
High-flow enable / auto idle enable button error
H2405 Rear rod output short to battery L0202
ON
H2406 Rear rod output short to ground L0302 Auxiliary enable button error ON
H2407 Rear rod output open circuit L0402 Information button error ON
H2432 Rear rod output overcurrent L7404 Main controller no communication
H2505 Diverter #2 short to battery L7672 Left display panel needs programming
H2506 Diverter #2 short to ground
H2507 Diverter #2 open circuit M0116 Air filter not connected
H2605 Front base output short to battery M0117 Air filter plugged
H2606 Front base output short to ground M0216 Hydraulic / Hydrostatic filter not connected
H2607 Front base output open circuit M0217 Hydraulic / Hydrostatic filter plugged


M0309 System voltage too low M1507 Traction lock pull output open circuit
M0310 System voltage too high M1528 Traction lock pull output failure
M0311 System voltage extremely high M1605 Traction lock hold solenoid short to battery
M0314 System voltage extremely low M1606 Traction lock hold solenoid short to ground
M0322 System voltage out of range low M1607 Traction lock hold solenoid open circuit
M0409 Engine oil pressure too low M1705 Hydraulic lock valve short to battery
M0414 Engine oil pressure extremely low M1706 Hydraulic lock valve short to ground
M0415 Engine oil pressure in shutdown M1707 Hydraulic lock valve open circuit
M0421 Engine oil pressure out of range high M1732 Hydraulic lock valve overcurrent
M0422 Engine oil pressure out of range low M1805 Lift spool lock output short to battery
M0509 Hydraulic charge pressure too low M1806 Lift spool lock output short to ground
M0510 Hydraulic charge pressure too high M1807 Lift spool lock output open circuit
M0511 Hydraulic charge pressure extremely high M1832 Lift spool lock output overcurrent
M0514 Hydraulic charge pressure extremely low M2005 Two-speed primary solenoid short to battery
M0515 Hydraulic charge pressure in shutdown M2006 Two-speed primary solenoid short to ground
M0521 Hydraulic charge pressure out of range high M2007 Two-speed primary solenoid open circuit
M0522 Hydraulic charge pressure out of range low M2032 Two-speed primary solenoid overcurrent
M0610 Engine speed too high M2102 Glow plug output error ON

M0611 Engine speed extremely high M2103 Glow plug output error OFF
M0613 Engine speed no signal M2107 Glow plug output open circuit
M0615 Engine speed in shutdown M2128 Glow plug output failure
M0618 Engine speed out of range M2202 Starter output error ON
M0634 Engine speed invalid information from ECU M2203 Starter output error OFF
M0710 Hydraulic oil temperature too high M2207 Starter output open circuit
M0711 Hydraulic oil temperature extremely high M2228 Starter output failure
M0715 Hydraulic oil temperature in shutdown M2302 Starter relay error ON
M0721 Hydraulic oil temperature out of range high M2303 Starter relay error OFF
M0722 Hydraulic oil temperature out of range low M2402 Fuel pull relay error ON
M0810 Engine coolant temperature too high M2403 Fuel pull relay error OFF
M0811 Engine coolant temperature extremely high M2502 Traction pull relay error ON
M0815 Engine coolant temperature in shutdown M2503 Traction pull relay error OFF
M0821 Engine coolant temperature out of range high M2602 Glow plug relay error ON
M0822 Engine coolant temperature out of range low M2603 Glow plug relay error OFF
M0909 Fuel level too low M2721 Throttle primary sensor out of range high
M0921 Fuel level out of range high M2722 Throttle primary sensor out of range low
M0922 Fuel level out of range low M2821 Throttle secondary sensor out of range high
M1016 Hydraulic charge filter not connected M2822 Throttle secondary sensor out of range low
M1017 Hydraulic charge filter plugged M3028 Controller memory failure
M1121 Seat bar sensor out of range high M3128 Interrupted power failure
ACS (AHC) no communication to Bobcat
M1122 Seat bar sensor out of range low M3204
controller
M1128 Seat bar sensor failure M3304 Deluxe panel no communication
M1305 Fuel hold solenoid short to battery M3404 Deluxe panel in error
M1306 Fuel hold solenoid short to ground M3505 Hydraulic fan short to battery
M1307 Fuel hold solenoid open circuit M3506 Hydraulic fan short to ground
M1402 Fuel pull solenoid error ON M3507 Hydraulic fan open circuit
M1403 Fuel pull solenoid error OFF M3532 Hydraulic fan overcurrent
M1407 Fuel pull solenoid open circuit M3705 Two-speed second output short to battery
M1428 Fuel pull solenoid failure M3706 Two-speed second output short to ground
M1502 Traction lock pull output error ON M3707 Two-speed second output open circuit
M1503 Traction lock pull output error OFF M3732 Two-speed second output overcurrent


M3805 Auxiliary hydraulic lock short to battery M6702 HVAC output error ON
M3806 Auxiliary hydraulic lock short to ground M6703 HVAC output error OFF
M3807 Auxiliary hydraulic lock open circuit M6707 HVAC output open circuit
M3832 Auxiliary hydraulic lock overcurrent M6728 HVAC output failure
M4109 Alternator too low M6802 HVAC relay error ON
M4110 Alternator high M6803 HVAC relay error OFF
M4111 Alternator extremely high M7002 Switched power output error ON
M4304 Keyless panel no communication M7003 Switched power output error OFF
M4404 Auxiliary no communication M7007 Switched power output open circuit
M4510 Water in fuel sensor too high M7028 Switched power output failure
M4511 Water in fuel sensor extremely high M7304 Remote control no communication
M4521 Water in fuel sensor out of range high M7316 Remote control no communication to transmitter
M4522 Water in fuel sensor out of range low M7423 Main controller not programmed
M4621 5 volt sensor supply out of range high M7472 Main controller needs programming
M4622 5 volt sensor supply out of range low M7497 Main controller programmed
M4721 8 volt sensor supply out of range high M7504 Drive no communication
M4722 8 volt sensor supply out of range low M7604 Left display panel no communication
M4802 Front light relay error ON M7748 Key switch multiple

M4803 Front light relay error OFF M7839 Hourmeter changed
M4902 Rear light relay error ON M7974 Door open
M4903 Rear light relay error OFF M8541 DPF automatic regeneration active
DPF automatic regeneration active (Operate
M5002 Front light output error ON M8542
machine under load)
M5003 Front light output error OFF M8551 DPF regeneration needed - inhibit active
DPF regeneration needed - inhibit active
M5007 Front light output open circuit M8552
(Operate machine under load)
DPF remote parked regeneration required
M5028 Front light output failure M8553
(Remote regeneration kit required)
DPF service regeneration required (Contact
M5102 Rear light output error ON M8554
dealer)
M5103 Rear light output error OFF M8555 DPF service required
M5107 Rear light output open circuit M8560 DPF service regeneration active
M5128 Rear light output failure M8561 DPF service regeneration active
M5202 Press to operate button error ON M8562 DPF service regeneration active
M5221 Press to operate button out of range high M8563 DPF service regeneration active
M5222 Press to operate button out of range low M8564 DPF service regeneration active
M5305 Press to operate light short to battery M8615 Engine speed derate in shutdown
M5306 Press to operate light short to ground M8625 Engine speed derate unresponsive
M5405 Tilt spool lock short to battery
M5406 Tilt spool lock short to ground R7404 Main controller no communication
M5407 Tilt spool lock open circuit
M5432 Tilt spool lock overcurrent T9002 Service tool output C error ON
M5902 DPF regeneration switch error ON T9003 Service tool output C error OFF
M6002 DPF inhibit regeneration switch error ON T9102 Service tool output D error ON
M6102 Remote parked regeneration switch error ON T9103 Service tool output D error OFF
M6402 Switched power relay error ON T9202 Service tool output E error ON
M6403 Switched power relay error OFF T9203 Service tool output E error OFF
M6505 ECU power short to battery T9302 Service tool output F error ON
M6506 ECU power short to ground T9303 Service tool output F error OFF
M6507 ECU power open circuit
ACS (AHC) no communication to Bobcat
M6604 ECU no communication W3204
controller


W3223 ACS (AHC) calibration required W3257 ACS (AHC) lift actuator reduced performance
W3224 ACS (AHC) calibration performed W3258 ACS (AHC) tilt actuator reduced performance
W3225 ACS (AHC) actuator calibration failed W3259 ACS (AHC) lift actuator wrong direction
W3231 ACS (AHC) tilt actuator W3260 ACS (AHC) tilt actuator wrong direction
W3232 ACS (AHC) tilt actuator wiring W3261 ACS (AHC) handle lock short to ground
W3233 ACS (AHC) tilt handle wiring W3262 ACS (AHC) handle lock short to battery
W3234 ACS (AHC) tilt actuator not in neutral W3263 ACS (AHC) pedal lock short to ground
W3235 ACS (AHC) tilt handle / pedal not in neutral W3264 ACS (AHC) pedal lock short to battery
W3236 ACS (AHC) lift actuator W3265 ACS (AHC) sensor supply voltage out of range
W3237 ACS (AHC) lift actuator wiring W3266 ACS (AHC) battery voltage out of range
W3238 ACS (AHC) lift handle wiring W3267 ACS (AHC) switch flipped while operating
W3239 ACS (AHC) lift actuator not in neutral W3268 ACS (AHC) lift handle information error
W3240 ACS (AHC) lift handle / pedal not in neutral W3270 ACS (AHC) right drive handle short to ground
W3241 ACS (AHC) no communication W3271 ACS (AHC) right drive handle short to battery
W3249 ACS (AHC) lift actuator short to ground W3274 ACS (AHC) left joystick X-axis out of range
W3250 ACS (AHC) tilt actuator short to ground W3275 ACS (AHC) interrupted unswitched power
W3251 ACS (AHC) lift actuator short to battery W3276 ACS (AHC) CAN joystick information error
W3252 ACS (AHC) tilt actuator short to battery W3277 ACS (AHC) remote control information error

W3253 ACS (AHC) lift handle / pedal short to ground W3297 ACS (AHC) controller programmed
W3254 ACS (AHC) tilt handle / pedal short to ground W3905 Left joystick X-axis not in neutral
W3255 ACS (AHC) lift handle / pedal short to battery W4005 Right joystick X-axis not in neutral
W3256 ACS (AHC) tilt handle / pedal short to battery W4007 Right joystick Y-axis not in neutral

DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT) Figure 60-110-2
Viewing Trouble Codes 5 3

2
WARNING
1
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust 4 6
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
P107600
Connect the Diagmaster (Service Tool). (See Diagmaster

(Service Tool) on Page 10-70-1.) Select DTC (Item 1) to generate a list of any trouble
codes (Item 2) [Figure 60-110-2].
The Trouble Codes will aid in diagnosing conditions
which can damage the machine. Highlight a list item (Item 3) to see the DTC exclamation
(Item 4) [Figure 60-110-2] for the DTC.
Start the engine.

Highlight a list item with a ! (Item 5) and click the FF
Figure 60-110-1 icon (Item 6) [Figure 60-110-2].
Figure 60-110-3
1 1
2
P107602
Select start diagnosis (Item 1), select new diagnosis

(Item 2) or restart diagnosis (Item 3) [Figure 60-110-1] P107601
from the start menu.
A new window opens (Item 1) [Figure 60-110-3] with
additional freeze frame information. Information
contained here is a snapshot of the information at the
time the trouble code was generated.

DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT)
(CONTD)
Viewing Trouble Codes (Contd)
Figure 60-110-4
2
3
1 4
7
5 6
P107600
Select read DTC (Item 1) to read trouble codes [Figure

60-110-2].

Select successive read DTC (Item 2) to receive a
continuously generated DTC list [Figure 60-110-2].
Select freeze frame DTC (Item 3) to view freeze frame

information [Figure 60-110-2].
Select save data in CSV format (Item 4) to save data to a

csv file [Figure 60-110-2].
Select clear DTC (Item 5) clears DTC data [Figure 60-

110-2].
Select save DTC (Item 6) to save DTC to file [Figure 60-

110-2].
Select print DTC (Item 7) to print DTC list [Figure 60-

110-2].
Stop the engine.
Remove the diagmaster.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Figure 60-120-1
1 2 3
P-90668C
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

consists of the traction lock, seat bar sensor and the lift
and tilt lockout solenoids.
These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-120-1] of the loader cab.
The Press To Operate button (Item 4) [Figure 60-120-1]

activates the system and allows the operator to function
the loader.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Traction Lock And Parking Brake
(CONT'D) (Engine RUNNING)
See the SERVICE SCHEDULE for the correct service 6. Fasten seat belt, disengage parking brake, press the
interval. (See SERVICE SCHEDULE on Page 10-80-1.) PRESS TO OPERATE LOADER button, and raise
seat bar fully. Move left joystick slowly forward and
Inspecting The BICS (Engine STOPPED - Key ON) backward. The TRACTION lock must be engaged.
Lower the seat bar. Press the PRESS TO OPERATE
Figure 60-120-2 LOADER button.
1 7. Engage parking brake and move left joystick slowly

2 3
forward and backward. The TRACTION lock must be
engaged.
NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
4 engine is started, the PRESS TO OPERATE
LOADER button is pressed, and the parking
brake is disengaged.
5
Inspecting The Lift Arm Bypass Control
6 8. Raise the lift arms 2 m (6 ft) off the ground. Stop

P-85413E engine. Turn lift arm bypass control knob 90

clockwise. Pull up and hold lift arm bypass control
knob until lift arms slowly lower.
1. Sit in operators seat. Turn key switch to RUN. Lower
seat bar and disengage parking brake. Press the
Inspecting Deactivation Of Lift And Tilt Functions
PRESS TO OPERATE LOADER button (Item 6). Two
BICS lights (Items 1 and 2) [Figure 60-120-2]
9. Sit in operators seat and fasten seat belt. Lower seat
[SEAT BAR and LIFT AND TILT VALVE] on left
bar, start engine, and press the PRESS TO
instrument panel must be OFF. The PRESS TO
OPERATE LOADER button.
OPERATE LOADER button will light.
10. Raise lift arms about 2 m (6 ft) off the ground.
2. Raise seat bar fully. All three BICS lights (Items 1,
2, and 3) [Figure 60-120-2] [SEAT BAR, LIFT AND
11. Turn key switch to STOP and wait for the engine to
TILT VALVE, and PARKING BRAKE] on left
come to a complete stop.
instrument panel must be ON. The PRESS TO
OPERATE LOADER button light will turn OFF.
12. Turn key switch to RUN. Press the PRESS TO
OPERATE LOADER button, move the right joystick to
Inspecting Deactivation Of The Auxiliary Hydraulics
lower the lift arms. Lift arms must not lower.
System (Engine STOPPED - Key ON)
13. Move the right joystick to tilt the bucket (or
3. Sit in operators seat, lower seat bar, and press the
attachment) forward. The bucket (or attachment)
PRESS TO OPERATE LOADER button (Item 6).
must not tilt forward.
Press the Auxiliary Hydraulics button (Item 5). The
auxiliary hydraulics light will turn ON (Item 4) [Figure
60-120-2]. Raise the seat bar. The light will turn OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING) WARNING

4. Sit in operators seat, lower seat bar, engage parking AVOID INJURY OR DEATH
brake, and fasten seat belt. The Bobcat Interlock Control System (BICS) must
deactivate the lift, tilt and traction drive functions. If it
5. Start engine and operate at low idle. Press the does not, contact your dealer for service. DO NOT
PRESS TO OPERATE LOADER button. While raising modify the system.
the lift arms, raise the seat bar fully. The lift arms must W-2151-1111
stop. Repeat using the tilt function.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Check for codes. Refer to BATS for description
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.

4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.


SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS system
The seat bar sensor is part of the BICS system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
1. Check sensor wire connection.

2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-130-3
Testing
Figure 60-130-1
1
P-4698
If there is no power light (Item 1) [Figure 60-130-3] on

P-85653 the sensor tester, check the tester or wiring harness.
Figure 60-130-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:

Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-130-1].
Figure 60-130-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-130-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-130-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-130-2]
inline, to the seat bar sensor connectors. [Figure 60-130- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-130-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS) Circuit Test on Page 60-130-6.)
The toggle switch (Item 2) [Figure 60-130-3] can be in
either the Absent or Present position.

SEAT BAR SENSOR (CONT'D) NOTE: Approximately 4 turns of the clevis bolt
should be adequate to release the spring
Removal And Installation tension. When tension is released, the clevis
pin can easily be rotated using the retaining
NOTE: This procedure is performed with the seat bar pin.
in the raised position and the technician in the
operators seat. Figure 60-130-7
Figure 60-130-5
1
3
2 P100745
P100742
Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-130-7]. Remove the seat bar mounting bolt
Remove the sensor mounting bolt and nut (Item 1) and nut (Item 3) [Figure 60-130-7].
[Figure 60-130-5]. Disconnect the sensor wiring
connector (Item 2) [Figure 60-130-5].
Figure 60-130-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-130-6].


3
Figure 60-130-8
2
1
4
P100748
Install the new keyed bushing (Item 1), magnet bushing

P100746
(Item 2) and seat bar sensor (Item 3) [Figure 60-130-10].
Reinstall the metal pivot bushing (Item 4) [Figure 60-
Pull the front of the seat bar down slightly from the top of 130-10].
the cab, while raising the sensor end of the seat bar up,
away from the mount [Figure 60-130-8]. NOTE: The sensor must be centered on the metal
pivot bushing. When centered, the assembly

NOTE: The sensor end of the seat bar will raise easily will slide freely into the mount.
ONLY if the front of the seat bar is pulled
slightly down from the top of the cab. Figure 60-130-11
Figure 60-130-9
4 3
1
3
6 1
2
P100749
2
P100747
Position the clevis (Item 1) over the mount (Item 2) and
Place a soft jaw locking pliers (Item 1) [Figure 60-130-9] lower the end of the seat bar until the mounting bolt (Item
on the cab side screen to hold the seat bar above the 3) [Figure 60-130-11] is resting on the top of the mount.
mount.
Remove the nut from the mounting bolt. Remove the
Remove the clevis pin bushing (Item 2) [Figure 60-130- mounting bolt and lower the seat bar until the seat bar
9]. Apply grease to the shoulder of the bushing to help and mount holes align and the clevis is over the clevis pin
retain it during assembly. Reinstall the clevis pin bushing. bushing. Reinstall the seat bar mounting bolt. Apply
Loctite 243 to the nut threads. Install the nut and tighten
Remove and dispose of the keyed bushing (Item 3), to 46 Nm (34 ft-lb) torque.
magnet bushing (Item 4), and seat bar sensor (Item 5)
[Figure 60-130-9].
Remove and save the metal pivot bushing (Item 6)

[Figure 60-130-9].

SEAT BAR SENSOR (CONT'D)
Figure 60-130-12
1
2

P100751
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-130-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-130-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-130-5] and tighten to 6,8 Nm (60 in-lb)
torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS) inspection as described in the loader Operation
& Maintenance Manual.

Bobcat Interlock Control System (BICS) Circuit

Test
Figure 60-130-13
3
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-130-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor

adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-130-14] on the sensor tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-130-13].
NOTE: The sensor test light (Item 3) [Figure 60-130-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit

Test (Contd)
Figure 60-130-15
P-90668C
The BICS seat bar indicator light (Item 1) [Figure 60-

130-15] should turn OFF.
Figure 60-130-16
P-4699
Move the toggle switch (Item 1) [Figure 60-130-16] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-130-15] should

illuminate.
If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.


TRACTION LOCK
Description
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS).

TRACTION LOCK (CONT'D)
The following troubleshooting chart is provided for quick
reference in locating and correcting traction lock Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. See adjustments can cause injury or death.
BATS for detailed troubleshooting procedures if an error W-2004-1285
code is present.
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of brake. 2,3,5,6,7
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. Measure the resistance of the brake solenoid, the resistance should be approximately 9.8 ohms.
4. Test for voltage at the brake solenoid, should read battery voltage when the brake is disengaged.
5. Inspect wire connections for loose or disconnected connector body.

6. Inspect for loose or pushed back bent pins in connectors.
7. Check the left panel display for engine rpm, if no rpm check crankshaft sensor, camshaft sensor, wiring and
adjustment.

TRACTION LOCK (CONT'D)
Inspecting
Figure 60-140-1
P-85413
Sit in operators seat, lower the seat bar, engage the

parking brake and fasten seat belt.

Start the engine and operate at low idle. Disengage the
parking brake switch, press the PRESS TO OPERATE
LOADER button (Item 1) and raise the Seat Bar fully.
Move the steering levers slowly forward and backward.
The TRACTION lock must be engaged. Lower the Seat
Bar. Press the PRESS TO OPERATE LOADER button
(Item 1) [Figure 60-140-1].
Engage the parking brake switch and move the steering

levers slowly forward and backward. The TRACTION lock
must be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.


ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 4 5 11 13 14 15 16 17
9 10
18
6 7 19
12
B-19873A / NA5719 / B-19874A
REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL

Also: SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
3 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
5 ATTACHMENT FUNCTION CONTROL
6 SPEED MANAGEMENT
7 FRONT HORN
8 JOYSTICKS
9 FOOTRESTS
10 ENGINE SPEED CONTROL (FOOT OPERATED)
11 ENGINE SPEED CONTROL (HAND OPERATED)
12 LIFT ARM BYPASS CONTROL
13 ATTACHMENT FUNCTION CONTROL
14 NOT USED
15 FRONT AUXILIARY HYDRAULICS
16 NOT USED
17 TURN SIGNALS (Option)
18 FLOAT CONTROL
19 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONTD)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for

more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-160-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool The tools listed will be needed to do the following
procedure:
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start
Tool (Service Tool) Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
7003030 - Remote Start Tool (Service Tool)
NOTE: Make all connections with the key in the OFF 6689747 - Loader Service Tool Harness
position. 6689746 - Computer Service Tool Harness
6689745 - BOSS Service Tool Harness
Figure 60-160-1
NOTE: Make all connections with the key in the OFF
1 2 position.
Figure 60-160-2

2
P16119
3
The Service PC (Item 1) with the Remote Start Tool (Item 1
2)
P-76450
[Figure 60-160-1]. When connected to the loader, the

Service PC is used to monitor, conduct diagnostics, and The Service PC (Item 1) with the Remote Start Tool
upgrade software. (Service Tool) (Item 2) [Figure 60-160-2]. When
connected to the loader, the Service PC is used to
Connect the Service Tool Harness Communicator monitor, conduct diagnostics, and upgrade software.
(MEL1566) (Item 3) [Figure 60-160-1] to the designated
serial port on the Service PC. Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 60-160-2] to the
NOTE: The recommended serial cable length should designated serial port on the Service PC.
not exceed 4,6 m (15 ft). A serial cable longer
than 4,6 m (15 ft) will create a degraded signal NOTE: The recommended serial cable length should
causing communication errors. not exceed 4,6 m (15 ft). A serial cable longer
than 4,6 m (15 ft) will create a degraded signal
Connect the other end to the connector on the Remote causing communication errors.
Start Tool.
Connect the other end to the connector on the Remote
Connect the remote start tool to the loader. (See Start Tool (Service Tool).
REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.)
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7217666 on Page 10-61-1.)

SERVICE PC (LAPTOP COMPUTER) (CONTD) Connecting Remote Parked Regeneration Kit
Connecting Diagmaster (Service Tool) The tools listed will be needed to do the following
procedure:
NOTE: Do not connect to the service PC before
installing the communication software. Order from Bobcat Parts P/N: 7218446 - Remote Parked
Regeneration Kit.
procedure: Kit Includes:
Order from Bobcat Parts P/N: 7024161 - Diagmaster 6709527 - Start Key
(Service Tool) Kit. 6693245 - Start Switch
7218694 - DPF Regen Harness
Kit Includes: 7218424 - Switch Mount
Diagmaster (Service Tool) (DST-i)

7024272 - Vehicle Cable Figure 60-160-4
7024271 - USB Cable
Diagmaster Diagnostic Software
3
Figure 60-160-3

2
2 1
P107838
3
The Start Key (Item 1), Start Switch (Item 2) and DPF
P107543 Regen Harness (Item 3) [Figure 60-160-4], when used
with the Service PC (Item 1) [Figure 60-160-3] and the
Diagmaster software allow the Remote Parked
The Service PC (Item 1) with the Diagmaster (Service Regeneration Kit to start the loader for regeneration of
Tool) (Item 2) [Figure 60-160-3]. When connected to the the Diesel Particulate Filter (DPF). (See Connecting
loader, the Service PC is used to monitor, conduct Diagmaster (Service Tool) on Page 60-160-2.) and (See
diagnostics, and update information. Operation (Optional Remote Parked Regeneration Kit) on
Page 70-30-8.)
NOTE: Make all connections with the key in the OFF
position. Install the Remote Parked Regeneration Kit on the loader
per installation instructions included with the kit.
Connect USB cable (7024271) (Item 3) [Figure 60-160-
3] to the designated USB port on the Service PC. NOTE: Make all connections with the key in the OFF
position.
Connect the other end to the connector on the
Diagmaster (Service Tool) (DST-i). NOTE: Kit does not need to be permanently mounted
for service use.
Connect the diagmaster to the loader. (See Diagmaster
(Service Tool) on Page 10-70-1.)

CALIBRATION Actuator Testing
Description Figure 60-170-1
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in error codes, poor
performance or reduced life of actuator(s).
There are two methods to perform the lift and tilt

calibration, one is the Actuator Test and the other is
manually. The Actuator Test is performed with the
Service PC. The Actuator Test should be used if reduced
performance codes are present or when replacing a
controller or actuator.
CONTROL VALVE ACTUATORS
P-54336
The Lift and Tilt Calibration is performed by physically
moving the joysticks to provide set points to the ACS
controller to actuate the lift and tilt valve. The Lift and Tilt Excessive actuator loading can occur if the actuator and
Calibration should be used if reduced performance codes valve spool components are misaligned. Misalignment
are present or when replacing a controller or actuator. may reduce spool stroke performance and reduce the life
of the actuator [Figure 60-170-1].

NOTE: The Actuator Test should be used as the
preferred method of lift and tilt calibration. Connect the Service PC (See SERVICE PC (LAPTOP
COMPUTER) on Page 60-160-1.)
The Hydrostatic Pump Calibration provides set points to
the Drive controller to actuate the hydrostatic controller If a Service PC is not available. (See Lift And Tilt
that directs flow to a servo piston. Hydrostatic Pump Calibration on Page 60-170-4.)
Calibration should be performed when a desired travel
path cannot be attained or replacing the hydrostatic NOTE: Warm the hydraulic oil to room temperature
pump, hydrostatic motor, or controller. After Performing a 22C (72F), stop the engine and clear all
Hydrostatic Pump Calibration, Steering Drift active service codes before running the test.
Compensation can be used to fine tune the hydrostatic
pump control. Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
For more information on Steering Drift Compensation will be performed and the results can be viewed on the
(See STEERING DRIFT COMPENSATION on Page 60- Service PC monitor.
180-1.)
NOTE: The Actuator Test calibrates the lift and tilt

system therefore no further lift and tilt
calibration is required if using this method.

CALIBRATION (CONTD) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Contd) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-170-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
If the Actuator Test failed due to a slow return to neutral
Actuator did not fully extend / retract. During the test, after checking the probable causes in Column 1 [Figure
the spool was not able to fully stroke in both 60-170-2], check the following probable causes in
directions. Column 2 [Figure 60-170-2].
Actuator out of neutral. The spool did not return to the Contamination in the spool.
neutral window during the test.

The spool end cap may be loose, damaged or the
NOTE: A time out will occur if the test cannot be centering spring may be broken. Inspect the end cap
completed within 8 seconds. If this happens, and the centering spring, replace if necessary.
retry the test.
The wire harness or connectors may have an
Figure 60-170-2 intermittent short. Check the connections and wire
Run Actuator Test harnesses.
The controller may be malfunctioning, replace the

Pass Fail controller.
Retest With Warm Hydraulic Oil
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
Misaligned Assembly Actuator
Pin End Cap / Center Spring
Contamination in Spool Wire Harness
Controller
Contamination in Spool
If the initial Actuator Test results in a fail mode due to a

slow return to neutral, follow the troubleshooting tree to
pinpoint the probable cause [Figure 60-170-2].

CALIBRATION (CONTD)
Actuator Testing (Contd)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
The actuator may be weak, replace the actuator.

centering spring may be broken. Inspect the end cap
and the centering spring, replace if necessary.
Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.
The actuator may be weak, replace the actuator.

centering spring may be broken. Inspect the end cap
and the centering spring, replace if necessary.
Contamination in the spool.

CALIBRATION (CONTD) Figure 60-170-4
Lift And Tilt Calibration
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-170-1.)
NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-85958 P-85958
or tilt actuator. Failure to calibrate after
component replacement may result in error
codes, poor performance or reduced life of Move the right joystick to the forward-right corner position
actuator(s). [Figure 60-170-4] and hold in position.
The operator must be in the seat and the seat bar down.
Close the cab door. (If equipped.)

Figure 60-170-3
P106145
Place the loader Control Pattern Switch (Item 1) [Figure

60-170-3] in the skid-steer position.

Lift And Tilt Calibration (Contd)
Figure 60-170-5
P-85413C
P-85493A
At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the key switch to the RUN (Item 1) [Figure 60-170-7] while holding the right joystick
position [Figure 60-170-5]. in position.
NOTE: Do not start the engine. Release the joystick.

Figure 60-170-6 NOTE: During the calibration cycle, the system will
beep. Once the calibration is complete, code
W3224 (Calibration Successful) or W3225
(Calibration Failure) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P106145
The Control Pattern Switch (Item 1) [Figure 60-170-6]

will start flashing and will continue to flash until the
calibration procedure is completed.

Hydrostatic Pump Calibration
WARNING
W-2017-0286 P-85493A
NOTE: If the speed sensors are removed or

With the seat bar down, turn the key switch to the RUN
disconnected the drive calibration procedure
position [Figure 60-170-9].
must be performed.
NOTE: Do not start the engine.
NOTE: If swash plate sensors have been removed
and reinstalled, replaced or adjusted the drive
Figure 60-170-10
calibration procedure must be performed.

10-10-1.)
Operator must be in the seat and the seat bar down.
Close the cab door. (If equipped.)
Figure 60-170-8
P106145

will start flashing.
P106145
Place the loader Control Pattern Switch (Item 1) [Figure

60-170-8] in the skid-steer position.
Verify that the parking brake / switch is in the OFF

position.

CALIBRATION (CONT'D) Figure 60-170-13
Hydrostatic Pump Calibration (Cont'd)
Figure 60-170-11
B-19873
P-85960
B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-170-13] and hold in position.
Figure 60-170-14
Move the left joystick to the forward-left corner position
[Figure 60-170-11] and hold in position.

Figure 60-170-12
P-85413C
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-170-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-170-12] while holding the left joystick in
position.
Audible beeps will sound, release handle.

CALIBRATION (CONT'D) Figure 60-170-17
Hydrostatic Pump Calibration (Cont'd)
Figure 60-170-15
P106145

P-85961 will stop flashing, and will remain ON for the rest of the
calibration procedure.
Allow the left joystick to go to the neutral position [Figure Figure 60-170-18
60-170-15].

Figure 60-170-16
P107184
1
P-85413C Move the engine speed control (Item 1) [Figure 60-170-

18] to high idle.
Press the PRESS TO OPERATE LOADER Button (Item NOTE: If at any time during calibration the operator
1) [Figure 60-170-16]. needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
Audible beeps will sound. neutral position. The calibration procedure
will stop. To return to calibration mode, the
Start the engine from the RUN, position. DO NOT TURN operator must start the complete procedure
TO STOP POSITION. This would cancel the calibration from the beginning.
mode and the procedure would have to be repeated.

CALIBRATION (CONT'D) Continue to hold the left joystick in the forward position
until the loader wheels come to a stop and an audible
Hydrostatic Pump Calibration (Cont'd) beep is heard.
Forward calibration is complete.
WARNING NOTE: If the wheels do not stop moving in Full Speed

Forward in 2 minutes or less, there was an
error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
W-2017-0286
Figure 60-170-21
Figure 60-170-19

B-19873
P-85963
B-19873
P-85962 Move and hold the left joystick to the reverse position
[Figure 60-170-21] until the reverse calibration is
completed.
Move and hold the left joystick to the forward position
[Figure 60-170-19] until the forward calibration is
completed.
Figure 60-170-20
NA5744
The loader tires will momentarily reverse then rotate

forward and stair step the speed (Item 1) [Figure 60-
170-20] until it reaches full speed and then stair step
down and come to a stop.

CALIBRATION (CONT'D) Stop the engine, and remove the loader from jackstands.
Hydrostatic Pump Calibration (Cont'd) The calibration procedure is completed.
Figure 60-170-22 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-180-1.)
1
If loader does not maintain a desired travel path with
Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 60-10-2.)
NA5744
The loader tires or tracks will momentarily reverse then

continue to rotate in reverse and stair step the speed

(Item 1) [Figure 60-170-20] until it reaches full speed
and then stair step down and come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels come to a stop and an audible
beep is heard.
Reverse calibration is complete.
NOTE: If the wheels do not stop moving in Full Speed

Reverse in 2 minutes or less, there was an
error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 75-98 error code will clear. There should be no other
codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.
Press the PRESS TO OPERATE LOADER button. Move

the left joystick to forward position [Figure 60-170-19]
and check for normal forward wheel or track rotation.
Move the left joystick to the reverse position [Figure 60-

170-21] and check for normal reverse wheel or track
rotation.

STEERING DRIFT COMPENSATION Operation
Description NOTE: Changes CANNOT be performed until the seat

bar is lowered, the engine is started and the
Steering Drift Compensation can be used to reduce PRESS TO OPERATE LOADER button is
steering drift to maintain a desired travel path in both pressed to activate the BICS.
forward and reverse directions.
Perform pre-starting and starting procedures:
Examples of applications where this feature can be used:
1. Fasten seat belt.
To compensate for normal variations such as tire
inflation pressure, track tension, tire wear and track 2. Lower seat bar.
wear.
3. Place joysticks in neutral position.
Using side shift attachments such as trenchers,
planers and silt fence installers. 4. Start the engine.
Driving on uneven terrain such as crowned road 5. Press the PRESS TO OPERATE LOADER button.
surfaces.
6. Current drive response setting will be displayed briefly
Figure 60-180-1 in the data display.
Steering Drift Compensation NOTE: Raising the seat bar or changing control
mode (All-Wheel steer Mode / Skid-Steer

Mode) will cause the machine to disengage
from steering drift compensation. The last
displayed setting will remain in effect until the
machine is turned OFF.
NA3115
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-180-1].

STEERING DRIFT COMPENSATION (CONTD) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Contd) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-180-2 to appear in the data display (Item 2) [Figure 60-180-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-180-3
2
1
NA1011
3 4 5
P-76461L 2
P-76461N
1

P-76461M
NA1011
Left Joystick Right Joystick
3 4
P-76461K
P-76461O
6 7
P-24820C P-24802C Saving The Steering Drift Compensation Setting:
The current steering drift compensation setting can be

Press and hold the PRESS TO OPERATE LOADER
saved by pressing and holding the PRESS TO OPERATE
button (Item 1) for three seconds to enter the drive
LOADER button (Item 1) for three seconds. [SET] (Item
response adjustment menu. Press the PRESS TO
3) will appear in the data display (Item 2) [Figure 60-180-
OPERATE LOADER button (Item 1) again to adjust the
3] and the machine will exit from the steering drift
loaders steering drift compensation setting. The current
compensation adjustment menu.
steering drift compensation setting will appear in the data
display (Item 2) [Figure 60-180-2].
OR
Press the upper left button (Item 6) on the left joystick to
Press the PRESS TO OPERATE LOADER button to exit
adjust the machine left. [S-L01] (Item 3) through a
from the steering drift compensation adjustment menu
maximum of [S-L10] will appear in the data display (Item
without saving the current setting. [DONE] (Item 4) will
2) [Figure 60-180-2]. The number will increase by one
appear in the data display (Item 2) [Figure 60-180-3] and
each time you press the button. The higher the number,
the upper left and upper right buttons on the left joystick
the greater the amount of steering drift compensation to
will no longer make changes to steering drift
the left. Adjustments to steering drift compensation will
compensation.
be effective immediately.
NOTE: The last displayed steering drift
compensation setting will remain in effect
until the machine is turned OFF. The machine
will revert back to the last saved setting the
next time it is started.

CONTROL PANEL SETUP Vitals
Right Panel Setup (Deluxe Instrumentation Panel)
Icon Identification Press a scroll button (Item

Figure 60-190-1 Vitals screen icon (Inset)
is highlighted.
1 1
Displays select system

operating levels.
You can monitor real-time displays of:

Engine Speed
NA3189 Engine Oil Pressure
Engine Coolant Temperature
Fuel Consumption

System Voltage
ICON DESCRIPTION Hydraulic Charge Pressure
Hydraulic Fluid Temperature
DATE / TIME Operating Hours Since Last DPF Regeneration
USER / HOURMETER The Deluxe Instrumentation Panel is easy to use.

Continue to set your own preferences for operating /
CURRENT JOB HOURS monitoring your Bobcat loader.
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
HOME icon (Return to MAIN screen)
LEFT SCROLL button

RIGHT SCROLL button
ENTER button

CONTROL PANEL SETUP (CONTD)
Right Panel Setup (Deluxe Instrumentation Panel) (Contd)
Date And Time Languages
Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Display screen icon (Inset) Display screen icon (Inset)
is highlighted. is highlighted.
1 1 1 1
Select [2. LANGUAGES].
Select [1. CLOCKS].

Select the desired
Select [1. TIME].
language.
Use the keypad to enter

English / Metric Display
time.

Select AM / PM / 24hr.

Press [ENTER] to
continue.
Display screen icon (Inset)
is highlighted.
1 1
Select [2. DATE].
Select [4. DISPLAY

SETTINGS].

date.

Press [ENTER] to
continue.
Press [1] to cycle between
ENGLISH and METRIC.

CONTROL PANEL SETUP (CONTD) Job Clock Reset
Right Panel Setup (Deluxe Instrumentation Panel)

(Contd)
Auto Idle Time Delay 1) repeatedly until the
Security screen icon
(Inset) is highlighted.
1 1
Select [1. PASSWORDS/
1 1 LOCKOUTS].
Select [3. ENGINE

SETTINGS].
Enter owner password
and press [ENTER].

the desired delay time
between 4 and 250
seconds.
Select [1. USER
Press [ENTER] to save SETTINGS].
and continue. Press left
scroll button to exit without
saving.
Select user.
Select [3. RESET JOB

STATISTICS].
Press [9] to reset job

statistics.

Press left scroll button or
[0] to exit without saving.

CONTROL PANEL SETUP (CONTD)
Right Panel Setup (Deluxe Instrumentation Panel) (Contd)
Machine Lockouts Machine Performance
Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Security screen icon Security screen icon
(Inset) is highlighted. (Inset) is highlighted.
1 1
1 1
Select [2. MACHINE

Select [1. PASSWORDS/ PERFORMANCE].
LOCKOUTS].

and press [ENTER].
and press [ENTER].
Select [1. USER LOG-IN

INFO].

Select [2. USER JOB
STATISTICS].
Select [3. HIGH FLOW].
Select [3. OVERALL JOB
Select [4. TWO-SPEED]. STATISTICS].
USER LOG-IN INFO
HIGH FLOW Displays select log-in

information for all users.
Press user number to
cycle between LOCKED
and UNLOCKED.
USER JOB STATISTICS
Displays select job

TWO-SPEED statistics for all users.
Press user number to

cycle between LOCKED OVERALL STATISTICS
and UNLOCKED.
Displays select machine
job statistics.
NOTE: High Flow and Two-Speed lockouts for the Press [9] to reset machine
owner are active even if the Password job statistics.
Lockout feature is unlocked. Press left scroll button or
[0] to exit without saving.

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Password Setup is available on machines with a Deluxe

Instrumentation Panel. Press a scroll button (Item
Password Description Security screen icon
All new machines with a Deluxe Instrumentation Panel
1 1
arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start
the engine.
For security purposes, your dealer may change the Select [1. PASSWORDS/
password and also set it in the locked mode. Your dealer LOCKOUTS].
will provide you with the password.
Master Password:
A permanent, randomly selected password set at the

factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner Enter owner password
password is not known; or to change the owner and press [ENTER].
password.

Owner Password:
Allows for full use of the loader and to setup the

Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner Select [1. USER
or user passwords. Owner should change the SETTINGS].
password as soon as possible for security of the
loader.
User Password:
Allows starting and operating the loader; cannot

change password or any of the other setup features. Select [1. OWNER].
For the procedures to change passwords (See Changing

The Owner Password on Page 60-200-1.) and (See
Changing The User Passwords on Page 60-200-2.)
Select [2. CHANGE

PASSWORD].
Enter new owner

password and press
[ENTER].

You will be prompted to
reenter the new owner
password.

PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) (CONTD)
Changing The User Passwords Password Lockout Feature
This feature allows the owner to unlock the password

feature so that a password does not need to be used
Press a scroll button (Item every time the engine is started.
1 1 Press a scroll button (Item
Select [1. PASSWORDS/ 1 1

LOCKOUTS].
Select [1. PASSWORDS/

LOCKOUTS].

and press [ENTER].

and press [ENTER].
Select [1. USER

SETTINGS].
Select [2. MACHINE

LOCK].
Select user.
NOTE: The procedure above can be followed to reset

the machine lock so that the machine requires
a password to start the engine.
Select [2. CHANGE

PASSWORD].
Enter new user password

and press [ENTER].

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Turn the key switch to the RUN position to turn on the
factory which cannot be changed. This password is loaders electrical system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-201-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
Turn the key switch to the RUN position to turn on the

loaders electrical system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.

1 2
Figure 60-201-1
P-90805
Press the unlock key (Item 2) [Figure 60-201-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2
The loader can now be started without using a password.
P-90805 NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-201-1] keys for 2 seconds. Turn the key switch to the RUN position to turn on the
loaders electrical system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-201-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.


MAINTENANCE CLOCK This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
Description maintenance clock is reset.
The Maintenance Clock alerts the operator when the next Figure 60-210-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-210-1
2
1
NA3086 NA3198
During machine operation, a two beep alarm will sound The Deluxe Instrumentation Panel (if equipped) will
when there are less than 10 hours until the next planned display a bar (Item 1) [Figure 60-210-3] showing the time
maintenance. remaining until next service. This bar will turn red when

service is past due. NEXT MAINTENANCE DUE will
The remaining hours before maintenance is required will change to MAINTENANCE PAST DUE and display the
appear in the data display (Item 1) for 5 seconds while number of hours past due.
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-210-1] flash. Keys [4] and [9] can be used to adjust the service
interval when the owner is logged in [Figure 60-210-3].
NOTE: The display will show negative numbers after
counting down to zero.
The display will then revert back to the previous display

and will appear for 5 seconds every time the machine is
started until the maintenance clock is reset.
Figure 60-210-2
NA3195
The Deluxe Instrumentation Panel (if equipped) will

display a message (Item 1) [Figure 60-210-2] alerting
the operator to service the machine.

MAINTENANCE CLOCK (CONTD) Figure 60-210-6
Setup
Figure 60-210-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-210-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-210-4] to Figure 60-210-7
view the next analyzer screen.

Figure 60-210-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-210-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-210-5] the information is now stored.

Setup (Contd)
Figure 60-210-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-210-10] to scroll
P-76114 through the tabs.
Figure 60-210-11
A green COMPLETE (Item 1) [Figure 60-210-8]

message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-210-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-210-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-210-11] to

view the maintenance clock screen.
Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-210-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-210-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
210-11] to reset and set the maintenance clock.

Setup (Contd)
Figure 60-210-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-210-14] to

P-76111 view the maintenance clock.
Figure 60-210-15
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
display the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-210-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-210-13
After the maintenance clock has been activated, the next

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-210-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-210-13] to return to the

main menu.

MAINTENANCE CLOCK (CONTD)
Reset
Figure 60-210-16
NA3199
Press the information button (Item 2) [Figure 60-210-16]

until the display screen shows the maintenance clock.
Press and hold the information button (Item 2) for 7

seconds until [RESET] (Item 1) [Figure 60-210-16]
appears in the display screen.


BACK-UP ALARM SYSTEM Inspecting
Figure 60-220-1
1
1
P-90644
P-85645B
Inspect for damaged or missing back-up alarm decal
(Item 1) [Figure 60-220-2]. Replace if required.
The back-up alarm (Item 1) [Figure 60-220-1] is located
on the inside of the rear door. Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
A back-up alarm is not a substitute for looking to the the engine. Press the PRESS TO OPERATE LOADER

rear when operating the loader in reverse, or for button. Disengage the parking brake.
keeping bystanders away from the work area.
Operators must always look in the direction of travel, Move the left joystick into the reverse position. The back-
including reverse, and must also keep bystanders away up alarm must sound when all wheels are moving in
from the working area, even though the loader is reverse.
equipped with a back-up alarm.
The back-up alarm is located on the inside of the rear
Operators must be trained to always look in the direction door.
of travel, including when operating the loader in
reverse and to keep bystanders away from the work Figure 60-220-3
area. Other workers should be trained to always keep
away from the operators work area and travel path.
2
P100048
Inspect the back-up alarm electrical connections (Item 1)

and wire harness (Item 2) [Figure 60-220-3] for tightness
and damage. Repair or replace any damaged
components.
NOTE: See your dealer for service if your back-up

alarm does not sound.

BACK-UP ALARM SYSTEM (CONTD)
most common. Instructions are necessary before operating or
W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 4, 5

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Inspect the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONTD)
Alarm Removal And Installation
Figure 60-220-4
P100048

Remove the two nuts (Item 1) [Figure 60-220-4] and
remove the wire harness from the alarm.
Remove the two nuts (Item 2) [Figure 60-220-4].
Remove the alarm and bracket from the loader.


FRONT HORN Figure 60-230-2
Description
1
The front horn will sound when the operator presses the
front switch on the left lever.
The front horn is located on the inside of the cab in the

front lower left corner.
Inspecting 2
Figure 60-230-1
P-90901
Figure 60-230-3

P-93995
Inspect for damaged or missing parts [Figure 60-230-1]. 1 3

Replace if required.
P-90902
Depress the front button on the left lever and front horn
must sound.
Disconnect wire harness (Item 1) [Figure 60-230-2] and
Removal And Installation [Figure 60-230-3] from the front horn.
NOTE: Two different style horns are used. Remove the two bolts and nuts (Item 2) [Figure 60-230-
2] and [Figure 60-230-3].
Remove the left side lower panel. (See Removal And
Installation on Page 50-160-1.) Remove the front horn and bracket from the loader (Item
3) [Figure 60-230-3].

FRONT HORN (CONTD)
most common. Instructions are necessary before operating or
W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6


2. The front horn is damaged.
3. The front horn wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-10
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-22
Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-24
ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

DIESEL PARTICULATE FILTER (DPF) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

DPF Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
DPF Regeneration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
Operation (Standard Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6
Operation (Optional Inhibit Switch Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-7
Operation (Optional Remote Parked Regeneration Kit) . . . . . . . . . . . . . . . . . . . . . . 70-30-8
Remote Parked Regeneration (Level 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-8
DPF Service Regeneration (Level 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-10
DPF Cleaning (Level 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-13
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

ENGINE COOLING SYSTEM (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-2
Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Motor Assembly Removal And Installation (Early Models) . . . . . . . . 70-50-3
Fan Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Hydraulic Fan Motor Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . 70-50-4
Hydraulic Fan Disassembly And Assembly (Early Models) . . . . . . . . . . . . . . . . . . . . 70-50-5
Hydraulic Fan Motor Assembly Removal And Installation (Later Models) . . . . . . . . 70-50-7
Fan Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Hydraulic Fan Motor Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . 70-50-9
Hydraulic Fan Disassembly And Assembly (Later Models) . . . . . . . . . . . . . . . . . . . 70-50-10
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-15
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-15
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-16
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-16
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-17
ENGINE COOLING SYSTEM (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-1

Radiator/Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-3

Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-3
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-51-4
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-5
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-6
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-7
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-12
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-13
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-13
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-14
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-14
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Crankcase Ventilation Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Supply Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Supply Pump Difference Learning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Bypass Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Rail Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Supply Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Injector Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Intake Air Heater - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Intake Air Heater Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Valve Guide - Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Arm And Shaft - Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Valve Bridge Arm And Shaft - Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Push Rod Alignment - Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Bore - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8

Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Timing Gears Backlash - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-4
EGR Cooler Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-5
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-2

ENGINE INFORMATION
Description
Figure 70-10-1
P107467A
The loader has a Kubota direct injected V3800-CR-

TE4CB Interim Tier 4 turbo diesel engine with a

displacement of 3,8 L (230 in3). The engine is rated at an
SAE Gross 68,6 kW (92.0 hp) and has a crankcase
breather filter ventilation system [Figure 70-10-1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with an air intake heater and electronic timer with cold
start advance function for assisting in cold starts. Engine
block heaters are also available from Bobcat Parts.
To meet emission regulations it is also equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and

is located above the oil filter. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic /
hydrostatic fluid temperature sensor.

ENGINE INFORMATION (CONTD)
Specifications
Valve Springs
Free Length (Intake and Exhaust) 35,1 - 35,6 mm (1.39 - 1.40 in)
Allowable Limit 34,6 mm (1.36 in)
Fitted Length (Intake and Exhaust) 31,5 mm (1.24 in)
Setting Load / Setting Length (Intake and Exhaust) 63,5 N / 31,5 mm (14.3 lb / 1.24 in)
Allowable Limit 45,9 N / 31,5 mm (10.3 lb / 1.24 in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 mm (0.039 in)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 45 degrees B.B.D.C.
(Close) 17 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 15,973 - 15,984 mm (0.62886 - 0.62929 in)
I.D. of Rocker Arm Bushings 16,000 - 16,018 mm (0.62993 - 0.63062 in)
Oil Clearance Between Rocker Arm and Bushing 0,016 - 0,045 mm (0.00063 - 0.0017 in)

Camshaft
Journal O.D. 45,934 - 45,950 mm (1.8085 - 1.8090 in)
Bearing I.D. 46,0 - 46,025 mm (1.8111 - 1.8120 in)
Oil Clearance 0,050 - 0,091 mm (0.002 - 0.0035 in)
Alignment Allowable Limit 0,01 mm (0.0004 in)
Cam Lobe Height (Intake) 37,64 mm (1.482 in)
Allowable Limit (Intake) 37,14 mm (1.462 in)
Cam Lobe Height (Exhaust) 38,96 mm (1.534 in)
Allowable Limit (Exhaust) 38,46 mm (1.514 in)
Side Clearance Allowable Limit 0,30 mm (0.012 in)
Tappet
Oil Clearance Between Tappet and Guide 0,020 - 0,062 mm (0.0079 - 0.0024 in)
Tappet O.D. 23,959 - 23,980 mm (0.94327 - 0.94409 in)
Tappet Guide I.D. 24,000 - 24,021 mm (0.94489 - 0.94570 in)

Specifications (Contd)
Cylinder Bore
Cylinder Bore I.D. 100,000 - 100,022 mm (3.93701 - 3.93787 in)
Oversized Cylinder Bore I.D. 100,500 - 100,522 mm (3.95670 - 3.95755 in)
Piston Rings
Ring Gap (Top Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (2nd Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (Oil Ring) 0,25 - 0,45 mm (0.0099 - 0.017 in)
Side Clearance of Ring Groove:
Top Ring 0,05 - 0,09 mm (0.002 - 0.003 in)
Second Ring 0,0930 - 0,120 mm (0.00367 - 0.00472 in)

Oil Ring 0,020 - 0,060 mm (0.00079 - 0.0023 in)
Pistons
Piston Pin Bore 30,006 - 30,013 mm (1.1811 - 1.1816 in)
Connecting Rod
Piston Pin O.D. 30,006 - 30,011 mm (1.1814- 1.1815 in)
Small End Bushing I.D. 30,031 - 30,046 mm (1.1824 - 1.1829 in)
Oil Clearance Between Piston Pin and Small End Bushing 0,020 - 0,040 mm (0.00079 - 0.0015 in)
Connecting Rod Alignment Allowable Limit 0,05 mm (0.002 in)
Oil Pump
Oil Pressure Rated rpm 200 - 390 kPa (2 - 4 bar) (29 - 56 psi)
Allowable Limit 150 kPa (1,5 bar) (21 psi)
Idle Speed Allowable Limit 50 kPa (0,5 bar) (7 psi)
Clearance Between Inner Rotor and Outer Rotor 0,040 - 0,16 mm (0.0016 - 0.0062 in)
Clearance Between Outer Rotor and Pump Body 0,100 - 0,184 mm (0.00394 - 0.00724 in)
End Clearance Between Inner Rotor and Cover 0,025 - 0,075 mm (0.00099 - 0.0029 in)

Specifications (Contd)
Crankshaft
Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)
Oil Clearance Between Journal and Bearing 0,18 - 0,062 mm (0.00071 - 0.0024 in)
Limit Permitted 0,020 mm (0.0079 in)
Journal O.D. 74,977 - 74,990 mm (2.9519 - 2.9523 in)
Oil Clearance Between Crank Pin and Bearing 0,018 - 0,051 mm (0.00071 - 0.0020 in)
Crank Pin O.D. 52,977 - 52,990 mm (2.0857 - 2.0862 in)
Crank Pin I.D. (Blue) 56,010 - 56,020 mm (2.2052 - 2.2055 in)
Crank Pin I.D. (No Color) 56,000 - 56,010 mm (2.2048 - 2.2051 in)
Crankshaft Side Clearance 0,15 - 0,31 mm (0.0059 - 0.012 in)
Timing Gear
Timing Gear Backlash:
Crank Gear - Idle Gear 0,0490 - 0,193 mm (0.00193 - 0.00759 in)
Idle Gear - Cam Gear 0,0490 - 0,189 mm (0.00193 - 0.0074 in)

Idle Gear - Supply Pump Gear 0,0300 - 0,165 mm (0.00119 - 0.00649 in)
Oil Clearance Between Idle Gear Shaft and Idle Gear Bushing: 0,050 - 0,091 mm (0.0020 - 0.0035 in)
Idle Gear Bushing I.D. 45,025 - 45,050 mm (1.7727 - 1.7736 in)
Idle Gear Shaft O.D. 44,959 - 44,975 mm (1.7701 - 1.7706 in)
Idle Gear Side Clearance 0,15 - 0,30 mm (0.0059 - 0.011 in)
Thermostat
Valve Opening Temperature 74,5 - 78,5C (166.1 - 173.3F)
Valve Fully Open 90C (194F)

Sensor Location
Figure 70-10-2
1 3

7
8
10
9
P106596
Component location [Figure 70-10-2].
1. Intake Air Flow Sensor (MAP)
2. Intake Manifold Pressure Sensor
3. Intake Manifold Temperature Sensor
4. Intake Throttle Valve
5. EGR Valve
6. Fuel Rail Pressure Sensor
7. Fuel Rail Pressure Limiter
8. Fuel Temperature Sensor
9. Suction Control Valve (SCV)
10. Crankcase Ventilation Filter

Sensor Location (Contd)
4
2
P106598

4. EGR Cooler
3
Figure 70-10-5
5
P106597
1. Coolant Temperature Sensor
2. Camshaft Position Sensor (NE)
3. Crankshaft Position Sensor (G) P106601
5. Engine Control Unit (ECU)

Sensor Location (Contd)
P106599 P106600
Component location [Figure 70-10-6]. Component location [Figure 70-10-8].

6. Atmospheric Pressure Sensor (on backside of ECU) 9. Diesel Particulate Filter (DPF)
13 11 10
12
8
P107818A P107535
Component location [Figure 70-10-7]. Component location [Figure 70-10-9].
7. Water in Fuel Sensor 10. DOC Inlet Temperature Sensor (T0)
8. Electric Fuel Pump 11. DPF Inlet Temperature Sensor (T1)
12. DPF Outlet Temperature Sensor (T2)
13. Differential Pressure Sensor

Torque Values
Thread Size Material

(Dia. x Pitch)
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 Nm
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 Nm 8 - 12 Nm
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 Nm 15 - 22 Nm 24 - 34 Nm
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 Nm 30 - 41 Nm 49 - 68 Nm
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 Nm 54 - 73 Nm 94 - 118 Nm
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 Nm 79 - 108 Nm 157 - 186 Nm
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Engine malfunction light on. 3,4,5,6,7,9,10,11,12,14,15,16,18,20,23,24,27,28,29,30,31,32,33,35,36 38
Engine will not start. 2,3,4,5,6,7,8,12,13,15,16,18,19,20,22,24,25,27,28,29,30,31,34,35,36, 38
Difficult to start. 2,3,4,5,6,7,8,12,13,15,19,22,24,25,28,29,30,31,33,34,35,36,38
Idle failure. 1,2,3,4,5,6,7,8,12,13,15,28,29,34,35,36,38
Engine noise. 1,2,3,4,12,13,15,23,26,28,29,34,35,36,37,38
Too much fuel consumption. 1,2,3,4,5,6,7,8,12,13,15,21,23,26,28,29,34,35,36,37,38,39
No power for engine. 1,2,3,4,5,6,7,8,10,11,12,13,15,21,23,26,28,29,33,34,35,36,37,38,39
Black exhaust. 1,2,3,6,7,8,12,13,15,17,21,23,26,28,29,35,36,37,38,39
White exhaust. 1,2,3,4,5,6,7,8,11,12,13,15,17,21,23,24,26,28,29,35,36,38
Engine stalls on deceleration. 2,3,4,5,7,8,12,15,21,28,29,35,36,38
1. Supply pump learning failure. 21. Plugged air cleaner.
2. Incorrect grade of fuel. 22. Faulty starter relay.

3. Faulty fuel injectors. 23. Intake leak.
4. Faulty fuel supply pump. 24. Faulty intake air heater relay.
5. Plugged fuel filter. 25. Faulty intake air heater.
6. Faulty fuel rail pressure limiter. 26. Faulty turbocharger.
7. Plugged suction control valve (SCV). 27. Crankshaft position sensor no signal.
8. SCV leak. 28. Faulty crankshaft position sensor pulsar gear.
9. Cooling system failure (radiator, hoses, etc). 29. Crankshaft position sensor air gap too large.
10. Intake manifold pressure sensor no signal. 30. Camshaft position sensor no signal.
11. intake manifold pressure sensor false signal). 31. Faulty camshaft position sensor pulsar gear.
12. Fuel rail pressure sensor no signal. 32. Camshaft position sensor air gap too large.
13. Fuel rail pressure sensor false signal. 33. Coolant temperature sensor no signal.
14. Fuel temperature sensor no signal. 34. Coolant temperature sensor false signal.
15. Faulty SCV. 35. Low compression pressure.
16. Faulty main relay. 36. Engine internal fault.
17. Faulty EGR valve. 37. Valve clearance fault.
18. Battery not charging. 38. Valve timing fault.
19. Battery not discharging. 39. Low engine oil viscosity.
20. Faulty charging system.

ENGINE INFORMATION (CONTD) Figure 70-10-10
Engine Removal And Installation 1
DANGER 3
P106390
P-90328
AVOID DEATH Remove the engine ground cable (Item 1) and chassis
Disconnecting or loosening any hydraulic ground cable (Item 2) [Figure 70-10-10].
can cause lift arms to drop. Remove the positive cable (Item 3) [Figure 70-10-10]
Keep out of this area when lift arms are raised from the starter.

Figure 70-10-11
D-1009-0409
WARNING
2
support device. Failure to use an approved lift arm 1
to fall and cause injury or death. 4
W-2059-0598
Raise the lift arms and install an approved lift arm P106392
Raise the operator cab. (See Raising on Page 10-30-2.) Slide the red lock (Item 1) down, press in on the tab (Item
2) and disconnect the harness (Item 3) [Figure 70-10-11]
from the engine harness.
Remove the battery from the loader. (See Removal And Disconnect the harness (Item 4) [Figure 70-10-11] from
Installation on Page 60-20-1.) the engine harness.
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-100-4.)
NOTE: If compressor is being removed for engine
removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor.

ENGINE INFORMATION (CONTD) Remove the bolt, nut and clamp (Item 2) [Figure 70-10-
13] from the cover.
Engine Removal And Installation (Cont'd)
Figure 70-10-14
Figure 70-10-12
1
2
1
2
P106580
P106394

Open the cover (Item 1) and remove the engine positive the bottom of the filter.
cable (Item 2) [Figure 70-10-12].


explosion or fire.
W-2103-0508
Figure 70-10-13
P106400
1 2
Disconnect the fuel return line (Item 1) [Figure 70-10-
15]. Install cap and plug.
P106398
Remove fuel line (Item 1) [Figure 70-10-13] from the

filter. Install cap and plug.

Figure 70-10-16
2 1
3
1
P106403
1
Remove the hose / clamp (Item 1) [Figure 70-10-18]
P106566 from the radiator.
Figure 70-10-19
Remove the two tie straps (Item 1) [Figure 70-10-16] and
lower the harness.

Remove the two bolts (Item 2) and bracket (Item 3) 1
[Figure 70-10-16].
Figure 70-10-17
2
1
1
P106568
Remove the bolt / nut (Item 1) and clamp (Item 2) [Figure

2 70-10-19] from the hose.
P106567
Remove the two bolts / nuts (Item 1) and lower the

solenoid / bracket (Item 2) [Figure 70-10-17].

Figure 70-10-20 1
P106407

P106405 from the thermostat housing.
Figure 70-10-23
from the engine.

Figure 70-10-21
1 2
P107402
Disconnect the coolant temperature connector (Item 1)

P106406 [Figure 70-10-23].
Disconnect the heater hoses (Item 2) [Figure 70-10-23]

Remove the hose / clamp (Item 1) [Figure 70-10-21] (if equipped).
from the radiator.

Figure 70-10-24
1
2
P106569
Loosen the clamp (Item 1) and remove the air hose

P106408 assembly (Item 2) [Figure 70-10-26].
Figure 70-10-27
Remove the harness connector (Item 1) from the mass
air flow sensor (MAF) (Item 2) [Figure 70-10-24].
1

NOTE: The position of the mass air flow sensor is
critical for emission certification. Mark the
location of the sensor to the hoses before
removing.
2
If the sensor location was not marked, the
sensor must be located as follows: The
mounting is determined from ground level
view, rotating sensor 45 degrees from TDC on 1
the intake pipe towards the engine plus or
minus 15 degrees.
P106571
Figure 70-10-25
Locate the two connectors (Item 1) and engine control

unit (Item 2) [Figure 70-10-27].
NOTE: The connectors / ECU must be thoroughly

1 cleaned. DO NOT USE PRESSURIZED
WATER. Use compressed air and small brush.
Remove the connectors. (See Removal And Installation

on Page 60-80-3.)
2
P1064
11
Loosen the clamp (Item 1) remove the nut, bolt and

clamp (Item 2) [Figure 70-10-25].

Figure 70-10-28
3
2
1 P106420
P106573
Remove the fuel hose / clamp (Item 1) [Figure 70-10-30]

from the filler neck.
P106417
Figure 70-10-31
Slide the red lock (Item 1) forward and press the tab (Item
2) down, to release the lever (Item 3) [Figure 70-10-28].

1
Figure 70-10-29
P107421

P106573
Rotate the lever (Item 1) [Figure 70-10-29] up and

forward, remove the connector from the ECU by pulling
straight up on the connector.
Repeat above procedure on remaining connector.

Figure 70-10-32
1 2
P100729
Remove the inlet hose (Item 1) [Figure 70-10-33] from

P106422 the fan.
Remove the outlet hose (Item 2) [Figure 70-10-33] from

Remove the clamp / hose (Item 1) [Figure 70-10-32] the fan.
from the tank.

Figure 70-10-34
IMPORTANT 1

damage the system.
I-2003-0888
P106449
Remove the lower fan duct. (See Lower Fan Duct
bracket. (both sides)

Figure 70-10-35
1
1 P10649
Remove the inlet hose (Item 1) [Figure 70-10-37] from

P100319 the bottom of the hydraulic control valve.
Figure 70-10-38
Mark the location of the four hoses (Item 1) [Figure 70-
10-35] and disconnect.

NOTE: The fittings on the hydrostatic pump must be
tightened to 190 - 216 Nm (140 - 160 ft-lb)
torque. Tighten the hoses to 127 - 138 Nm (94
- 102 ft-lb) torque. 1
Remove the case drain hose (Item 2) [Figure 70-10-35]

from the pump.
Figure 70-10-36
P106432
1
1 Remove the rear engine mounting bolt (Item 1) [Figure
70-10-38].
Installation: Tighten the bolt to 122 -135 Nm (90 - 100

ft-lb) torque.
P106428
Remove both suction hoses (Item 1) [Figure 70-10-36]

from the pump.
Remove the charge pump inlet hose (Item 2) [Figure 70-

10-36].

Figure 70-10-39
1 1
P106437
Disconnect the four connectors (Item 1) [Figure 70-10-

P106433 41].
Figure 70-10-42
Remove the engine mounting bolt (Item 1) [Figure 70-
10-39] from the left side of the engine.

Installation: Tighten the bolt to 122 - 135 Nm (90 - 100
ft-lb) torque.
Figure 70-10-40
1
1
1
P106438
Remove the three bolts (Item 1) [Figure 70-10-42] and

reposition the bracket.
P106435
Remove the engine mounting bolt (Item 1) [Figure 70-

10-40] from the right side of the engine.
Installation: Tighten the bolt to 122 - 135 Nm (90 - 100

ft-lb) torque.

Figure 70-10-43
3
2 1
1
P106473
1 Remove the bolt (Item 1) and clamp (Item 2) [Figure 70-

P106463 10-45]. Reposition the fuel cooler lines.
Installation: Make sure the drain hose (Item 3) [Figure

Remove the two bolts (Item 1) and reposition the harness 70-10-45] is installed (as shown).
/ bracket assembly (Item 2) [Figure 70-10-43] to allow

placement of engine removal tool.
Figure 70-10-44
P106464
Remove the tie strap (Item 1) [Figure 70-10-44] from the

fuel cooler lines.

Figure 70-10-46
P100332
Use the engine removal tool (MEL1653-1) [Figure 70-10-

46] and the attachment (MEL1653-6) [Figure 70-10-47]
and (MEL1653-8) [Figure 70-10-48] to aid in the removal
and installation of the engine.

P-76872
Figure 70-10-47
P109575

Figure 70-10-49
1 3 2
2 P106478
Install the engine removal tool (Item 1) into the

P106471 attachment (Item 2) and install the pin (Item 3) [Figure
70-10-51].
Figure 70-10-50 Figure 70-10-52

2
P106469
Install the engine removal bracket (Item 1) on the engine

using the two bolts (Item 2) [Figure 70-10-49] and
[Figure 70-10-50].
Tighten the two bolts and nuts that hold the engine
removal bracket into the engine.
P106477
Connect a chain hoist to the first hole (Item 1) on the

engine removal tool (Item 2) [Figure 70-10-52].
Remove the engine / hydrostatic pump assembly from

the loader.

Engine Mount Replacement Washer

Engine
Figure 70-10-53 Mounting
Bracket
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-54].
Tighten the mounting bolts to 122 - 135 Nm (90 - 100 ft-

Use the following procedure to install new rear engine lb) torque.
mount:

Figure 70-10-55
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 1
locations. 4
Replace all three engine mounts one rear and two sides.
5 2
Use the parts shown to install the new engine mounts
[Figure 70-10-53]: 6 3
Hex Nut - (Item 1) 7
Washer - (Item 2)
Cup Washer - (Item 3)

P-85990A
Engine Mount - (Item 4)
Tube Spacer - (Item 5) Use the parts shown to install the new side engine
mounts [Figure 70-10-55].
Mounting Bolt - (Item 1)
Mounting Bolt - (Item 8)
Tube Spacer - (Item 4)
Retaining Nut - (Item 7)

Engine Mount Replacement (Contd)
Figure 70-10-56
Washer
Engine
Mounting
Bracket
Engine
Mount
Snubbing
Washer
Spacer
Loader
Frame P-85987
Install the new engine mount as shown in the cut away

side view [Figure 70-10-56].

Tighten the mounting bolts to 122 - 135 Nm (90 - 100 ft-
lb) torque.

Compression - Testing
Use the following dimensions for the injector nozzle adapter tool [Figure 70-10-57] or order MELxxxx from Bobcat parts.
Figure 70-10-57

P107812
A 16,14 - 16,20 mm dia. (0.6355 - 0.6377 in dia.) W 65 mm (2.6 in)

B 29,80 - 30,00 mm dia. (1.174 - 1.181 in dia.) X 102,5 mm (4.035 in)
C 41 mm (1.6 in) Y 112 mm (4.41 in)
D 11 mm (0.43 in) Z 112,6 mm (4.433 in)
E 0.271 rad (15.5) a 20,3 - 20,5 mm (0.800 - 0.807 in)
F 20,5 - 21,0 mm (0.807 - 0.826 in) b 120,7 - 121,3 mm (4.752 - 4.775 in)
G 5,0 mm (0.20 in) c 5,0 mm (0.20 in)
H 2.09 rad (120) d 146 mm (5.75 in)
I 3,0 mm (0.12 in) e 28,5 mm (1.12 in)
J 13,000 - 13,011 mm (0.51182 - 0.51224 in) f 11 mm (0.43 in)
K 44 mm (1.7 in) g 12,9835 - 13,0055 mm (0.511162 - 0.512027 in)
L 112,6 mm (4.433 in) h 5/8-18UNF-2B
M 19,84 - 19,95 mm (0.7811 - 0.7854 in) i 3,0 mm dia. (0.12 in dia.) through hole
N 16,14 - 16,20 mm (0.6355 - 0.6377 in) j 0.271 rad (15.5)
O 19,06 - 19,20 mm (0.7504 - 0.7559 in) k 3,0 mm dia., 134,5 - 135,5 mm depth
(0.12 in dia., 5.296 - 5.334 in depth)
P 16,89 - 17,00 mm (0.6650 - 0.6692 in) l 11 mm (0.43 in)
Q 7,10 - 7,20 mm (0.280 - 0.283 in) m 0,8 mm radius (0.03 in radius)
R 16 mm dia. (0.63 in dia.) n 0.4 mm radius (0.02 in radius)
S 18 mm (0.71 in) o Ra = 1.6a
T 48,6 mm (1.91 in) p Ra = 3.2a
U 3,20 - 3,45 mm (0.126 - 0.135 in) CO.5 Chamfer 0,5 mm (0.02 in)
V 53,6 mm (2.11 in) C1 Chamfer 1,0 mm (0.039 in)

Compression - Testing (Contd)

1
Figure 70-10-58
P100685
Figure 70-10-60
P107400
1
After warming up the engine, stop the engine and remove
the fuel injectors. (See Fuel Injector Removal And

NOTE: Keep the injectors in the same order as 2
removed. If the injectors get out of order, it is
necessary to perform injector correction
(writing the injector ID codes to the ECU).
Install a compression tester and nozzle adapter

(MEL1725) for diesel engines into the nozzle holder hole
P100352
(Item 1) [Figure 70-10-58].
Engage the starter 7 - 10 seconds until a maximum
compression reading is obtained.
Repeat this procedure multiple times per cylinder until a

average compression reading is recorded.
If the measurement is below the allowable limit, apply a
small amount of oil to the cylinder wall through the nozzle
hole and measure the compression pressure again.
If the compression pressure increase after applying oil.
check the cylinder wall and piston rings.
If the compression pressure is still less than the allowable
limit, check the top clearance, valve and cylinder head.
NOTE: Check the compression pressure with the
specified valve clearance.
Always use a fully charged battery for
performing this test.
Variances in cylinder compression values
should be under 10%.

Compression - Testing (Contd)
Compres- Factory spec. 3089 - 3282 kPa /

sion pressure 200 rpm (30,9 - 32,8
bar / 200 rpm)
(448 - 476 psi / 200
rpm)
Allowable limit 2413 kPa / 200 rpm
(24,1 bar / 200 rpm)
(350 psi / 200 rpm)
Tightening Injector clamp nut 24 - 27 Nm

Torque (18 - 20 ft-lb)
Overflow pipe 9,8 - 11,2 Nm
assembly retain- (7.24 - 8.31 ft-lb)
ing bolt
Intermediate head 6,9 - 11,2 Nm
cover bolt (5.1 - 8.31 ft-lb)
Upper head cover 9,8 - 11,2 Nm
bolt (7.2 - 8.31 ft-lb)

Injection pipe 23 - 36 Nm
retaining nut (17 - 26 ft-lb)

ENGINE SPEED CONTROL (HAND) Figure 70-20-3
Figure 70-20-1 1
1
2
1 P107696
Remove the fastener (Item 1) and the two screws (Item 2)

P107184 [Figure 70-20-3] from the right side switch panel.
Figure 70-20-4
Remove the knob (Item 1) [Figure 70-20-1] from the
engine speed control.

Figure 70-20-2
1
P107697
Carefully remove the speed control decal (Item 1)

P107695 [Figure 70-20-4].
Remove the fastener (Item 1) and the screw (Item 2)

[Figure 70-20-2] from the right switch panel.

ENGINE SPEED CONTROL (HAND) (CONTD)
Figure 70-20-5
P107706
Remove the two screws (Item 1) [Figure 70-20-5].

Figure 70-20-6
P107475
Disconnect the electrical connector (Item 1) and remove

the engine speed control (Item 2) [Figure 70-20-6].

ENGINE SPEED CONTROL (FOOT) Figure 70-21-3

1 1
Figure 70-21-1
2 P106591
Remove the four bolts (Item 1) [Figure 70-21-3].
Tilt the assembly towards the center of the loader.

P106589
Figure 70-21-4

Remove the two nuts (Item 1) [Figure 70-21-1] from the
right side foot rest (Item 2) [Figure 70-21-1].
2
Remove the foot rest from the loader.
Figure 70-21-2
1
P107707
2
1
Disconnect the wire harness (Item 1) from the engine
speed control (Item 2) [Figure 70-21-4].
Remove panel assembly from the loader.

P106590
Loosen the bolt (Item 1) and remove the engine speed

control foot pedal (Item 2) [Figure 70-21-2].
NOTE: Mark the speed control foot pedal prior to

removal to aid in assembly.

ENGINE SPEED CONTROL (FOOT) (CONT'D) Figure 70-21-7
Figure 70-21-5
P107710
The pivot assemblies shown disassembled [Figure 70-

P-90755A 21-7].
NOTE: No lubrication is necessary or recommended

Remove the two bolts (Item 1) and the snap ring (Item 2) on the engine speed control.
[Figure 70-21-5] from the engine speed control

assembly. Figure 70-21-8
Figure 70-21-6
P107711
P107709
The engine speed control foot pedal pivot assembly
shown disassembled, [Figure 70-21-8] replace worn
Remove pivot bolt, nut (Item 1) and the spring (Item 2) parts as needed.
[Figure 70-21-6].
NOTE: No lubrication is necessary or recommended
on the engine speed control.

ENGINE SPEED CONTROL (FOOT) (CONT'D)
Figure 70-21-9
P107712
Remove the two screws (Item 1) and the engine speed

control (Item 2) [Figure 70-21-9].

Figure 70-21-10
P107713
The engine speed control [Figure 70-21-10] shown

disassembled.
Align the tab (Item 1) with the slot (Item 2) [Figure 70-21-
10] during reassembly.


DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
The engine exhaust system is equipped with a diesel

particulate filter (DPF). The DPF is an emissions
reduction device that removes diesel particulate matter
(soot) from the exhaust gases of the diesel engine. The
DPF will trap and collect the soot until it is burned off. The
process of burning off the collected soot is called
regeneration.
Ash residue will remain after the regeneration process is

complete. The ash must be periodically removed from the
DPF. (See DPF Cleaning (Level 5) on Page 70-30-13.)
The DPF muffler full assembly serial number is located

on the side of the DPF and on the differential pressure
sensor.

DIESEL PARTICULATE FILTER (DPF) SYSTEM NOTE: Use care during removal and installation
(CONTD) since the DPF cannot be reused if dropped or
given a shock, even if there is no outward
Removal And Installation damage, replace with a new one.
Before removing the DPF, connect the

diagnostic tool (Diagmaster), check the failure
WARNING history and save the project. (See
DIAGMASTER (SERVICE TOOL) KIT - 7024161
on Page 10-70-1.)
HOT SURFACES CAN CAUSE SERIOUS INJURY
Do not touch. Figure 70-30-2
Allow to cool before servicing.
W-2533-1012
WARNING
support device. Failure to use an approved lift arm 1

W-2059-0598
P106436

support device. (See Installing on Page 10-20-1.) Mark the location of the four sensor connectors (Item 1)
[Figure 70-30-2] and disconnect.
Figure 70-30-3
Open the rear door.
Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)
2
Figure 70-30-1
1
1
1
2
2
1 1
1
P106438
Remove the three bolts (Item 1) from the mounting

brackets (Item 2) [Figure 70-30-3].
P106402 Position the mounting brackets / harness connectors on

top of the DPF canister.
Remove the four bolts (Item 1) and remove engine cover

(Item 2) [Figure 70-30-1].

DIESEL PARTICULATE FILTER (DPF) SYSTEM Figure 70-30-6
(CONTD)
Figure 70-30-4
1
1
1
P106558

bracket.
P107748
Figure 70-30-7
Remove the four nuts (Item 1) from the turbo (Item 2)

[Figure 70-30-4].

Installation: Tighten the retaining nuts to 49 - 55 Nm
Installation: When reassembling replace with new

gaskets.
Figure 70-30-5
1
1
P106539

bracket.
P100729
NOTE: It may be necessary to remove the shield (Item

1) [Figure 70-30-5] from under the cab to allow
access to one of the flange nuts (Item 1)
[Figure 70-30-4].

(CONTD)
Removal And Installation (Contd) 1
Figure 70-30-8
3
P106461
1
Remove the DPF assembly (Item 1) [Figure 70-30-10].
P106460 The DPF muffler full assembly serial number is located

on the side of the DPF (Item 2) and on the differential
pressure sensor (Item 3) [Figure 70-30-10].
Position the DPF to the side and remove the three bolts
(Item 1) [Figure 70-30-8] from the bracket.

Figure 70-30-9
P106439
Remove the bracket (Item 1) [Figure 70-30-9].

DIESEL PARTICULATE FILTER (DPF) SYSTEM Active Regeneration - The engine control unit (ECU)
(CONTD) automatically controls active regeneration. Active
regeneration can occur anytime the engine is operating.
DPF Regeneration
Service Regeneration - Remote parked regeneration
There are three types of regeneration, passive, active (optional) or dealers use specialized equipment to
and service. perform a service regeneration.
Passive Regeneration - The engine provides adequate Optional kits are available to inhibit regeneration and to
exhaust temperature during operation for regeneration. perform a remote parked regeneration. (See Operation
(Optional Inhibit Switch Kit) on Page 70-30-7.) and (See
Operation (Optional Remote Parked Regeneration Kit) on
Page 70-30-8.)
DPF Regeneration Table
DERATE
ACTIVE GENERAL
SERVICE ENGINE DISPLAY OVERRIDE DPF / DEF
LEVEL REGENERATION ALARM WARNING
CODE DERATE SCREEN SWITCH ICON
STATUS ICON
LIGHT

0 None None Not Required
1 M8541 None Regenerating One Beep REGEN On
2 M8542 25% Regenerating Two Beeps REGEN Flashing
3 M8553 25% Not Regenerating Two Beeps M8553 On Flashing
4 M8554 50% Not Regenerating Two Beeps M8554 Flashing Flashing
5 M8555 50% Not Regenerating Two Beeps M8555 Off Flashing Flashing
NOTE: The data display, DEF icon, and general warning icon are located on the left panel. (See Left Panel on Page
60-50-1.) Two different DPF switches can be installed. (See Operation (Standard Switch) on Page 70-30-
6.) or (See Operation (Optional Inhibit Switch Kit) on Page 70-30-7.)
Level 0 - Passive Regeneration.
Level 1 - Active Regeneration. (See Operation (Standard Switch) on Page 70-30-6.) or (See Operation (Optional
Inhibit Switch Kit) on Page 70-30-7.)
Level 2 - Active Regeneration. (See Operation (Standard Switch) on Page 70-30-6.) or (See Operation (Optional
Inhibit Switch Kit) on Page 70-30-7.)
Level 3 - Service Regeneration. (See Operation (Optional Remote Parked Regeneration Kit) on Page 70-30-8.) or
(See Remote Parked Regeneration (Level 3) on Page 70-30-8.)
Level 4 - Service Regeneration. (See DPF Service Regeneration (Level 4) on Page 70-30-10.)
Level 5 - DPF Cleaning Required. (See DPF Cleaning (Level 5) on Page 70-30-13.)

DIESEL PARTICULATE FILTER (DPF) SYSTEM If level 2 is reached during operation (See DPF
(CONTD) Regeneration Table on Page 70-30-5.), the light will start
flashing and the engine will derate to 25 percent.
Operation (Standard Switch) Pressing the top switch (Item 1) [Figure 70-30-12] will
override the engine derate and cause the light to stop
There is no indication of passive regeneration. flashing and remain on. The switch will return to the
normal position when the regeneration cycle has
Figure 70-30-11 finished.
NOTE: The machine should be operated under load

when the engine derate is overridden. The
engine derate switch light (Item 1) [Figure 70-
30-12] will flash every 10 minutes if the load is
not sufficient. It is recommended to continue
operating the machine until the regeneration
cycle is complete.
P107183

The DPF switch (Item 1) [Figure 70-30-11] is located
above the engine speed control in the right switch panel.
Figure 70-30-12
P107237
The DPF will regenerate automatically as needed. The

top of the switch (Item 1) [Figure 70-30-12] will light
while the DPF is regenerating.
NOTE: The regeneration process can last for 40

minutes or longer.

DIESEL PARTICULATE FILTER (DPF) SYSTEM If level 2 is reached during operation (See DPF
(CONTD) Regeneration Table on Page 70-30-5.), the light will start
flashing and the engine will derate to 75 percent.
Operation (Optional Inhibit Switch Kit) Pressing the top of the switch (Item 1) [Figure 70-30-14]
will clear the engine derate and cause the light to stop
There is no indication of passive regeneration. flashing and remain on. The switch will return to the
center position when released. The light will turn off when
Figure 70-30-13 the regeneration cycle has finished.
NOTE: It is recommended to operate the machine

under load during this regeneration level. Do
not stop the engine during regeneration.
Stopping DPF regeneration can damage the
DPF.
Press the bottom of the switch (Item 3) [Figure 70-30-14]

to prevent the DPF from automatically regenerating. The
switch will return to the center position when released.
1 The bottom of the switch will light while the DPF is
prevented from regenerating.
NOTE: The DPF will be prevented from regenerating

P107183B until the machine is turned OFF. The machine
will revert to automatic DPF regeneration the

next time the machine is turned ON.
The DPF switch (Item 1) [Figure 70-30-13] is located
above the engine speed control in the right switch panel.
Pressing and holding the bottom of the switch (Item 3)
[Figure 70-30-14] for 4 seconds will prevent the DPF
Figure 70-30-14
from automatically regenerating even if the machine is
turned OFF and back ON. The switch will return to the
center position when released. The bottom of the switch
will light while the DPF is prevented from regenerating.
Press the top of the switch to return the regeneration
1 process to automatic.
2
NOTE: Preventing the DPF from regenerating for an
3 extended period of time may result in the DPF
reaching a level 3, 4, or 5. (See DPF Regeneration
Table on Page 70-30-5.) Service may be required by
your dealer.
P107237A
This DPF switch has three positions:
The center position (Item 2) [Figure 70-30-14] is used for

normal operation. The DPF will regenerate automatically
as needed. The top switch will light while the DPF is
regenerating.
NOTE: The regeneration process can last for 40

minutes or longer. Do not stop the engine
during regeneration.

DIESEL PARTICULATE FILTER (DPF) SYSTEM Remote Parked Regeneration (Level 3)
(CONTD)
NOTE: Parked regeneration is possible with the
Operation (Optional Remote Parked Regeneration optional remote parked regeneration kit.
Kit)
Figure 70-30-16
A remote parked regeneration cycle may be required if
too much soot is allow to accumulate in the DPF. This can
occur in the following situations: 2
1
The loader is often operated for brief periods (less
than 30 minutes) that do not allow sufficient time for
the DPF to complete an automatic regeneration cycle. 4
The DPF switch is left in the inhibit position for an

3
extended period of time. This will prevent the DPF
from automatically regenerating and burning off the
collected soot.
NA3298
Figure 70-30-15
The requirement for a remote parked regeneration is
indicated by service code. The DPF / DEF icon (Item 2)
and the service indicator (Item 3) will FLASH. Press the
Information button (Item 4) until the display screen shows

the service codes. Service code [M8553] (DPF Remote
Parked Regeneration Required) will show in the display
screen (Item 1) [Figure 70-30-16] when remote parked
1 regeneration is necessary.
NOTE: Failure to perform a remote parked

regeneration when required can result in the
engine becoming further derated. Continued
loader operation will require exhaust system
service by your dealer.
P107300
Ensure the loader has enough fuel to operate for 60
minutes minimum.
The loader is equipped with the remote parked
regeneration kit if this switch (Item 1) [Figure 70-30-15]
is mounted in the rear door.
WARNING
Exhaust gas temperature and exhaust system
components are hot during regeneration. Keep
flammable material, explosive dust, and explosive
gases away from exhaust system.
W-2936-0412
Park the loader on a level surface, engage the parking

break, stop the engine and exit the loader. (See LOADER
STORAGE AND RETURN TO SERVICE on Page 10-
190-1.)

(CONTD)
1
Remote Parked Regeneration (Level 3) (Contd) 2
WARNING
Before you leave the operators seat:
Lower the lift arms and put the attachment flat on
the ground.
Stop the engine.
Raise the seat bar. P107299
Turn the remote parked regeneration key switch to the
START position (Item 3). Release the key when the
engine starts and allow the switch to return to the RUN
The seat bar system must deactivate these functions
position (Item 2) [Figure 70-30-17].
when the seat bar is up. See your Bobcat dealer for
W-2463-1110

NOTE: The lift, tilt, auxiliary hydraulics, and traction
NOTE: Ensure the key switch is off before exiting the drive functions are disabled during remote
loader. The procedure cannot be performed parked regeneration.
with the operator cab key switch in the RUN
position. The engine will idle for a brief period. The engine speed
will increase 300 rpm and begin regenerating the DPF.
Open the rear door.
WARNING IMPORTANT
Stopping the engine during the regeneration cycle
AVOID INJURY OR DEATH may cause severe damage to the DPF.
When an engine is running in an enclosed area, fresh I-2352-0412
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible After DPF regeneration is complete, the engine will
gases which can kill without warning. continue to operate for a brief cool down period and shut
W-2050-0807 down automatically.
Open the rear door.

STOP position (Item 1) [Figure 70-30-17] and remove
the key.
NOTE: The loader cannot be operated from the

operator cab if the remote parked
regeneration key switch is in the RUN
position.

DIESEL PARTICULATE FILTER (DPF) SYSTEM
(CONTD)
DPF Service Regeneration (Level 4)

WARNING
NOTE: Parked regeneration is impossible with AVOID INJURY OR DEATH
remote parked regeneration kit alone. Before you leave the operators seat:
Regeneration is possible with service tools Lower the lift arms and put the attachment flat on
only. (Service tools are available among all the ground.
levels without level 5). Stop the engine.
Figure 70-30-18 Raise the seat bar.
2
The seat bar system must deactivate these functions
1 when the seat bar is up. See your Bobcat dealer for
W-2463-1110
4
3
NOTE: Ensure the key switch is off before exiting the
loader. The procedure cannot be performed
with the operator cab key switch in the RUN

position.
NA3299 Open the rear door.
The requirement for a DPF service regeneration is

indicated by service code. The DPF / DEF icon (Item 2)
and the service indicator (Item 3) will FLASH. Press the WARNING
Information button (Item 4) until the display screen shows
the service codes. Service code [M8554] (DPF Service AVOID INJURY OR DEATH
Regeneration Required) will show in the display screen When an engine is running in an enclosed area, fresh
(Item 1) [Figure 70-30-18] when remote parked air must be added to avoid concentration of exhaust
regeneration is necessary. fumes. If the engine is stationary, vent the exhaust
Ensure the loader has enough fuel to operate for 60 gases which can kill without warning.
minutes minimum. W-2050-0807
WARNING
Exhaust gas temperature and exhaust system
components are hot during regeneration. Keep
flammable material, explosive dust, and explosive
gases away from exhaust system.
W-2936-0412
Park the loader on a level surface, engage the parking

break, stop the engine and exit the loader. (See
STOPPING THE ENGINE AND LEAVING THE LOADER
on Page 10-200-1.)

DIESEL PARTICULATE FILTER (DPF) SYSTEM NOTE: Kit does not need to be permanently mounted
(CONTD) for service use.
DPF Service Regeneration (Level 4) (Contd) Figure 70-30-21
Connect the diagmaster to the loader. (See 1

DIAGMASTER (SERVICE TOOL) KIT - 7024161 on Page 2
10-70-1.)
3
NOTE: The remote parked regeneration kit is also
required with the diagmaster to perform level
4 regeneration.
Figure 70-30-19
P107299
2
1 Turn the remote parked regeneration key switch to the

START position (Item 3). Release the key when the
engine starts and allow the switch to return to the RUN

position (Item 2) [Figure 70-30-21].
P107591 NOTE: The lift, tilt, auxiliary hydraulics, and traction

drive functions are disabled during remote
parked regeneration.
Remove the cover (Item 1) from the loader harness
connector (Item 2) [Figure 70-30-19]. Figure 70-30-22
NOTE: Replace the connector cap after service.
Figure 70-30-20
1
2
1 2
3
P107938
Select DPF Manual Regeneration (Item 1) from the Utility

P107592 menu (Item 2), click on the >> icon (Item 3) [Figure 70-
30-22].
Connect the remote park regeneration switch connector

(Item 1) to the loader harness connector (Item 2) [Figure
70-30-20].

DIESEL PARTICULATE FILTER (DPF) SYSTEM After DPF regeneration is complete, the engine will
(CONTD) continue to operate for a brief cool down period and shut
down automatically.
DPF Service Regeneration (Level 4) (Contd)
Open the rear door.
Figure 70-30-23
2 STOP position (Item 1) [Figure 70-30-21] and remove
the key.
NOTE: The loader cannot be operated from the

operator cab if the remote parked
regeneration key switch is in the RUN
position.
Figure 70-30-25
1
3 1
P107596
2
Click select signal and monitor icon (Item 1), select
signals and click add icon (Item 2) and click check icon

(Item 3) [Figure 70-30-23] when ready.
Figure 70-30-24
3
1
P107938
Select DPF Soot Load Reset (Item 1) click the >> icon
(Item 3) [Figure 70-30-25], follow the on screen
instructions to reset.
Select DPF Regeneration Interval Time Reset (Item 2)

click the >> icon (Item 3) [Figure 70-30-25], follow the
on screen instructions to reset.
Disconnect the diagmaster from loader.

P107597
Click the active test icon (Item 1) [Figure 70-30-24] to
start the regeneration process.
The engine will idle for a brief period. The engine speed
will increase 300 rpm and begin regenerating the DPF.
IMPORTANT
Stopping the engine during the regeneration cycle
may cause severe damage to the DPF.
I-2352-0412

(CONTD)
DPF Cleaning (Level 5)

2 1
See the SERVICE SCHEDULE for the correct service 4
Figure 70-30-26
3
1 2
5
3
5
P107535
4
Remove DPF bracket 1 (Item 1) and the DPF bracket 2
(Item 2) [Figure 70-30-27].
NA3300
Installation: Tighten the DPF bracket 1 and 2 to 49 - 55
Clean the DPF at the specified interval or when indicated.

Remove the tubes (Item 3) from the differential pressure
The general warning icon (Item 1), the DPF / DEF icon sensor (Item 4) [Figure 70-30-27].
(Item 2), and the service indicator (Item 4) will FLASH.
Press the Information button (Item 5) until the display Remove the filter compartment (DPF) mounting bolts
screen shows the service codes. Service code [M8555] (Item 5) [Figure 70-30-27] located on both sides of the
(DPF Service Required) will show in the display screen DPF.
(Item 3) [Figure 70-30-26] when DPF cleaning is
necessary. Installation: Tighten the mounting nuts to 49 - 55 Nm
The DPF is a critical component of the engine exhaust
system and must be properly maintained. Specialized Figure 70-30-28
equipment is required to clean the ash from the DPF.
NOTE: Before removing the DPF for cleaning, keep

the records of the engine serial number, DPF
muffler full assembly serial number and
engine operating time, which is required in
preparing the DPF cleaning order form.
The DPF muffler full assembly serial number is located

on the side of the DPF and on the differential pressure
sensor.
1
Remove the DPF from the engine. (See Removal And
P107534
NOTE: The engine operating time is recorded in the
engine control unit (ECU), check the engine
operating time by connecting the diagmaster Replace the gaskets (Item 1) [Figure 70-30-28] during
service tool. (See DIESEL PARTICULATE reassembly.
FILTER (DPF) SYSTEM on Page 70-30-1.)


AIR CLEANER Housing Removal And Installation (Later Models)
Housing Removal And Installation (Early Models) Remove the rear grille from the loader. (See Removing
on Page 50-60-1.)
Remove the rear grille from the loader. (See Removing
on Page 50-60-1.) Raise the lift arms and install an approved lift arm
Figure 70-40-1
Figure 70-40-2
2
1 2
1
P100229
P121310

Remove the top two mounting bolts (Item 1) [Figure 70-
40-1] from the air cleaner assembly. Loosen the hose clamp (Item 1) [Figure 70-40-1] and
disconnect the hose from the air cleaner.
Loosen the hose clamp (Item 2) and disconnect the hose
(Item 3) [Figure 70-40-1] from the air cleaner. Disconnect the wire harness (Item 2) [Figure 70-40-1]
from the air cleaner sender.
Disconnect the wire connector (Item 4) [Figure 70-40-1]
from the air cleaner sender. Figure 70-40-3
Disconnect the scavenger hose (Item 5) [Figure 70-40-

1]. 1
1
Remove the air cleaner from the loader.
P115760
Remove the four bolts (Item 1) [Figure 70-40-3] from the

air cleaner assembly.
Remove the air cleaner from the loader.


ENGINE COOLING SYSTEM (EARLY MODELS) Figure 70-50-2
Radiator Removal And Installation
Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)
1
Remove the oil cooler. (See Removal And Installation on
Page 20-90-1.)
WARNING
P107794
AVOID BURNS
Do not remove radiator cap when the engine is hot. Disconnect the coolant tank fill hose (Item 1) [Figure 70-
You can be seriously burned. 50-2].
W-2070-1203
Figure 70-50-3
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-100-4.)

Figure 70-50-1 1
1
P107793A
Remove the hardware (Item 1) from the fuel cooler (Item

P107792A 2) [Figure 70-50-3] and reposition cooler.
Disconnect the radiator air bleed hose (Item 1) [Figure

70-50-1].

ENGINE COOLING SYSTEM (EARLY MODELS) Hydraulic Fan Description
(CONT'D)
The hydraulic fan is used to cool the engine and hydraulic
Radiator Removal And Installation (Cont'd) / hydrostatic systems. The hydraulic fan consists of a fan
and hydraulic motor that is controlled by a proportioning
Figure 70-50-4 valve.
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from the engine and
hydraulic temperature sensors.
NOTE: The proportioning valve is factory set and can

not be adjusted.
1
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed can
range from 0 - 4000 rpm.
P107336B The hydraulic fan speed at cold engine startup will range
from 0 - 500 rpm until the engine coolant and the
hydraulic fluid reach normal operating temperatures.
Disconnect the radiator hose (Item 1) [Figure 70-50-4].

During normal operating temperatures the fan speed may
Figure 70-50-5
range from approximately 1900 - 3500 rpm.
2 1 2
P107796
Disconnect the radiator hose (Item 1) [Figure 70-50-5].
Remove radiator hold down bolts (Item 2) [Figure 70-50-

5].
Lift the radiator up and remove it from the loader.

ENGINE COOLING SYSTEM (EARLY MODELS) Hydraulic Fan Motor Assembly Removal And
(CONTD) Installation (Early Models)
Lower Fan Duct Removal And Installation Figure 70-50-7
Figure 70-50-6
1 2
5
5
1
4
1
3
P100729
P100275
Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-50-7].
Unhook the rubber straps (Item 1) [Figure 70-50-6] and
remove the lower fan duct.

Remove the fan case drain hose (Item 3) [Figure 70-50-
7].
Remove the charge pressure hose (Item 4) [Figure 70-

50-7].
Cap and plug all hoses.
Disconnect the electrical connectors (Item 5) [Figure 70-

50-7].
Figure 70-50-8
1
1
P100729
Remove fan assembly (Item 2) [Figure 70-50-8].
NOTE: The fan grill (Item 3) [Figure 70-50-8] has been

eliminated on late model machines.

ENGINE COOLING SYSTEM (EARLY MODELS) Hydraulic Fan Motor Removal And Installation (Early
(CONT'D) Models)
Fan Removal And Installation (Early Models) Figure 70-50-10
Figure 70-50-9
P-90065
1
P-90313
Remove the nut (Item 1) [Figure 70-50-10] and washer
from the motor shaft.
Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-9].

torque.
Installation: Tighten the bolts to 10,2 Nm (7.5 ft-lb)
torque. Figure 70-50-11
3 2
2
P-90062
Use the following procedure to remove the fan hub from

the fan motor shaft:
Install a bushing (Item 1) [Figure 70-50-11] in the hub to

protect the fan motor shaft and threads during removal.
Use two bolts (Item 2) to position a puller (Item 3) on the

bushing (Item 1) as shown [Figure 70-50-11].
NOTE: If a puller is not available one can be made if

needed to remove the hub from the shaft.
Tighten the bolts and strike the puller with a hammer to

loosen the hub from the motor shaft.

ENGINE COOLING SYSTEM (EARLY MODELS) Hydraulic Fan Disassembly And Assembly (Early
(CONT'D) Models)
Hydraulic Fan Motor Removal And Installation (Early Figure 70-50-14

Models) (Contd)
Figure 70-50-12
4
1
3
2 2
1
P-76714A
P-90069 NOTE: The mounting gasket (Item 1), proportioning

valve, and proportioning valve O-rings, back-
up washer and coil mounting nut (Item 2) are
Remove and discard the two nuts and cotter pins (Item 1)

available from Bobcat Parts. The fan motor
[Figure 70-50-12]. (Item 3) [Figure 70-50-14] must be replaced as
an assembly if damaged.
Remove the filter cover (Item 4) [Figure 70-50-14].
Installation: Tighten the nuts to 10,2 Nm (7.5 ft-lb)
torque. Installation: Tighten filter cover (Item 4) [Figure 70-50-
14] to 65 - 70 Nm (48 - 52 ft-lb) torque.
Figure 70-50-13
P-90076
Remove and discard the two bolts (Item 1) [Figure 70-

50-13] then remove motor.

torque.
NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.

(CONT'D)
Hydraulic Fan Disassembly And Assembly (Early

Models) (Contd)
Figure 70-50-15
1
4
3
P-76717
2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 17].
P-76716A Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-17] to 10 - 10,9 Nm (7.4 - 8.1 ft-lb) torque.
Remove coil mounting nut (Item 1), the coil (Item 2), and

Figure 70-50-18
the coil valve stem (Item 3) [Figure 70-50-15].
NOTE: Coil mounting nut must be replaced each time

it is removed. Coil mounting nuts are
available from Bobcat Parts.
Installation: Install coil mounting nut with the

counterbored space (Item 4) [Figure 70-50-15] facing
towards the coil and tighten securely by hand.
Installation: Tighten coil valve stem (Item 3) [Figure 70-

1
50-15] to 28 - 34 Nm (21 - 25 ft-lb) torque.
Figure 70-50-16
P-76726
1
P-76637
Replace the O-rings (Item 1) and back-up ring (Item 2)

[Figure 70-50-16].

(CONT'D)
Hydraulic Fan Motor Assembly Removal And

Installation (Later Models)
Figure 70-50-19 1
2 P115442A
3
21] on the back of the fan motor assembly.
P115657A Figure 70-50-22
Remove the fan motor inlet hose (Item 1) and the charge

pressure tubeline (Item 2) [Figure 70-50-19].

50-19].
Figure 70-50-20 1 1
2
1 P115647
Remove the four nuts (Item 1) [Figure 70-50-22].
2
P115655
Remove the fan motor outlet hose (Item 1) [Figure 70-

50-20].

50-20].

ENGINE COOLING SYSTEM (EARLY MODELS)
(CONT'D)
Fan Removal And Installation (Later Models)
Figure 70-50-23
1
P115646
2) [Figure 70-50-23].

torque.
Figure 70-50-24
P-90065A

motor shaft.

torque.

ENGINE COOLING SYSTEM (EARLY MODELS) Remove the two washers (Item 2) [Figure 70-50-26].
(CONT'D)
Installation: Tighten the nuts to 10,2 Nm (7.5 ft-lb)
Hydraulic Fan Motor Removal And Installation (Later torque.
Models)
Figure 70-50-27
Figure 70-50-25
2
2
1
P115434
P-90062A

Use the following procedure to remove the fan hub from

torque.
motor.

Figure 70-50-26
2 2
P115433
[Figure 70-50-26].

(CONT'D)
Hydraulic Fan Disassembly And Assembly (Later

Models) 1
Figure 70-50-28
1
2 2
P115322
Replace the O-rings (Item 1) and back-up rings (Item 2)

[Figure 70-50-30].
P115320 Figure 70-50-31
Remove the filter (Item 1) [Figure 70-50-28].

Installation: Lubricate threads and filter O-ring prior to
installation. Tighten the filter (Item 1) [Figure 70-50-28]
to 37 - 45 Nm (27 - 33 ft-lb) torque.
Figure 70-50-29
1
P115323A
3 Remove the pressure transducer (Item 1) [Figure 70-50-

31].
2 Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-31] to 10 Nm (88 in-lb) torque.
1
P115321
the proportional valve (Item 3) [Figure 70-50-29].
Installation: Tighten the proportional valve (Item 3)

Installation: Tighten the coil mounting nut (Item 1)


(CONT'D)

Models) (Contd)
Figure 70-50-32
P115329
1
Installation: Tighten the bolts (Item 1) [Figure 70-50-34]

P-76726 to 37 - 45 Nm (27 - 33 ft-lb) torque.
Figure 70-50-35

2
Figure 70-50-33 1
1
2
3
3
4
4 P115326
P115328 Remove the fan motor (Item 1) from the filter adapter
(Item 2) [Figure 70-50-35].
Remove and inspect the fitting (Item 1), the spring (Item Remove the seals (Item 3 and 4) [Figure 70-50-35].
2), and the check valve (Item 3) [Figure 70-50-33] for

33] and lubricate with oil before installing.

(CONT'D)

Models) (Contd)
Figure 70-50-36
P115458
Inspect the condition of the gear faces and the mating

1 surfaces of the wear blocks [Figure 70-50-38]. If
excessive wear or damage is visible, replace the fan
P115457 motor.
Check the bushings in the wear blocks [Figure 70-50-

Remove the two bolts (Item 1) and the slinger (Item 2)

38]. If excessive wear is visible, replace the fan motor.
[Figure 70-50-36].
Figure 70-50-39
Figure 70-50-37
2
1
1 2 3
5
3
4 P115459
P115460
Remove the snap ring (Item 1), washer (Item 2) and the
Remove the front cover (Item 1) from the fan motor (Item seal (Item 3) [Figure 70-50-39].
2) [Figure 70-50-37].
Remove the seals (Item 3 and 4) [Figure 70-50-37].
Remove the pump assembly (Item 5) [Figure 70-50-37].

ENGINE COOLING SYSTEM (EARLY MODELS) NOTE: Orientation of the seals must be followed for
(CONT'D) correct operation of the fan motor.
Hydraulic Fan Disassembly And Assembly (Later Figure 70-50-42

Models) (Contd)
Figure 70-50-40 3 1
2 1 3
2
P115476
P115459 Install a new black rubber seal (Item 1) with the channel
(Item 2) [Figure 70-50-42] of seal facing down and press
firmly into groove of casing.
Install a new washer (Item 1), snap ring (Item 2) and seal

(Item 3) [Figure 70-50-40]. Press a new yellow plastic seal (Item 3) [Figure 70-50-
42] firmly onto the black rubber seal.
Figure 70-50-41
Figure 70-50-43
2 1
1 1
P115460A 1
P115475A
Install the pump assembly (Item 1) and the new seal

(Item 2) [Figure 70-50-41] in the housing. The ejector pads (Item 1) [Figure 70-50-43] on the
yellow plastic seal will be facing up.
NOTE: Verify that both seals are flush with the

surface of the housing.

ENGINE COOLING SYSTEM (EARLY MODELS) NOTE: Orientation of the seals must be followed for
Hydraulic Fan Disassembly And Assembly (Later Figure 70-50-46

Models) (Contd)
Figure 70-50-44
1
2
2
1 P115430
P115457 Install a new black rubber seal (Item 1) with the channel
firmly into grove of casing.
Assemble the fan motor and the front cover. Install the

two bolts (Item 1) and install a new slinger (Item 2) Figure 70-50-47
[Figure 70-50-44].
1
Installation: Tighten the two bolts (Item 1) [Figure 70- 2
50-44] to 3 - 5 Nm (2 - 4 ft-lb) torque.
Figure 70-50-45
P115432
Press a new yellow plastic seal (Item 1) firmly onto the

black rubber seal (Item 2) [Figure 70-50-47].
P115326A The ejector pads (Item 3) [Figure 70-50-47] on the

Install a new seal (Item 1) [Figure 70-50-45] into the fan NOTE: Verify that both seals are flush with the
motor. surface of the housing.

ENGINE COOLING SYSTEM (EARLY MODELS) Water Pump Removal And Installation
(CONT'D)
Drain the fluid from the radiator. (See Removing And
Blower Housing Removal And Installation Replacing Coolant on Page 10-90-4.)
Figure 70-50-49
IMPORTANT 1 3

damage the system.
I-2003-0888 4
Remove the air conditioning condenser if equipped. (See

Remove the oil cooler. (See Removal And Installation on P107330

Page 20-90-1.)
Remove the radiator. (See Radiator Removal And Remove the alternator belt (Item 1) [Figure 70-50-49].

Remove the four bolts (Item 2) from the water pump
Figure 70-50-48 pulley (Item 3) [Figure 70-50-49].
Remove the water pump pulley (Item 3) [Figure 70-50-

49]
Remove the six water pump bolts (Item 4) [Figure 70-50-

49].
Figure 70-50-50
1 1
2
P-90063
Remove the blower housing (Item 2) [Figure 70-50-48]

from the loader.
NOTE: Engine and hydraulic fan assembly removed 3EEABAC1P120A

for photo clarity.
Remove the water pump (Item 1) and gasket (Item 2)

[Figure 70-50-50] from the gearcase.

ENGINE COOLING SYSTEM (EARLY MODELS) Thermostat Housing Removal And Installation
(CONTD)
Figure 70-50-52
Water Pump Disassembly And Assembly
Figure 70-50-51 2
1
1 3
4
P100372
B-22926A Remove the thermostat cover mounting bolts (Item 1),

and remove the thermostat cover (Item 2) [Figure 70-50-
52].
NOTE: The water pump is not serviceable. Order a
new pump assembly and gasket (Item 1)

Remove the thermostat assembly (Item 3) [Figure 70-
[Figure 70-50-51]. 50-52].
Apply a liquid gasket only at the thermostat cover side of

the gasket (Item 4) [Figure 70-50-52].
Figure 70-50-53
P-37152
Attach the thermostat (Item 1) with the hole (Item 2)

facing toward the air suction side [Figure 70-50-53].

ENGINE COOLING SYSTEM (EARLY MODELS)
(CONTD)
Thermostat - Testing
Push down the thermostat valve and insert a string

between the valve and the valve seat.
Figure 70-50-54
P-37172

Place the thermostat and a thermometer in a container
with water and gradually heat the water [Figure 70-50-
54].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

thermostat.
Thermostats Factory 74,5 - 78,5C

valve opening spec. (166.1 - 173.3F)
temperature
Temperature at Factory 90C
which thermostat spec. (194F)
completely opens


ENGINE COOLING SYSTEM (LATER MODELS) Figure 70-51-3
Radiator/Oil Cooler Removal And Installation
Remove the rear grille and side panels. (See Removing 3

on Page 50-60-1.)
Drain the coolant. (See Removing And Replacing 1

1
Coolant on Page 10-100-4.) 2
2
Remove the air cleaner. (See Housing Removal And P115765
Installation (Later Models) on Page 70-40-1.)
Figure 70-51-1 Reposition the clamps (Item 1). Remove the hoses (Item
2) [Figure 70-51-3].
Remove the hose (Item 3) [Figure 70-51-3].
Figure 70-51-4

1
P115888B
Disconnect and plug the radiator air bleed hose (Item 1)

[Figure 70-51-1].
P115752
Figure 70-51-2

reservoir bracket.
P121309
Reposition the clamp (Item 1) [Figure 70-51-2] on the

hose.

(CONT'D)
Radiator/Oil Cooler Removal And Installation

(Cont'd) 1
Figure 70-51-5
P121148A
Figure 70-51-8
P115766
Remove the reservoir tank and bracket (Item 1) [Figure

70-51-5].
1 1
Figure 70-51-6
1
P115769
Remove the nuts and bolts (Item 1) [Figure 70-51-8].
Lift the radiator/oil cooler up and remove it from the

loader.
P115767

ENGINE COOLING SYSTEM (LATER MODELS) Lower Fan Duct Removal And Installation
(CONT'D)
Hydraulic Fan Description
Figure 70-51-9
The proportional relief valve meters the flow through the
fan motor. The valve receives signals from the controller
which gathers information from both the engine and
hydraulic temperature sensors. 1
The hydraulic fan is used to cool the engine and hydraulic

/ hydrostatic systems. The hydraulic fan consists of a fan
and hydraulic motor that is controlled by a proportional
relief valve.
NOTE: The proportional relief valve is factory set and

can not be adjusted accurately in the field due
to the adjustment being tamper proof.
The fan speed is determined by the engine coolant P115755

temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpms)
can range from 0 - 4000 rpms. Unhook the rubber straps (Item 1) [Figure 70-51-9] and
remove lower fan duct.

(CONT'D)
Hydraulic Fan Motor Assembly Removal And

Installation
Figure 70-51-10
1 1
2 P115776
Remove the four nuts (Item 1) [Figure 70-51-12].

P115777
NOTE: The fan mounting nuts are a single use part
and should be replaced whenever they are

removed.
10] from the back of the fan motor assembly.
Figure 70-51-11
1
2
4 4
P115778A
Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 70-51-11].
Remove the charge pressure tubeline (Item 4) [Figure

70-51-11].
Disconnect the electrical connectors (Item 5) [Figure 70-

51-11].

ENGINE COOLING SYSTEM (LATER MODELS)
(CONT'D)
Fan Removal And Installation
Figure 70-51-13
1
P115692A
2) [Figure 70-51-13].

torque.
Figure 70-51-14
P115641

motor shaft.

torque.

(CONT'D)
Hydraulic Fan Motor Removal And Installation
Figure 70-51-15 2
2
2
2
3
1
1
P115643
[Figure 70-51-16].
P115642A
Use the following procedure to remove the fan hub from Installation: Tighten the nuts to 10,2 Nm (7.5 ft-lb)

torque.
Figure 70-51-17

1

P115644


torque.

motor.

(CONT'D)
Hydraulic Fan Disassembly And Assembly

1
Figure 70-51-18
1
2 2
P115322
Replace the O-rings (Item 1) and back-up rings (Item 2)

[Figure 70-51-20].
P115320
Figure 70-51-21
Remove the filter (Item 1) [Figure 70-51-18].

Installation: Lubricate threads and filter O-ring prior to
installation. Tighten the filter (Item 1) [Figure 70-51-18]
to 37 - 45 Nm (27 - 33 ft-lb) torque.
Figure 70-51-19
P115323A
3
Remove the pressure transducer (Item 1) [Figure 70-51-
21].
2
Installation: Tighten the pressure transducer (Item 1)
1 [Figure 70-51-21] to 10 Nm (88 in-lb) torque.
P115321
the proportional valve (Item 3) [Figure 70-51-19].
Installation: Tighten the proportional valve (Item 3)

Installation: Tighten the coil mounting nut (Item 1)


(CONT'D)
Hydraulic Fan Disassembly And Assembly (Contd)
Figure 70-51-22
P115329
1
P-76726 Installation: Tighten the bolts (Item 1) [Figure 70-51-24]

to 37 - 45 Nm (27 - 33 ft-lb) torque.
Replace the O-ring (Item 1) [Figure 70-51-22]. Figure 70-51-25

Figure 70-51-23 2
1
1
2
3
3
4
4
P115326
P115328
Remove the fan motor (Item 1) from the filter adapter
(Item 2) [Figure 70-51-25].
Remove and inspect the fitting (Item 1), the spring (Item
2), and the check valve (Item 3) [Figure 70-51-23] for Remove the seals (Item 3 and 4) [Figure 70-51-25].

23] and lubricate with oil before installing.

(CONT'D)
Figure 70-51-26
P115458
1 Inspect the condition of the gear faces and the mating

surfaces of the wear blocks [Figure 70-51-28]. If
P115457 excessive wear or damage is visible, replace the fan
motor.
Remove the two bolts (Item 1) and the slinger (Item 2) Check the bushings in the wear blocks [Figure 70-51-
[Figure 70-51-26].

28]. If excessive wear is visible, replace the fan motor.
Figure 70-51-27 Figure 70-51-29
2
1
1 2
5 3
3
4
P115460
P115459
Remove the front cover (Item 1) from the fan motor (Item Remove the snap ring (Item 1), washer (Item 2) and the
2) [Figure 70-51-27]. seal (Item 3) [Figure 70-51-29].
Remove the seals (Item 3 and 4) [Figure 70-51-27].
Remove the pump assembly (Item 5) [Figure 70-51-27].

ENGINE COOLING SYSTEM (LATER MODELS) NOTE: Orientation of the seals must be followed for
Hydraulic Fan Disassembly And Assembly (Contd) Figure 70-51-32
Figure 70-51-30
3 1
2 1 3
2
P115476
P115459
Install a new black rubber seal (Item 1) with the channel
Install a new washer (Item 1), snap ring (Item 2) and seal firmly into groove of casing.
(Item 3) [Figure 70-51-30].

Press a new yellow plastic seal (Item 3) [Figure 70-51-
Figure 70-51-31 32] firmly onto the black rubber seal.
Figure 70-51-33
2
1
1
1
P115460A
1
P115475A
Install the pump assembly (Item 1) and the new seal
(Item 2) [Figure 70-51-31] in the housing.
The ejector pads (Item 1) [Figure 70-51-33] on the
NOTE: Verify that both seals are flush with the


ENGINE COOLING SYSTEM (LATER MODELS) NOTE: Orientation of the seals must be followed for
Hydraulic Fan Disassembly And Assembly (Contd) Figure 70-51-36
Figure 70-51-34
1
2
2
1
P115430
P115457
Install a new black rubber seal (Item 1) with the channel
Assemble the fan motor and the front cover. Install the firmly into grove of casing.
two bolts (Item 1) and install a new slinger (Item 2)

[Figure 70-51-34]. Figure 70-51-37
Installation: Tighten the two bolts (Item 1) [Figure 70- 1

51-34] to 3 - 5 Nm (2 - 4 ft-lb) torque. 2
Figure 70-51-35
P115432
Press a new yellow plastic seal (Item 1) firmly onto the

black rubber seal (Item 2) [Figure 70-51-37].
P115326A
The ejector pads (Item 3) [Figure 70-51-37] on the
Install a new seal (Item 1) [Figure 70-51-35] into the fan
motor. NOTE: Verify that both seals are flush with the

ENGINE COOLING SYSTEM (LATER MODELS) Blower Housing Removal And Installation
(CONT'D)
Figure 70-51-38 IMPORTANT

damage the system.
I-2003-0888
Remove the air conditioning condenser if equipped. (See

1 Removal And Installation on Page 80-61-1.)
Remove the radiator/oil cooler. (See Radiator/Oil Cooler

P115329
Figure 70-51-39
Assemble the fan motor and the filter adapter. Install the
four bolts (Item 1) [Figure 70-51-38].

Installation: Tighten the four bolts (Item 1) [Figure 70-
51-38] to 37 - 45 Nm (27 - 33 ft-lb) torque.
P115776A
Push the blower housing (Item 1) [Figure 70-51-39] up

and remove the housing from the loader.
NOTE: Hydraulic fan assembly removed for photo

clarity.

ENGINE COOLING SYSTEM (LATER MODELS) When mounting the water pump, use a new gasket (Item
(CONT'D) 2) [Figure 70-51-41].
Water Pump Removal And Installation Water Pump Disassembly And Assembly
Drain the fluid from the radiator. (See Removing And Figure 70-51-42
Replacing Coolant on Page 10-90-6.)
Figure 70-51-40
2
1
1 3
B-22926A
P100371 Remove the water pump assembly.

NOTE: The seal (Item 1) [Figure 70-51-42] is not a
Remove the alternator belt (Item 1) [Figure 70-51-40]. replacement part, order water pump
assembly.
Remove the four bolts (Item 2) from the water pump
pulley (Item 3) [Figure 70-51-40]. The gasket (Item 2) [Figure 70-51-42] is
available from Bobcat parts.
Remove the water pump pulley (Item 3) [Figure 70-51-
40]
Remove the six water pump bolts (Item 4) [Figure 70-51-

40].
Figure 70-51-41
3EEABAC1P120A
Remove the water pump (Item 1) [Figure 70-51-41] from

the gearcase.

ENGINE COOLING SYSTEM (LATER MODELS) Thermostat - Checking
(CONT'D)
Figure 70-51-45
Thermostat Housing Removal And Installation
Figure 70-51-43
2
1
3
4
P-37172
P100372 Push down the thermostat valve and insert a string

between the valve and the valve seat.
Figure 70-51-44 Place the thermostat and a thermometer in a container

with water and gradually heat the water [Figure 70-51-
45].
Hold the string to suspend the thermostat in the water.

5
When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

6
thermostat.
Thermostats valve Factory 74,5 - 78,5C

P-37152
opening spec. (166.1 - 173.3F)
temperature
Remove the thermostat cover mounting bolts (Item 1), Temperature at Factory 194F
and remove the thermostat cover (Item 2) [Figure 70-51- which thermostat spec. 90C
43]. completely opens
Remove the thermostat assembly (Item 3) [Figure 70-

51-43].
Apply a liquid gasket only at the thermostat cover side of

the gasket (Item 4) [Figure 70-51-43].
Attach the thermostat (Item 5) with its hole (Item 6)

[Figure 70-51-44] facing toward the air suction side.

LUBRICATION SYSTEM Figure 70-60-3
Oil Pan Removal And Installation
Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-10.)
Figure 70-60-1
P-37127
Remove the oil strainer mounting bolts and remove the

oil strainer (Item 2) [Figure 70-60-3].
Install the oil strainer, using care not to damage the O-

ring.
P107434

Apply liquid gasket to the oil pan (Item 3) [Figure 70-60-
2].
Remove the oil pan mounting bolts and remove the oil
pan (Item 1) [Figure 70-60-1]. Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
Figure 70-60-2
Carefully apply the adhesive evenly.
NOTE: When mounting the adhesive-applied parts,

take care to fit them to the mating parts.
Assemble the adhesive-applied parts within

ten minutes.
To avoid uneven tightening, tighten mounting

bolts in diagonal order from the center.
Tightening Oil pan bolts 18 - 20 Nm

torque (13 - 15 ft-lb)
P-37126

LUBRICATION SYSTEM (CONTD) Oil Pump Inspection
Oil Pump Removal And Installation Figure 70-60-5
Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70-
110-1.)
Figure 70-60-4
P-37220
1
Measure the clearance between lobes of the inner rotor

and the outer rotor with a feeler gauge [Figure 70-60-5].
P-100076 If the clearance exceeds the factory specifications,

replace the oil pump rotor assembly.
Remove the oil pump cover (Item 1) [Figure 70-60-4]. Clearance Factory spec. 0,040 - 0,16 mm
between (0.0016 - 0.0062 in)
inner rotor Allowable 0,03 mm (0.01 in)
and outer Limit
rotor

LUBRICATION SYSTEM (CONTD) Figure 70-60-7
Oil Pump Inspection (Contd)
Figure 70-60-6
P-100077
Put a strip of plastigage onto the rotor face with grease

P-37218 [Figure 70-60-7].
Install the cover and tighten the screws with the specified
Measure the clearance between the outer rotor and the torque.
pump body with a feeler gauge [Figure 70-60-6].

Remove the cover carefully, and measure the amount of
If the clearance exceeds the factory specifications, the flattening with the scale and record the clearance.
replace the oil pump rotor assembly.
If the clearance exceeds the allowable limit, replace oil
Clearance Factory 0,100 - 0,184 mm pump rotor assembly and the cover.
between outer spec. (0.00394 - 0.00724 in)
rotor and Allowable 0,3 mm (0.01 in) Clearance Factory spec. 0,025 - 0,075 mm
pump body limit between (0.00099 - 0.0029 in)
rotor and Allowable 0,225 mm
cover limit (0.00886 in)
Tightening Oil pump cover 7,9 - 9,3 Nm

torque screw (5.8 - 6.8 ft-lb)

LUBRICATION SYSTEM (CONTD) Oil Filter Cooler Removal And Installation
Oil Pump Inspection (Contd) Figure 70-60-9
Relief Valve 1
Figure 70-60-8
4 P100079
1
1 Remove the water pipe (Item 1) [Figure 70-60-9].
P100078
Remove the oil filter cartridge (Item 2) [Figure 70-60-9].

Remove the bolt (Item 1) [Figure 70-60-8]. Figure 70-60-10
Remove the relief valve (Item 2), the spring (Item 3) and
the packing (Item 4) [Figure 70-60-8].
Tightening Relief valve 69 - 78 Nm

torque (51 - 57 ft-lb)
P100080
Remove the oil cooler joint bolt (Item 1) [Figure 70-60-

10] and [Figure 70-60-11].
Installation: Tighten the oil cooler joint bolt to 40 - 44

Nm (29 - 32 ft-lb)

LUBRICATION SYSTEM (CONTD) Figure 70-60-13
Oil Filter Cooler Removal And Installation (Contd)
Figure 70-60-11
1 P107382A
Install a pressure gauge [Figure 70-60-13].

P100081
Start the engine. After warming up, measure the oil
pressure of both idling and rated speeds.
Remove the oil cooler (Item 1) [Figure 70-60-11].
If the oil pressure is less than the allowable limit, check

Engine Oil Pressure - Testing the following:
Figure 70-60-12 Engine oil insufficient

Oil pump defective
Oil strainer clogged
Oil filter cartridge
Oil gallery clogged
Excessive oil clearance of bearing
Foreign matter in the relief valve
1
At idle speed Allowable limit 50 kPa
(0,5 bar)
(7 psi)
At rated Factory spec. 200,0 - 390 kPa

speed (2,0 - 3,9 bar)
P107382
(29 - 56 psi)
Allowable limit 150, kPa
(1,5 bar) (21 psi)
Remove the oil switch (Item 1) [Figure 70-60-12].
Installation: Tighten the oil pressure switch to 15 - 19

Nm (11 - 14 ft-lb)

LUBRICATION SYSTEM (CONTD)
Crankcase Ventilation Filter Removal And Installation
Figure 70-60-14
P107574
Remove the retaining bolt (Item 1), loosen the hose

clamps (Item 2) and remove the tubelines (Item 3)

[Figure 70-60-14].
Figure 70-60-15
3
2
1
P107699
Loosen the hose clamp (Item 1) and remove the hose

(Item 2) [Figure 70-60-15].
Remove the two bracket retaining bolts (Item 3) and the

crankcase ventilation filter (Item 4) [Figure 70-60-15].
Reverse the removal procedure for installation.

FUEL SYSTEM Figure 70-70-2
Supply Pump Removal
WARNING
AVOID INJURY OR DEATH 1
P106420
W-2072-0807
Remove the fuel hose / clamp (Item 1) [Figure 70-70-2]

NOTE: Allow 5 minutes after the engine is shut down from the filler neck.
for the fuel pressure to bleed down.
Figure 70-70-3
Figure 70-70-1
1

3
1
P106421
P109401



Supply Pump Removal (Contd)
Figure 70-70-4 4
2
1 3
P107545
Rotate the engine counterclockwise (as viewed from the

P106422 flywheel end) until the timing mark on the supply pump
gear (Item 1) is aligned with the idler gear (Item 2)
[Figure 70-70-6].
Remove the clamp / hose (Item 1) [Figure 70-70-4] from
the tank. Any time the timing mark (Item 1) on the supply pump

gear is aligned with the idler gear (Item 2) the engine is
NOTE: Plug the fuel tank opening. on top dead center of the compression stroke on number
four cylinder [Figure 70-70-6].
Remove the air conditioning belt. (See Belt Replacement
on Page 80-20-2.) Look for a timing mark on the idler gear (Item 2). If one is
not present, mark the engaged teeth (Item 3) [Figure 70-
Remove the alternator. (See Removal And Installation on 70-6] to aid in reassembly.
Page 60-30-4.)
Remove the supply pump gear mounting nut (Item 4)
Remove the crankcase ventilation filter from the engine. [Figure 70-70-6].
(See Crankcase Ventilation Filter Removal And
Installation on Page 70-60-6.) Figure 70-70-7
Figure 70-70-5
2
1
P107498
P107379
Use a gear puller (Item 1) to remove the supply pump

Remove the seven retaining bolts (Item 1) and remove gear (Item 2) [Figure 70-70-7].
the supply pump gear cover (Item 2) [Figure 70-70-5]

Supply Pump Removal (Contd)
Figure 70-70-8 1 4
3
2
1
3
2
1
3 P107940
Remove the two injection pipes (Item 1) and remove the

P107939 overflow pipe (Item 2) [Figure 70-70-9].
Remove the two supply pump assembly mounting nuts

Disconnect the fuel temperature sensor (Item 1) and the (Item 3) and remove the supply pump assembly (Item 4)
suction control valve connection (Item 2) [Figure 70-70- [Figure 70-70-9].

7].
NOTE: Cap and store the supply pump assembly and
Remove the fuel return clamp / hose (Item 3) and [Figure injector pipes to protect against dust and
70-70-7]. other contaminants.

Supply Pump Installation
Figure 70-70-10
2
1
2
3
1
P107939
Connect the fuel return clamp / hose (Item 1) [Figure 70-

NA5840 70-12].w
Connect the fuel temperature sensor (Item 2) and the

Replace the 0-ring (Item 1) on the supply pump assembly suction control valve connector (Item 3) [Figure 70-70-
(Item 2) [Figure 70-70-10]. 12].

Figure 70-70-11 Figure 70-70-13
3 1
4
3
P107940 P107527
Install the supply pump assembly (Item 1) [Figure 70-70- Align the key of the supply pump gear (Item 1) [Figure
11] into the engine. 70-70-13] to the supply pump assembly.
Install the supply pump mounting nuts (Item 2) [Figure

70-70-11] and tighten to 24 - 27 Nm (18 - 20 ft-lb)
torque.
Install the two injection pipes (Item 3) [Figure 70-70-11]

and tighten to 23 - 36 Nm (17 - 26 ft-lb) torque.
Install the overflow pipe (Item 4) [Figure 70-70-11] and

tighten to 16 - 19 Nm (12 - 14 ft-lb) torque at supply
pump and 7,9 - 12 Nm (5.8 - 9.4 ft-lb) at engine.

FUEL SYSTEM (CONTD) Install the alternator. (See Removal And Installation on
Page 60-30-4.)
Supply Pump Installation (Contd)
Install the air conditioning belt. (See Belt Replacement on
Figure 70-70-14 Page 80-20-2.)
Install fuel filter and fuel tank fill hose. (See Supply Pump
Removal on Page 70-70-1.)
2 P107497
Install the supply pump gear (Item 1) and align the marks
(Item 2) [Figure 70-70-14] for correct timing.

Install the supply pump gear mounting nut (Item 3)
[Figure 70-70-14] and tighten to 59 - 68 Nm (44 - 50 ft-
lb).
Figure 70-70-15
P107379
Install the supply pump gear cover (Item 1) and the

supply pump gear cover bolts (Item 2) [Figure 70-70-15].
Installation: Tighten the supply pump gear cover bolts to

24 - 27 Nm (18 - 20 ft-lb) torque.
NOTE: Replace the gasket on the supply pump gear

cover.
Install the crankcase ventilation filter on the engine. (See

Crankcase Ventilation Filter Removal And Installation on
Page 70-60-6.)

Supply Pump Difference Learning
The tools listed will be needed to do the following 2

procedure:
7217666 - Remote Start Tool Kit 1

7024161 - Diagmaster (Service Tool)
WARNING 3

P107938
fumes. If the engine is stationary, vent the exhaust Select Utility (Item 1), then select Supply Pump Learning
outside. Exhaust fumes contain odorless, invisible (Item 2) and press the >> icon (Item 3) [Figure 70-70-
gases which can kill without warning. 16].
W-2050-0807
Figure 70-70-17

WARNING 2
1

When the engine is running during service, the
steering levers or joysticks must be in neutral and
the parking brake engaged.
W-2717-0208
3
NOTE: When replacing the supply pump or ECU, use
4
the Diagmaster (Service Tool) to conduct
supply pump learning.
P107560
Supply pump learning should be performed
within every 3000 hours or when supply pump
or ECU is replaced. A new window will open (Item 1), follow the on screen
instructions (Item 2), green light condition ok (Item 3).
Open the rear door. Click the >> icon (Item 4) [Figure 70-70-17].
Connect the Remote Start Tool. (See REMOTE START

TOOL (SERVICE TOOL) KIT - 7217666 on Page 10-61-
1.)
Connect the Diagmaster (Service Tool). (See

DIAGMASTER (SERVICE TOOL) KIT - 7024161 on Page
10-70-1.)
Start the engine.

FUEL SYSTEM (CONTD) Fuel Bypass Valve Removal And Installation
Supply Pump Difference Learning (Contd) Figure 70-70-20
Figure 70-70-18
1
1
2
P121311
P107585
Remove the clamps (Item 1) [Figure 70-70-20] and fuel
lines.
Follow the on screen instructions (Item 1) and press the
>> icon (Item 2) [Figure 70-70-18]. Remove the tie strap (Item 2) [Figure 70-70-20].

Figure 70-70-19 Remove the bypass valve.
Installation: Install the bypass valve according to the

flow arrow printed on the valve.
P107586
To start supply pump learning, click the start icon (Item 1)

[Figure 70-70-19].
Allow pump learning to complete before closing

Diagmaster.
Stop the engine.
Remove the remote start tool and the diagmaster.

FUEL SYSTEM (CONTD) NOTE: When removing the fuel rail assembly do not
hold it by the fuel rail pressure limiter and fuel
Fuel Rail Assembly Removal And Installation rail pressure sensor.

WARNING
Installation: Tighten the injection pipe retaining nuts to
23 - 36 Nm (17 - 26 ft-lb) torque.
NOTE: Cap and store the fuel rail assembly and
injector pipes to protect against dust and
other contaminants.
Figure 70-70-22
W-2072-0807
3
NOTE: Allow 5 minutes after the engine is shut down 2
for the fuel pressure to bleed down. 1
Remove the crankcase ventilation filter from the engine.

(See Crankcase Ventilation Filter Removal And

Remove the EGR valve (See Removal And Installation on

Page 70-140-4.)
Remove the air cleaner flange, intake throttle valve and P107515
intake air heater from the engine. (See Intake Air Heater
Do not remove the fuel rail pressure sensor (Item 1) or
Figure 70-70-21 the fuel rail pressure limiter (Item 2) from the fuel rail
assembly (Item 3) [Figure 70-70-22].
NOTE: Do not disassemble the fuel rail assembly.

The fuel rail pressure sensor, fuel rail
pressure limiter and the fuel rail are not
1 serviceable parts. Fuel rail assembly must be
replaced as a single unit.
5 Reverse procedure for installation.

3
4
2
4
1
P107499
Remove the injection pipes (Item 1) [Figure 70-70-21].
Remove the fuel return hose (Item 2) and disconnect the

fuel rail pressure sensor (Item 3) [Figure 70-70-21].
Remove the fuel rail assembly mounting bolts (Item 4)

and the fuel rail assembly (Item 5) [Figure 70-70-21].

FUEL SYSTEM (CONTD) NOTE: The engine may need to be rotated multiple
times to line up the timing marks.
Supply Pump - Timing
The Idler gear has three timing marks (one
Figure 70-70-23 dot, two dots and three dots). The single dot
on the supply pump gear and the single dot on
the idler gear should be aligned.
2
If the timing marks do not align. It may be
necessary to remove the supply pump gear
and rotate the supply pump shaft slightly to
align timing marks for correct timing.
Reinstall supply pump gear cover.

1
P107379
Remove the seven retaining bolts (Item 1) and remove

the supply pump gear cover (Item 2) [Figure 70-70-23]

Figure 70-70-24
1 3
P107545A
Rotate the engine counterclockwise (as viewed from the

flywheel end) until the timing mark (Item 1) on the supply
pump gear (Item 2) is aligned with the single dot timing
mark (Item 3) on the idler gear (Item 4) [Figure 70-70-
24].

FUEL SYSTEM (CONT'D) Installation: Tighten the injection lines to 23 - 36 Nm
Fuel Injector Removal And Installation
NOTE: Cap and store the injector pipes to protect
NOTE: Shown with engine removed for photo quality. against dust and other contaminants.
Figure 70-70-26
WARNING
penetrate skin or eyes, causing serious injury or 1 2 3
W-2072-0807
NOTE: Allow 5 minutes after the engine is shut down P107418

for the fuel pressure to bleed down.

Remove the crankcase ventilation filter from the engine. Remove the bolt (Item 1) and pull the injector harness
(See Crankcase Ventilation Filter Removal And adapter (Item 2) out of the upper head cover (Item 3)
Installation on Page 70-60-6.) [Figure 70-70-26].
Remove the EGR valve (See Removal And Installation on NOTE: Do not damage the injector harness during
Page 70-140-4.) removal.
Remove the air cleaner flange, intake throttle valve and Installation: Tighten the retaining bolts to 4 - 6 Nm (3 -
intake air heater from the engine. (See Intake Air Heater 4 ft-lb) torque.
Figure 70-70-27
Figure 70-70-25
1
1
2
1
1
1
P107407
P107416A
Disconnect the injector harness adapter (Item 1) from the

Disconnect the four injection lines (Item 1) [Figure 70-70- injector harness (Item 2) [Figure 70-70-27].
25] from the injection nozzle assemblies and the fuel rail
assembly. Replace the O-ring (Item 3) [Figure 70-70-27] during
reassembly.
Remove the injector lines from the engine.

FUEL SYSTEM (CONT'D) Figure 70-70-30
Fuel Injector Removal And Installation (Contd)
Figure 70-70-28
1
2
2
1 P107420A
To aid in assembly, mark one of the injector terminals

P107427 (Item 1) and the lead (Item 2) [Figure 70-70-30].
Do not remove the QR code tags (Item 3) [Figure 70-70-

Remove the injection nozzle oil seal (Item 1) from the 30].
intermediate head cover (Item 2) [Figure 70-70-28].

Installation: Tighten the injector terminal nuts to 1,6 -
Installation: Install new injection nozzle oil seals. 2,2 Nm (1.2 - 1.6 ft-lb) torque.
Figure 70-70-29 Figure 70-70-31
1
1 1 2
1
2
1 1
1
1 1
1
1
P107419 P107421
Remove the retaining bolts (Item 1) from the upper head Remove the retaining bolts (Item 1) and remove the
cover (Item 2) [Figure 70-70-29]. intermediate head cover (Item 2) [Figure 70-70-31].
NOTE: Do not damage the injector harness during NOTE: Do not dislodge or damage the QR tags during
removal. intermediate head cover removal.
Installation: Tighten the retaining bolts to 9,8 - 11,2 Nm Installation: Tighten the retaining bolts to 6,9 - 11,2 Nm
(7.24 - 8.31 ft-lb) torque. (5.07 - 8.31 ft-lb) torque.

FUEL SYSTEM (CONT'D) NOTE: Leak testing can be performed without upper
and intermediate head cover removal.
Fuel Injector Removal And Installation (Contd)
If the decreased pressure is higher than 1,0
Figure 70-70-32 kPa (0,01 bar) (0.1 psi) after four seconds,
there is a fuel leak.
If the engine oil is rising during operation due

to fuel leaking into the crankcase, inspect the
overflow pipe for leaks.
Figure 70-70-34
1
1
1
P107422
1
Remove the over flow tubeline retaining bolts (Item 1)

[Figure 70-70-32].
2

Always replace the overflow gaskets before installation.
P107424
Installation: Tighten the retaining bolts to 9,8 - 11,2 Nm
(7.24 - 8.31 ft-lb) torque.
NOTE: A magnet should be used during disassembly
Figure 70-70-33 to prevent ball (Item 1) [Figure 70-70-34] from
dropping into engine compartment. Do not
lose the ball.
The injector and the injector clamp must be

precisely seated (Item 2) [Figure 70-70-34]
during assembly for proper operation.
P107425
After installing the overflow pipe, in order to check the

fuel leakage, inject low air pressure 20,7 - 34,5 kPa (0,21
- 0,34 bar) (3 - 5 psi.) at the fuel pipe joint (Item 1)
[Figure 70-70-33] and check the fuel leakage of overflow
pipe and gaskets.
In case there is fuel leakage, replace the gaskets, then

check the fuel leakage again.

Fuel Injector Removal And Installation (Contd) 1
Figure 70-70-35
2
3
2
1 P107496A
Remove the injection nozzle assembly O-rings (Item 1)

P107423 and nozzle gasket (Item 2) [Figure 70-70-36].
Always replace the injection nozzle assembly O-rings

Remove the nut (Item 1) from the injection clamp (Item 2) and gasket before installation.
[Figure 70-70-35].

Remove the injector nozzle assembly and gasket (Item 3)
[Figure 70-70-35].
Installation: Check to make sure the ball is in the rocker

arm bracket before tightening the injector nozzle
assemble hold-down clamp.
Installation: Tighten the injection nozzle assembly hold-

down clamp nut to 24 - 27 Nm (18 - 20 ft-lb) torque.
NOTE: Do not disassemble the injector.
Do not remove or damage the injector QR

code tag.
Do not get the injectors out of order. If the

injectors get out of order, it is necessary to
perform injector correction. (See Injector
Correction on Page 70-70-14.)
When replacing injectors, it is necessary to

perform injector correction. (See Injector
Correction on Page 70-70-14.)

Injector Correction
NOTE: When replacing any of the injectors the ID

code must be written to the ECU using the
Diagmaster (Service Tool). 1
Connect the Diagmaster (Service Tool). (See 2

DIAGMASTER (SERVICE TOOL) KIT - 7024161 on Page
10-70-1.)
Figure 70-70-37
P107567
The injector ID code (Item 1) is written on the injector tag

(Item 2) [Figure 70-70-39].
Figure 70-70-40
1
1

2
3
P107548
From the opening screen, click menu (Item 1) [Figure 70-

70-37].
Figure 70-70-38
P107566
2
1 Write the ID code (Item 1) [Figure 70-70-40] to the

correct cylinder box for the injector.
Click on register cylinder (Item 2) or register correction

data for all cylinders (Item 3) [Figure 70-70-40] when
registering more than one cylinder to the ECU.
3
P107938
Select Utility (Item 1), then select Injector Compensation

(Item 2) and press the >> icon (Item 3) [Figure 70-70-
38].

CYLINDER HEAD Intake Air Heater Removal And Installation
Intake Air Heater - Testing Figure 70-80-3
Figure 70-80-1 2
1
4
1 1
P107616
P107481
Remove the two harness bracket retaining bolts (Item 1),
disconnect the boost pressure sensor (Item 2), air
Disconnect the electrical wire (Item 1) [Figure 70-80-1] temperature sensor (Item 3) and throttle valve sensor
from the air intake heater. (Item 4) [Figure 70-80-3].

Installation: Tighten the bolts to 3,5 - 5,3 Nm (2.6 - 3.9 Figure 70-80-4
ft-lb) torque.
1
Figure 70-80-2
4
2
2
5
3
P107617
1
P107481 Remove the two harness bracket retaining bolts (Item 1),
disconnect the DPF temperature sensors (Item 2),
differential pressure sensor (Item 3), mass air flow sensor
Measure the resistance between + terminal (Item 1) and (Item 4) and reposition the harness bracket (Item 5)
intake air heater body (Item 2) [Figure 70-80-2]. [Figure 70-80-4].
If the resistance is open, the intake air heater is faulty.
Intake air Factory spec. Approx. 0.3 ohm

heater resis- (At cold occasion)
tance

CYLINDER HEAD (CONTD) Figure 70-80-7
Intake Air Heater Removal And Installation (Contd)
Figure 70-80-5
1
1
2
P107619
1
Remove the four retaining bolts (Item 1) [Figure 70-80-

P107618 7].
Installation: Tighten the retaining bolts to 24 - 28 Nm

Remove the tubeline bracket retaining bolt (Item 1) and (17 - 20 ft-lb) torque.
remove the air intake hose and clamp (Item 2) [Figure

70-80-5]. Figure 70-80-8
Figure 70-80-6
1
P107484
P107481
Remove the air cleaner flange (Item 1), intake throttle
valve (Item 2) and the intake air heater (Item 3) [Figure
Disconnect the electrical wire from the intake air heater 70-80-8].
(Item 1) [Figure 70-80-6].

Valve Clearance Adjustment
NOTE: Valve clearance must be inspected and

adjusted when engine is cold.
2
Shown with engine removed for photo quality.
Remove the crankcase ventilation filter from the 1

engine.(See Crankcase Ventilation Filter Removal And
Remove the EGR valve (See Removal And Installation on

Page 70-140-4.)
P107435
Remove the air cleaner flange, intake throttle valve and
intake air heater from the engine. (See Intake Air Heater
Removal And Installation on Page 70-80-1.) Loosen the lock nut (Item 1) of adjusting screw (Item 2)
[Figure 70-80-10] (push rod side) and insert the feeler
Figure 70-80-9 gauge between the rocker arm and the bridge head. Set
the adjusting screw to the specified value, then tighten
2 the lock nut.
3

Valve clear- Factory spec. 0,23 - 0,27 mm
ance (0.0091 - 0.010 in)
NOTE: After adjusting, tighten the lock nut (Item 2)

[Figure 70-80-10] securely.
1 Adjustment IN. EX.

Location of piston cylinder
When No. 1 piston is 1st * *
P107499 at compression top 2nd *
dead center
3rd *
Remove the high pressure pipes (Item 1), the upper head 4th
cover (Item 2) and the intermediate head cover (Item 3)
[Figure 70-80-9]. When No. 1 piston is 1st
at overlap position 2nd *
Installation: Tighten the injection pipe retaining nut to 23 3rd *
- 36 Nm (17 - 26 ft-lb) torque.
4th * *
Installation: Tighten the intermediate head cover bolt to
6,9 - 11,2 Nm (5 - 8 ft-lb) torque.
Installation: Tighten the upper head cover bolt to 9,8 -

11,2 Nm (7 - 8 ft-lb) torque.
Set number one piston to top dead center on the

compression stroke.

Cylinder Head Removal And Installation

3
Remove the fuel injectors. (See Fuel Injector Removal
And Installation on Page 70-70-10.) 2
Figure 70-80-11
1 1
P107428
2
Loosen the hose clamps and remove the water return
3
Remove the intake manifold (Item 2) and the exhaust
P-37201 manifold (Item 3) [Figure 70-80-13].

Figure 70-80-14
Remove the rocker arm assembly (Item 1) [Figure 70-80-
11].
Remove the push rods (Item 2) [Figure 70-80-11].
Remove the bridge arms (Item 3) [Figure 70-80-11].
Figure 70-80-12
1
2 P-37266
Remove the cylinder head bolts in the order of (18) to (1)

[Figure 70-80-14], and remove the cylinder head.
Remove the cylinder head gasket.
P-37158 Tightening Cylinder head 98,1 - 107 Nm

torque bolts (72.4 - 79.5 ft-lb)
Place the push rods (Item 1) into the tappets (Item 2)

The cylinder head should be free of scratches and dust.
[Figure 70-80-12], check to see if their ends are properly
engaged with the grooves.
Tighten the cylinder head bolts gradually in the order of
(1) to (18) after applying engine oil to the threads.
NOTE: After reassembling the rocker arm, be sure to
adjust the valve clearance.
Be sure to adjust the valve clearance. (See Valve
Clearance Adjustment on Page 70-80-3.)

Cylinder Head Removal And Installation (Contd)
Figure 70-80-15
1 1
P-37203
Figure 70-80-17
P-100961
1
Make sure to note the notch (a), (b) or (c) of cylinder
head gasket (Item 1) [Figure 70-80-15] in advance.

Replace the same notch (a), (b) or (c) as the original
cylinder head gasket (Item 1) [Figure 70-80-15].
Select the cylinder head gasket thickness to meet with

the top clearance when replacing the piston, piston pin
bushing, connecting rod or crank pin bearing.
Take care handling the gasket so as not to damage it.

3EEABAC1P026A
NOTE: When replacing the piston, piston pin
bushing, connecting rod or crank pin bearing,
select the cylinder head gasket thickness to Measure the piston heads recessing or protrusion from
meet with the top clearance. the crankcase cylinder face (Item 1) [Figure 70-80-16] at
four spots per each piston (Item 1) [Figure 70-80-17]
using the dial gauge as shown in [Figure 70-80-16] and
average the four pistons.
Select the suitable cylinder head gasket, refer to the table below.
Notch of Cylinder Head Thickness of cylinder head gasket Piston Heads recessing
Gasket or protrusion from the
level of crankcase cylin-
der face. (average of 4
pistons)
Before tightening After tightening
2 notches (a) 0,90 mm 0,80 mm -0,07 - +0,049 mm
(0.035 in) (0.031 in) (-0.0028 - +0.0019 in)
1 notch (b) 1,00 mm 0,90 mm +0,050 - +0,149 mm
(0.0394 in) (0.035 in) (+0.0020 - +0.0058 in)
Without notch (c) 1,05 mm 0,95 mm +0,150 - +0,20 mm
(0.0413 in) (0.037 in) (+0.0059 - +0.0078 in)

CYLINDER HEAD (CONTD) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Thoroughly clean the cylinder head surface.
Figure 70-80-18 Figure 70-80-20
2 1
3
5
1 2
P-37204B P-37212
Using a suitable valve spring compression tool remove Measure the clearance with a straightedge (Item 1) and a
the valve spring collets (Item 1), the valve spring retainer feeler gauge (Item 2) [Figure 70-80-20].

(Item 2) and the valve spring (Item 3) [Figure 70-80-18].
Cylinder Head Top Clearance
Remove the valve seal (Item 4) and the valve (Item 5)
[Figure 70-80-18]. Figure 70-80-21
Figure 70-80-19
P-37162
2 P100962
Place a straightedge on the cylinder heads four sides
and two diagonal [Figure 70-80-21].
Install the valve spring with its small-pitch end (Item 1)
downward toward the head side (Item 2) [Figure 70-80- Cylinder Head Allowable 0,05 mm
19]. Surface Flatness Limit 0.002 in
Wash the valve stem and valve guide hole, and apply
If the measurement exceeds the allowable limit, correct it
engine oil sufficiently.
with a surface grinder.
After installing the valve spring collets, lightly tap the
NOTE: Be sure to check the valve recessing after
stem to assure proper fit with a plastic hammer.
correcting.

Valve Guide - Inspecting
The tool described below is not provided. The tool is

used for inserting and removing the valve guides.Use the
dimensions below [Figure 70-80-22] and [Figure 70-80-
23] to make this tool.
Figure 70-80-22
P-37138
Remove carbon from the valve guide section.
Measure the valve stem O.D. with an outside micrometer

[Figure 70-80-24].
Figure 70-80-25

P-37187
Figure 70-80-23
P-37139
P-37188 Measure the valve guide I.D. of the cylinder head at the
most wear part as shown in [Figure 70-80-25] with a
A 20 mm dia. (0.79 in dia.) small hole gauge and calculate the clearance.
B 11,7 - 11,9 mm dia. (0.461 - 0.468 in dia.)
C 6,50 - 6,60 mm dia. (0.256 - 0.259 in dia.)
D 225 mm (8.86 in)
E 70 mm (2.8 in)
F 45 mm (1.8 in)
G 25 mm (0.98 in)
H 5 mm (0.2 in)
I 6,70 - 7,00 mm dia. (0.264 - 0.275 in dia.)
J 20 mm dia (.0.79 in dia.)
K 12,5 - 12,8 mm dia (0.493 - 0.503 in dia.)
L 7,90 - 8,10 mm dia. (0.311 - 0.318 in dia.)
C1 Chamfer 1,0 mm (0.039 in)
C0.3 Chamfer 0,3 mm (0.01 in)

Valve Guide - Inspecting (Contd)
If the clearance exceeds the allowable limit, replace the

valves. If it still exceeds the allowable limit, replace the
valve guide. 1
2
Clearance Factory Intake 0,035 - 0,065
between spec. valve mm (0.0014 -
valve stem 0.0025 in) 3
and guide Exhaust 0,035 - 0,065
valve mm (0.0014 -
0.0025 in)
Allowable 0,1 mm (0.004 in) P-76091
limit
Valve stem Factory Intake 6,960 - 6,975 Press the used valve guide out of the cylinder head (Item
O.D. spec. valve mm (0.2741 - 1) [Figure 70-80-26] using the special driver tool.
0.2746 in)
Put oil on the outside diameter of the new valve guide.
Exhaust 6,960 - 6,975 Press the new valve guide into the cylinder head from the
valve mm (0.2741 - top side. Use the special driver tools (Items 2 and 3)

0.2746 in) [Figure 70-80-26], press the new guide until the tool
contacts the cylinder head.
Valve guide Factory Intake 7,010 - 7,025
I.D. spec. valve mm (0.2760 - Ream the valve guide to the correct specifications.
0.2765 in)
Exhaust 7,010 - 7,025
valve mm (0.2760 -
0.2765 in)

Reconditioning The Valve And Valve Seat 1 2

15 Exhaust
Figure 70-80-27 30 Intake
PI-9995
Check the seat surface and valve face (Item 1) [Figure

PI-9993 70-80-29].
(a) identical dimensions above and below the valve seat

Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-27]. If the seat surface (b) is too wide, use a 30 degree cutter

(Item 2) on the intake, and a 15 degree cutter on the
NOTE: Before correcting the valve and seat, check exhaust to get the correct width (Item 3) [Figure 70-80-
the valve stem and the I.D. of the valve guide 29].
section, and repair if necessary.
Valve Seat Intake 1,5 - 1,9 mm
After correcting the valve seat, be sure to Width (0.059 - 0.074 in)
check the valve recessing [Figure 70-80-31].
Exhaust 2,0 - 2,3 mm
Clean the valve seat and combustion chamber. (0.079 - 0.091 in)
Figure 70-80-28 Valve Seat & Intake 60 degrees

Face Angle Exhaust 45 degrees
Correct the valve with a valve refacer.
After resurfacing the seat, inspect for even valve seating,

apply a thin film of compound between the valve face and
valve seat, and fit them with valve lapping tool.
45 Exhaust
15 Exhaust 60 Intake Check the valve seating with Prussian blue. The valve
30 Intake seating surface should show good contact all the way
around.
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-28].

CYLINDER HEAD (CONTD) Valve Recessing
Reconditioning The Valve And Valve Seat (Contd) Figure 70-80-31
Valve Lapping
Figure 70-80-30
P-37213
Clean the cylinder head, the valve face and seat.

P-37214
Insert the valve into the valve guide.

Apply compound evenly to the valve lapping surface. Measure the valve recessing with a depth gauge [Figure
70-80-31].
Insert the valve into the valve guide. Lap the valve onto
its seat with a valve lapper [Figure 70-80-30]. If the measurement exceeds the allowable limit, replace
the valve.
After lapping the valve, wash the compound away and
apply oil, then repeat valve lapping with oil. If it still exceeds the allowable limit after replacing the
valve, correct the valve seat face of the cylinder head with
Apply Prussian blue to the contact surface to check the a valve seat cutter or valve seat grinder.
percentage of the seated valve. If it is less than 70%,
repeat valve lapping again. Then, correct the cylinder head surface with a surface
grinder, or replace the cylinder head.
NOTE: When valve lapping is performed, be sure to
check the valve recessing and adjust the Valve Factory Intake (recessing)
valve clearance after assembling the valve. recessing spec. valve 0,60 - 0,80 mm
(0.024 - 0.031 in)
Exhaust (recessing)
valve 0,850 - 1,05 mm
(0.0335 - 0.0413
in)
Allowable (recessing)
limit 1,2 mm (0.047 in)

Valve Spring
Figure 70-80-32
P-37254
Measure the free length (A) with vernier calipers [Figure

P-37255 70-80-33]. If the measurement is less than the allowable
limit, replace it.
Place the valve spring on a tester and compress it to the Put the spring on a surface plate, place a square on the
same length it is actually compressed in the engine side of the spring, and check to see if the entire side is

[Figure 70-80-32]. contact with the square. Rotate the spring and measure
the maximum (B) [Figure 70-80-33]. If the measurement
Read the compression load on the gauge. exceeds the allowable limit, replace.
If the measurement is less than the allowable limit, Check the entire surface of the spring for scratches.
replace it. Replace spring, if any are found.
Setting Factory Intake 63,5 N / 31,5 Free length Factory Intake 35,1 - 35,6 mm
load / setting spec. valve mm (14.3 lb / (A) spec. valve (1.39 - 1.40 in)
length 1.24 in)
Exhaust 35,1 - 35,6 mm
valve (1.39 - 1.40 in)
Exhaust 63,5 N / 31,5
Allowable Intake 34,6 mm
valve mm (14.3 lb /
limit valve (1.36 in)
1.24 in)
Exhaust 34,6 mm
Allowable Intake 45,9 N / 31,5
valve (1.36 in)
limit valve mm (10.3 lb /
1.24 in) Tilt (B) Allowable 1,0 mm (0.039 in)
limit
Exhaust 45,9 N / 31,5
valve mm (10.3 lb /
1.24 in)

Valve Tappets
Figure 70-80-34
P-37174
Measure the tappet O.D. with an outside micrometer

P-37202 [Figure 70-80-35].
Measure the I.D. of the tappet guide bore with a cylinder

Remove the tappets (Item 1) [Figure 70-80-34] from the gauge, and calculate the oil clearance [Figure 70-80-35].
crankcase.

If the oil clearance exceeds the allowable limit or the
Before installing the tappets (Item 1) [Figure 70-80-34], tappet is damaged, replace the tappet.
apply engine oil to aid in assembly and initial startup.
Oil clearance Factory 0,020 - 0,062 mm
NOTE: Mark the cylinder number to the tappets to between tappet spec. (0.00079 - 0.0024 in)
prevent interchanging. and guide Allowable 0,07 mm (0.003 in)
limit
Tappet O.D. Factory 23,959 - 23,980 mm

spec. (0.94327 - 0.94409 in)
Tappet guide Factory 24,000 - 24,021 mm
I.D. spec. (0.94489 - 0.94570 in)

CYLINDER HEAD (CONTD)
Rocker Arm And Shaft - Inspecting
Figure 70-80-36
P-37173
Measure the rocker arm bearing I.D. with an inside

micrometer [Figure 70-80-36].

Measure the rocker arm shaft O.D. with an outside
micrometer, and then calculate the oil clearance [Figure
70-80-36].

rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace the rocker arm shaft.

between spec. (0,00063 - 0,0017 in)
rocker arm Allowable 0,15 mm (0.0059 in)
shaft and limit
bearing
Rocker arm Factory 15,973 - 15,984 mm

shaft O.D. spec. (0.62886 - 0.62929
in)
Rocker arm Factory 16,000 - 16,018 mm
I.D. for shaft spec. (0.62993 - 0.63062
in)

CYLINDER HEAD (CONTD) Valve bridge Factory 9,023 - 3,032 mm
shaft arm spec. (0.3552 - 0.3555 in)
Valve Bridge Arm And Shaft - Inspecting
O.D.
Figure 70-80-37 Valve bridge Factory 9,050 - 9,065 mm
arm I.D. spec. (0.3563 - 0.3568 in)
Push Rod Alignment - Inspecting
Figure 70-80-39
P107523
Figure 70-80-38

P-76926
Place the push rod on V blocks [Figure 70-80-39].
Measure the push rod alignment [Figure 70-80-39].
If the push rod exceeds the allowable limit, replace the

push rod.
Push rod Allowable 0,25 mm (0.0099 in)

alignment limit
P107522
Measure the valve bridge arm I.D. with an inside

Measure the valve bridge arm shaft O.D. with an outside

micrometer, and then calculate the oil clearance [Figure
70-80-36].

valve bridge arm and measure the oil clearance again. If
it still exceeds the allowable limit, replace the valve bridge
arm shaft.

between valve spec. (0,00071 - 0,0016 in)
bridge arm Allowable 0,15 mm (0.0059 in)
shaft and limit
valve bridge
arm

CRANKSHAFT AND PISTONS Figure 70-90-2
Piston And Connecting Rod Removal And

Installation
Remove the oil pan. (See Oil Pan Removal And

Remove the cylinder head. (See Cylinder Head Removal

1
Figure 70-90-1
1 P-37159
Align the marks (Item 1) [Figure 70-90-2] with each

other. (Face the marks toward the supply pump.)
Apply engine oil to the connecting rod bolts and lightly

thread it in by hand then tighten it to the specified torque.
If the connecting rod bolts do not thread together

smoothly, clean the threads. If the connecting rod bolt is
still hard to thread in, replace it.
P-37128
NOTE: When using the existing crank bearing, put
marks on the crank pin bearing and the
Remove the connecting rod bolts (Item 1) [Figure 70-90- connecting rod in order to keep their position.
1] from connecting rod cap.
Insert the crank pin bearing.
Remove the connecting rod caps.
Tightening Connecting 79 - 83 Nm
torque rod bolt (58 - 61 ft-lb)

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-4
Piston And Connecting Rod Removal And

Installation (Contd) 1
Remove the top ridge from the cylinder bore with a ridge
reamer.
Turn the flywheel and set a piston to the top dead center.
Remove the piston and connecting rod.
Installation:
Before installing the piston into the cylinder, apply engine

oil to the cylinder to aid in reassembly and initial startup. P-37233A
NOTE: Do not change the combination of cylinder

and piston. Make sure of the position of each When inserting the piston into the cylinder, face the mark
piston by marking. For example, mark 1 on (Item 1) [Figure 70-90-4] on the connecting rod toward
the No. 1 position. the supply pump.

1 Top Ring Gap Oil Ring
Gap
0.79 rad. (45)
Piston
Pin Hole
Second Ring
Gap Oil Ring Gap
P-37208 P-37209
Install the pistons using a piston ring compressor (Item 1) NOTE: When inserting the piston into the cylinder,
[Figure 70-90-3]. place the gap of the compression ring 1 on the
opposite side of the combustion chamber and
stagger the gaps of the compression ring 2
and oil ring marking a right angle from the gap
of the compression ring 1 [Figure 70-90-5].

Piston And Connecting Rod - Servicing

7
The Small End Bushing Replacing Tool can be made
using the dimensions below. One set of dimensions is for 9
8
the press out tool and one for press fit.
6 1
Figure 70-90-6
5
4 3
P-37210
1. Piston Pin
2. Piston
P-37189
3. Piston Pin Snap Ring

4. Compression Ring 1
Small End Bushing Replacing Tool
5. Compression Ring 2
Application: Use to press out and to press fit the small
end bushing in the connection rod. 6. Oil Ring
(Press out) 7. Connecting Rod
A 157 mm (6.18 in) 8. Mark ()

B 14,5 mm (0.571 in)
C 120 mm (4.72 in) 9. Numbering Mark
D 30 mm dia. (1.18 in dia.)
E 32,95 mm dia. (1.297 in dia.) Remove the piston rings using a piston ring tool [Figure
F 20 mm (0.79 in) 70-90-7].
a 0,0000063 mm (0.00025 in)
b 0,0000063 mm (0.00025 in) Remove the piston pin (Item 1), and separate the
C1 Chamfer 1,0 mm (0.039 in) connecting rod (Item 7) from the piston (Item 2) [Figure
C2 Chamfer 2,0 mm (0.079 in) 70-90-7].
(Press fit) Installation: When installing the piston pin, immerse the
piston in 80C (176F) oil for 10 to 15 minutes and insert
A 157 mm (6.18 in) the piston pin to the piston.
B 14,5 mm (0.571 in)
C 120 mm (4.7244 in) Assemble the piston to the connecting rod with the
D 30 mm dia. (1.18 in dia.) mark (Item 8) and the connecting rod numbering mark
E 42,000 mm dia. (1.6535 in dia.) (Item 9) [Figure 70-90-7] facing same side.
F 20 mm (0.79 in)
a 0,0000063 mm (0.00025 in) NOTE: Mark the same number on the connecting rod
b 0,0000063 mm (0.00025 in) and the piston so as not to change the
C1 Chamfer 1,0 mm (0.039 in) combination.

Piston And Connecting Rod - Servicing (Contd)
Figure 70-90-8
P-37161
When installing the ring, assemble the rings so that the

2 manufactures mark (Item 1) [Figure 70-90-10] near the
P-37211A
gap faces the top of the piston.
Be sure the crank pin bearing and the connecting rod are Figure 70-90-11
same I.D. colors (Items 1 and 2) [Figure 70-90-8].

NOTE: Connecting rod is drilled for oil passage to pin
bushing. Make sure to line up pin bushing to
avoid oil starvation to piston pin.
Figure 70-90-9
1
P-37253
2
Measure the piston pin bore I.D. in both the horizontal

and vertical directions with a cylinder gauge [Figure 70-
90-11].
If the measurement exceeds the allowable limit, replace

P-37160
the piston.
When installing the oil ring onto the piston, place the Piston pin Factory 30,006 - 30,013 mm
expander joint (Item 1) on the opposite side of the oil ring bore I.D. spec. (1.1811 - 1.1816 in)
gap (Item 2) [Figure 70-90-9].
Allowable 30,05 mm (1.183 in)
limit

Piston And Connecting Rod - Servicing (Contd)
Figure 70-90-12
1 2
P-37179
Press out the used bushing using a small end bushing

P-37178 replacing tool (Item 1) [Figure 70-90-13].
Figure 70-90-14
Measure the O.D. of the piston pin where it contacts the
bushing with an outside micrometer [Figure 70-90-12].

Measure the I.D. of the piston pin bushing at the
connecting rod small end with a cylinder gauge [Figure 1
70-90-12].

bushing. If it still exceeds the allowable limit, replace the
piston pin.

between piston spec. (0.00079 - 0.0015 in)
pin and small Allowable 0,15 mm (0.0059 in)
end bushing limit P-37142A
Piston pin O.D. Factory 30,006 - 30,011 mm Clean a replacement small end bushing and connecting
spec. (1.1814 - 1.1815 in) rod bore, and apply engine oil to aid in assembly.
Small end Factory 30,031 - 30,046 mm
bushing I.D. spec. (1.1824 - 1.1829 in) Place the bushing onto the tool and press-fit it with a
press (Item 2) [Figure 70-90-13] so that the seam (Item
1) [Figure 70-90-14] of the bushing is flush with the
connecting rod.

CRANKSHAFT AND PISTONS (CONT'D) Piston Ring Gap
Piston And Connecting Rod - Servicing (Contd) Figure 70-90-16
Piston Ring Groove
Figure 70-90-15
P-37180
Insert the piston ring into the lowest part of the liner
P-37215 which is the least worn.
Measure the ring gap with a feeler gauge [Figure 70-90-

Remove carbon from the ring grooves. 16].
Measure the clearance between the ring and the groove If the gap exceeds the allowable limit, replace the piston
with a feeler gauge [Figure 70-90-15]. ring.
If the clearance exceeds allowable limit, check the new Compression Factory spec. 0,30 - 0,45 mm
rings on an old piston and if it is out of spec, replace the ring 1, 2 (0.012 - 0.017 in)
piston.
limit
Factory Compression 0,05 - 0,09 mm
spec. ring 1 (0.002 - 0.003 in)
Oil Ring Factory spec. 0,25 - 0,45 mm
Compression 0,0930 - 0,120 mm
(0.0099 - 0.017 in)
ring 2 (0.00367 - 0.00472 in)
Oil Ring 0,020 - 0,060 mm
limit
(0.00079 - 0.0023 in)
Allowable Compression 0,15 mm (0.0059 in)
limit ring 1
Compression 0,20 mm (0.0079 in)
ring 2
Oil ring 0,15 mm (0.0059 in)

Cylinder Bore - Testing
Figure 70-90-17
1
P-37164
When the cylinder is worn beyond the allowable limit

P-37169 (Item 1), bore and hone it to the specified dimension
(Item 2) [Figure 70-90-19].
Use a gauge to check the inside measurement of the Cylinder I.D. Oversize 100,500 - 100,522
cylinder bore [Figure 70-90-17]. (Item 2) (+ 0,5 mm) mm

Spec. (3.95670 - 3.95755
Figure 70-90-18 in)
Maximum Allowable limit 100,65 mm
wear (3.96260 in)
1
Finishing Hone to 1,2 - 3,0 m Rz.

(0.000048 - 0.00011 in Rz.)
Replace the piston and piston rings with oversize (0,5

mm) ones.
2 NOTE: When the oversize cylinder is worn beyond

the allowable limit, replace the cylinder block
with a new one.
P-37163
Measure six points with a cylinder gauge to find out the

maximum wear [Figure 70-90-18].
NOTE: Generally, position (Item 1) in the (a, b)

direction (at about 20 mm [0.79 in]) from the
top) shows the maximum wear. Since position
(Item 2) [Figure 70-90-18]at the lower part of
the bore will show the minimum wear
Cylinder bore Factory 100,000 - 100,022 mm

I.D. spec. (3.93701 - 3.93787 in)
Allowable 100,150 mm
limit (3.9429 in)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Gear Removal And Installation
Connecting Rod Alignment Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-90-20 110-1.)
Figure 70-90-21
2
3
P-37181
P107517
NOTE: Since the I.D. of the connecting rod small end
bushing is the basis of this check, check the

bushing for wear beforehand. Remove the idler gear (Item 1) [Figure 70-90-21]. (See
Idler Gear And Camshaft Removal And Installation on
Install the connecting rod on the connecting rod Page 70-110-2.)
alignment tool.
Remove the oil pump drive gear (Item 2) [Figure 70-90-
Put a gauge over the piston pin, and move it against the 21].
face plate [Figure 70-90-20].
Carefully remove the crankshaft pulsar gear assembly
If the gauge does not fit squarely against the face plate, (Item 3) [Figure 70-90-21].
measure the space between the pin of the gauge and the
face plate. Remove the crankshaft key.
If the measurement exceeds the allowable limit, replace Figure 70-90-22

the connecting rod.
Connecting rod Allowable 0,05 mm (0.002 in)

alignment limit
P107526
NOTE: Do not separate the pulsar gear or tap on the

pulsar gear when installing the gear.
Replacement of the assembly will be
necessary if separated.

Crankshaft And Bearings Removal 1
Remove the flywheel housing. (See Housing Removal

3 3
Remove the oil pan. (See Oil Pan Removal And
Figure 70-90-23
2
P-37130A
NOTE: Before disassembling, check the end play of

crankshaft. Also check it during reassembly.
Check the crankshaft end play. (See
Crankshaft And Bearings - Servicing on Page
70-90-13.)

3EEABAC1P115A Remove the eight bearing case cover mounting bolts
(Item 2) [Figure 70-90-24].
Application: Use for aligning the block and the lower Install the two bolts removed earlier into the bolt hole
block. (Item 3) [Figure 70-90-24] of bearing case cover to
remove it.
A 115 mm (4.53 in)
B 56 mm (2.2 in) NOTE: Install the bearing case cover / oil seal
C 17 mm (0.67 in) assembly with the casting mark labeled UP
D 20 mm (0.79 in) (Item 1) [Figure 70-90-24] at the top.
E 14 mm dia. (0.55 in dia.)
F 11 mm dia. (0.43 in dia.)
G 14 mm dia. (0.55 in dia.)
H 17,5 mm (0.6890 in)
I 17,5 mm (0.6890 in)
J 35 mm (1.4 in)
K 19 mm (0.75 in)

Crankshaft And Bearings Removal (Contd)
Figure 70-90-25
1
2
2
3EEABAC1P098A
Remove the fourth bearing case (Item 1) and the thrust

bearing (Item 2) [Figure 70-90-27].
P-37133
Figure 70-90-28
Remove the bolts (Item 1) that secure the lower block
[Figure 70-90-25] to the block.

Remove the lower block (Item 2) [Figure 70-90-25].
Figure 70-90-26
1
2
P-37137
Remove the crankshaft [Figure 70-90-28].
3EEABAC1P099A
Remove the bolts (Item 1) and the bearing cases (Item 2)

[Figure 70-90-26] from the block.

Crankshaft And Bearings Installation
Figure 70-90-29
1
1
2
2
3EEABAC1P098A
NOTE: Install the main bearing case having the same

number as the one engraved on the
3EEABAC1P097A
crankcase, and set the casting mark F/W
SIDE on the main bearing case towards the
Install the thrust bearing (Item 1) [Figure 70-90-29] on flywheel side.
both sides of the fourth mainbearing case with the oil
groove facing out. Install the fourth bearing case (Item 1) and the thrust

bearing (Item 2) [Figure 70-90-31].
Install the main bearings (Item 2) [Figure 70-90-29].
Figure 70-90-32
Figure 70-90-30
3EEABAC1P099A
P-37137
NOTE: Install the main bearing case having the same

Install the crankshaft [Figure 70-90-30]. number as the one engraved on the
crankcase, and set the casting mark F/W
SIDE on the main bearing case towards the
flywheel side.
Apply oil to the bearing case bolts and tighten to the

specified torque.
Tightening Main bearing 137 - 147 Nm

torque case bolt (102 - 108 ft-lb)

Crankshaft And Bearings Installation (Contd)

2
Figure 70-90-33
3EEABAC1P096A
Match the block (Item 1) and the lower block (Item 2)

P-37134 [Figure 70-90-34] referring to the flywheels contoured
face.
NOTE: Make sure the block and the lower block are Tighten the lower block mounting bolts loosely.
clean.

Install the tool (Item 3) [Figure 70-90-34] to the specified
Apply liquid gasket (Item 1) [Figure 70-90-33] torque. This helps to minimize the level difference
to the lower block as shown. between the block and the lower block (at the flywheel
side) Gap must be 0,05 mm (0.002 in) or smaller.
Tightening Flywheel housing 78 - 90 Nm

torque bolt (58 - 66 ft-lb)
Figure 70-90-35
P-37133
Tighten the lower block mounting bolts (Item 1) with even

force on the diagonal line to secure the lower block
[Figure 70-90-35] to the block.
Tightening Lower block mounting 49 - 55 Nm


CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Installation (Contd) The following special tools are not provided, [Figure 70-
90-38], [Figure 70-90-39] and [Figure 70-90-23].
Figure 70-90-36
Figure 70-90-38
P-37131
NOTE: When replacing the oil seal, use caution

installing the seal in the bearing case cover as
not to install it tilted. The seal should be flush
with the cover. P-37114

Apply liquid gasket (Item 1) [Figure 70-90-36] to the Gearcase Oil Seal Replacing Tool
bearing case cover evenly.
Application: Use to press fit the oil seal.
Figure 70-90-37
A 148,8 mm (5.858 in)
1
B 50 mm (2.0 in)
C 18,8 mm (0.740 in)
D 13,7 - 13,9 mm (0.540 - 0.547 in)
E 11 mm (0.43 in)
F 18 mm dia. (0.71 in dia.)
G 38 mm dia. (1.5 in dia.)
H 45 mm dia. (1.8 in dia.)
I 57,90 - 58,10 mm (2.280 - 2.287 in)
J 79,5 mm dia. (3.13 in dia.)
K 87 mm (3.4 in)
L 12 mm (0.47 in)
M 40 mm (1.6 in)
P-37130A N 120 mm (4.72 in)
NOTE: Install the bearing case cover / oil seal

assembly with the casting mark labeled UP
(Item 1) [Figure 70-90-37] at the top.
Tighten the bearing case cover mounting bolts with even

force on the diagonal line.
Tightening Bearing Case Cover 24 - 27 Nm

torque mounting bolt (18 - 20 ft-lb)

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft End Play
Crankshaft And Bearings - Servicing (Contd) Figure 70-90-40
Figure 70-90-39
3EEABAC1P105A
Set a dial indicator with its tip on the end of the

crankshaft [Figure 70-90-40].
Measure the end play by moving the crankshaft to the

front and rear.
Crankshaft Factory spec. 0,15 - 0,31 mm

end play (0.0059 - 0.012 in)
limit
P-37115
If the measurement exceeds the allowable limit, replace

Auxiliary Socket For Fixing Crankshaft Sleeve the thrust bearings.
Application: Use to fix the crankshaft sleeve of the diesel
engine.
A Rmax = 12.5 S
B 94,5 - 95,0 mm (3.72 - 3.74 in)
C 40 mm (1.6 in)
D 30 mm (1.2 in)
E 12 mm (0.47 in)
F 7,90 - 8,10 mm (0.311 - 0.318 in)
G 20 mm (0.079 in)
H 130 mm (5.12 in)
I 99,40 - 99,60 mm (3.914 - 3.921 in)
J 95,05 - 95,20 mm (3.743 - 3.748 in)
K 3 mm dia. (0.1 in dia.)
L 15 mm (0.59 in)
M 10 mm (0.39 in)
N 90 mm (3.5 in)
O 115 mm (4.53 in)
P 16,9 - 17,1 mm (0.666 - 0.673 in)

Crankshaft And Bearings - Servicing (Contd)
Figure 70-90-41
P-37182
Support the crankshaft with V block on the surface plate

P-37144 and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-90-42].
If the same size bearing can not be used because of the Rotate the crankshaft on the V block and get the
crankshaft journal wear, replace it with an oversized one misalignment (half of the measurement).

referring to the table and [Figure 70-90-41].
If the misalignment exceeds the allowable limit, replace
Oversize dimensions of crankshaft journal. the crankshaft.
Oversize 0,2 mm 0,4 mm Crankshaft Allowable 0,02 mm

(0.008 in) (0.016 in) alignment limit (0.0008 in)
Dimension A 29,20 - 29,25 mm 29,40 - 29,45 mm
(1.150 - 1.151 in) (1.158 - 1.159 in)
Dimension B 169,10 - 169,15 169,2 - 169,25
mm mm
(6.6575 - 6.6594 (6.6615 - 6.6633
in) in)
Dimension C 2,8 - 3,2 mm 2,8 - 3,2 mm
radius radius
(0.11 - 0.12 in (0.11 - 0.12 in
radius) radius)
The crankshaft journal must be fine-finished to higher

than Rmax = (0.8-S)

Figure 70-90-43 1
P-37147A
NOTE: To replace it with a specific STD service part,

P-37145 make sure the crank pin bearing has the same
ID color (Item 1) [Figure 70-90-44] as the
connecting rod.
Clean the crank pin and crank pin bearing.
ID Connecting Crank pin bearing

Put a strip of plastigage (Item 1) [Figure 70-90-43] on Color rod
the center of the crank pin.
Large-end Class Center wall
NOTE: Never insert the plastigage into the crank pin in dia. thickness
oil hole. Be sure not to move the crankshaft Blue 56,010 - L 1,496 - 1,501
while the connecting rod bolts are tightened. 56,020 mm mm
(2.2052 - (0.05890 -
Install the connecting rod cap and tighten the connecting 2.2055 in) 0.05909 in)
rod bolts to the specified torque, and remove the cap
without 56,00 - S 1,491 - 1,496
again.
Color 56,01 mm mm
(2.2048 - (0.05870 -
Measure the amount of the flattening with the scale, and
2.2051 in) 0.05889 in)
record the oil clearance.
If the oil clearance exceeds the allowable limit, replace Undersize crank pin bearing.
the crank pin bearing.
Undersize Bearing Marking
If the same size bearing can not be used because of the 0,2 mm Crank pin bearing 02 020 US
crank pin wear, replace it with an undersized one (0.008 in)
referring to the table.
0,4 mm Crank pin bearing 04 040 US
(0.016 in)
Crank pin Factory spec. 52,977 - 52,990 mm
O.D. (2.0857 - 2.0862 in)

between crank spec. (0.00071 - 0.0020 in)
pin and crank Allowable 0,20 mm
pin bearing limit (0.0079 in)

Figure 70-90-45
P-37149
Clean the crankshaft journal and crankshaft bearing.

P-37146
Put a strip of plastigage on the center of the journal
[Figure 70-90-46].
Undersize dimensions of crankpin.
NOTE: Never insert the plastigage into the oil hole of

Undersize 0,2 mm 0,4 mm the journal.
(0.008 in) (0.016 in)
Dimension 3,3 - 3,7 mm 3,3 - 3,7 mm radius Install the main bearing case and tighten the bolts to the
A radius (0.13 - 0.14 in specified torque, and remove the cases again.
(0.13 - 0.14 in radius)
radius) Measure the amount of the flattening with the scale and
record the oil clearance.
*Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm radius
B radius (0.040 - 0.059 in If the clearance exceeds the allowable limit, replace the
(0.040 - 0.059 in radius) crankshaft bearing.
radius)
Dimension 52,777 - 52,790 52,577 - 52,590 Crankshaft Factory spec. 74,977 - 74,990 mm
C mm mm Journal O.D. (2.9519 - 2.9523 in)
(2.0779 - 2.0783 (2.0700 - 2.0704
in) in) Oil clearance Factory spec. 0,018 - 0,062 mm
between (0.00071 - 0.0024 in)
crankshaft Allowable 0,20 mm (0.0079 in)
The crank pin must be fine-finished to higher than journal and limit
Rmax = (0.8-S) crankshaft
bearing
*Holes to be de-burred and edges rounded with 1,0 -
1,5 mm (0.040 - 0.059 in) relief.

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Sleeve
Crankshaft And Bearings - Servicing (Contd) Figure 70-90-48
Figure 70-90-47
2
1 4
P-37148
P-37269
Remove the used crankshaft sleeve (Item 1) [Figure 70-
90-48] using a special-use puller set.
Undersize dimensions of crankshaft journal [Figure 70-
90-47]. Set the sleeve guide (Item 4) to the crankshaft (Item 2)

[Figure 70-90-48].
Undersize 0,2 mm 0,4 mm
(0.008 in) (0.016 in) Heat a new sleeve to a temperature between 150 - 200C
Dimension 2,8 - 3,2 mm 2,8 - 3,2 mm radius (302 - 392F), and fix the sleeve to the crankshaft.
A radius (0.11 - 0.12 in
(0.11 - 0.12 in radius) Press the sleeve onto the shaft using the auxiliary socket
radius) (Item 3) [Figure 70-90-48].
*Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm radius
B radius NOTE: Install the sleeve with the chamfered surface
(0.040 - 0.059 in
(0.040 - 0.059 in facing outward.
radius)
radius)
Dimension 74,777 - 74,790 74,577 - 74,590
C mm mm
(2.9440 - 2.9444 (2.9361 - 2.9366
in) in)
Crankshaft pin must be fine-finished to higher than

Rmax = (0.8-S).
*Holes to be de-burred and edges rounded with 1,0 -

1,5 mm (0.040 - 0.059 in) relief.

CRANKSHAFT POSITION SENSOR Removal And Installation
NOTE: Engine removed for photo quality.
Figure 70-100-1
P107503
1
Remove the crankshaft position sensor mounting bolt
P107503 (Item 1) and the crankshaft position sensor (Item 2)
[Figure 70-100-3].

The crankshaft position sensor (Item 1) [Figure 70-100- Installation: Tighten bolt to 4 - 6 Nm (3 - 4 ft-lb) torque.
1] is mounted near the crankshaft gear of the gear case.
When the crankshaft pulsar gear passes by the sensor, it NOTE: If the sensor, gear case and / or the pulsar
alters the magnetic field inside the sensor, generating an gear have been replaced, shim(s) may already
AC voltage, which is output to the ECU. be present. Use care when removing sensor
to not lose the shim(s), if present.
Figure 70-100-2
Inspect the shims for damage and replace or recheck air
gap adjustment using the following method.
NOTE: If the sensor is dropped do not reuse due to

internal damage.
If the sensor, gear case and / or the pulsar
gear are replaced, use a combination of shims
to adjust the sensors air gap. (See Adjusting
on Page 70-100-2.)
P107572
The crankshaft gear has a gap between teeth (Item 1)

[Figure 70-100-3], which alters the waveform of the AC
voltage and the sensor detects the crankshaft position
with every revolution. The engine ECU uses the signals
to calculate the piston position and engine rpm.

CRANKSHAFT POSITION SENSOR (CONT'D) Air Gap of the Crankshaft Position Sensor Measuring tool
1
Adjusting
Application: Use to measure the air gap of the crankshaft
Use the following dimensions for the crankshaft position position sensor.
sensor tools, [Figure 70-100-4], [Figure 70-100-5] and
[Figure 70-100-6] or order MELxxxx from Bobcat parts. A 92 mm radius (3.6 in radius)
Figure 70-100-4 B 13,0 - 13,1 mm dia. (0.512 - 0.515 in dia.)

C 10,000 - 10,015 mm dia. (0.39370 - 0.39429 in
dia.)
D 18 mm dia. (0.71 in dia.)
E 16 mm (0.63 in)
F Chamfer 0,3 mm (0.01 in)
G Chamfer 0,5 mm (0.02 in)
H Chamfer 0,5 mm (0.02 in)
I Chamfer 0,5 mm (0.02 in)
J 5,00 - 5,05 mm (0.197 - 0.198 in)
K 7,0 mm (0.28 in)
L 39,990 - 40,010 mm (1.5744 - 1.5751 in)
M 50 mm (2.0 in)

N 5,0 mm radius (0.20 in radius)
O 0.35 rad (20)
P 0.35 rad (20)
Q 2,0 mm (0.079 in)
R 18,380 - 18,393 mm dia.
(0.72363 - 0.72413 in dia.)
S 92 mm radius (3.6 in radius)
T Chamfer 0,5 mm (0.02 in)
P107518
U 11 mm (0.43 in)
V 13 mm radius (0.51 in radius)
Figure 70-100-5
W 80 mm dia. (3.1 in dia.)
X 8.0 mm radius (0.31 in radius)
Y 6,5 mm dia. (0.26 in dia.)
Z 19,5 mm (0.768 in)
a 12,8 - 12,9 mm dia. (0.504 - 0.507 in dia.)
b Chamfer 0,3 mm (0.01 in)
c Chamfer 0,5 mm (0.02 in)
d 0,4 mm radius (0.02 in dia.)
e 4,95 - 5,00 mm (0.195 - 0.196 in)
f 70,940 - 70,960 mm (2.7930 - 2.7937 in)
g 2,0 mm (0.079 in)
P107519
h 0.35 rad (20)
i 9,978 - 9,987 mm (0.3929 - 0.3931 in)

CRANKSHAFT POSITION SENSOR (CONT'D)
Adjusting (Contd)
Figure 70-100-6
P107520
Air Gap of the Crankshaft Position Sensor Measuring tool

2

Application: Use to measure the air gap of the crankshaft
position sensor.
A 8,0 mm dia. reamer (0.31 in dia. reamer)

B 22,0 mm (0.866 in)
C M4 x Pitch 0.7
D 6,5 mm (0.26 in)
E 34,0 mm (1.34 in)
F 35 mm radius (1.4 in radius)
G 20 mm radius (0.79 in radius)
H 68,0 mm (2.68 in)

CRANKSHAFT POSITION SENSOR (CONT'D) Refer to the measurement recorded earlier and select the
number of shims from the following table.
Adjusting (Contd)
Thickness and Number of Shims
Figure 70-100-7
Protrusion 0,25m 0,50 mm 1,00 mm
(0.0098 in) (0.020 in) (0.0394 in)
2,25 - 2,50 mm 1 2
(0.0886 - 0.0984 in)
1 2,00 - 2,25 mm 2
(0.0788 - 0.0885 in)
1,75 - 2,00 mm 1 1 1
(0.0689 - 0.0787 in)
1,50 - 1,75 mm 1 1
(0.0591 - 0.0688 in)
1,25 - 1,50 mm 1 1
(0.0493 - 0.0590 in)
1,00 - 1,25 mm 1
P107504
(0.0394 - 0.0492)
0,750 - 1,00 mm 1 1
Install Crankshaft position measuring tool 1 (Item 1) (0.0296 - 0.0393 in)
[Figure 70-100-7] into the sensor mount location.
0,500 - 0,750 mm 1

(0.0197 - 0.0295 in)
Figure 70-100-8
0,250 - 0,500 mm 1
(0.00985 - 0.0196 in)
0 - 0,250 mm
(0 - 0.00984 in)
1
Figure 70-100-9
4 1
P107505 5
3
Set the dial gauge at the measurement tool 2 (Item 1)

[Figure 70-100-8] then measure and record the
protrusion of tool 1.
P107941
Air Gap Factory Spec. 0,25 - 1,4 mm
(0.0099 - 0.055 in)
Install the shims (Item 1) between the crankshaft position
sensor (Item 2) and the gear case (Item 3) for the correct
air gap (Item 4) between the crankshaft pulsar gear (Item
5) and the crankshaft position sensor (Item 2) [Figure
70-100-9].

CAMSHAFT AND TIMING GEARS Figure 70-110-3
Timing Gearcase Cover Removal And Installation
Figure 70-110-1
1
2
P-100968
Confirm that the liquid gasket coating surface is free of

P-37231 water, dust and oil in order to maintain sealing effect.
Carefully apply the adhesive evenly (Item 1) [Figure 70-

Remove the crankshaft bolt (Item 1) [Figure 70-110-1]. 110-3].

Remove the drive pulley (Item 2) [Figure 70-110-1]. NOTE: Apply a liquid gasket to the gearcase cover.
NOTE: Clean the crankshaft bolt and the drive pulley NOTE: Assemble the adhesive-applied parts within
sleeve surface thoroughly, apply engine oil to the manufactures specified cure time.
the bolt threads and tighten the bolt securely
to specified torque.
Figure 70-110-4
Tightening Crankshaft 255 - 274 Nm

Figure 70-110-2
1
2
P-100967
1 Be careful not to damage the O-ring (Item 1) and water

pipe (Item 2) [Figure 70-110-4] when reassembling.
P100972
NOTE: Replace O-ring (Item 1) [Figure 70-110-4] when
reassembling.
Remove the gearcase cover (Item 1) [Figure 70-110-2].
Tightening Gear case 25 - 27 Nm
NOTE: Use care when removing the gearcase cover
torque cover (18 - 20 ft-lb)
not to damage the water pipe (Item 2) [Figure
mounting
70-110-2].
bolts

CAMSHAFT AND TIMING GEARS (CONTD) Idler Gear And Camshaft Removal And Installation
Timing Gears Backlash - Testing Figure 70-110-6
Figure 70-110-5 3
4
1 2
5
P107517
P100970
Remove the three idler gear mounting bolts (Item 1) and
remove the idler gear (Item 2) [Figure 70-110-6].
Set a dial indicator (lever type) with its tip on the gear
tooth (Item 1) [Figure 70-110-5]. Remove the four camshaft pulsar gear mounting bolts

(Item 3) and remove the camshaft pulsar gear (Item 4)
Move the gear to measure the backlash, holding its [Figure 70-110-6].
mating gear.
Remove the camshaft set bolts and draw out the
If the backlash exceeds the allowable limit, check the oil camshaft (Item 5) [Figure 70-110-6].
clearance of the shafts and the gear.
Tightening Camshaft 24 - 27 Nm
If the oil clearance is proper, replace the gear. torque set bolt (18 - 20 ft-lb)
Camshaft 4,7 - 5,6 Nm
Crank gear and Factory 0,049 - 0,193 mm
pulsar gear (3.5 - 4.1 ft-lb)
Idle gear spec. (0.0019 - 0.0076 in)
mounting
Allowable 0,22 mm bolt
limit (0.0087 in)
Idle gear 24 - 27 Nm
Idle gear and Factory 0,049 - 0,189 mm mounting (18 - 20 ft-lb)
Camshaft gear spec. (0.0019 - 0.0074 in) bolt
Allowable 0,22 mm
limit (0.0087 in)
Idle gear and Factory 0,030 - 0,165 mm
Supply pump spec. (0.0012 - 0.0065 in)
gear Allowable 0,22 mm
limit (0.0087 in)

CAMSHAFT AND TIMING GEARS (CONTD) Camshaft - Servicing
Idler Gear And Camshaft Removal And Installation End Play

(Contd)
Figure 70-110-8
Installation:
Figure 70-110-7
2
3EEABAC1P102A
4
P100969 Set a dial indicator with its tip on the camshaft [Figure
70-110-8].

Set the crankshaft at the top dead center of No. 1 and 4 Measure the end play by moving the camshaft gear to the
cylinder and the camshaft key (Item 1) to the top position front and rear.
and align the marks of idle gear (Item 2) and camshaft
gear (Item 3) and crank gear (Item 4) [Figure 70-110-7] If the measurement exceeds the allowable limit, replace
to assemble them. the camshaft stopper.
End play Factory 0,070 - 0,22 mm

spec. (0.0028 - 0.0086 in)
Allowable 0,030 mm
limit (0.012 in)

CAMSHAFT AND TIMING GEARS (CONTD) Figure 70-110-10
Camshaft - Servicing (Contd)
Alignment
Figure 70-110-9
P-37176
Measure the height of the camshaft lobe at its highest

point with an outside micrometer [Figure 70-110-10].
P-37175 If the measurement is less than the allowable limit,

replace the camshaft.

Support the camshaft with V block on the surface plate Intake and Factory Intake 37,64 mm
and set a dial indicator with its tip on the intermediate exhaust spec. valve (1.482 in)
journal at right angle [Figure 70-110-9]. camshaft Exhaust 38,96 mm
lobe height valve (1.534 in)
Rotate the camshaft on the V blocks and get the
misalignment (half of the measurement). Allowable Intake 37,14 mm
limit valve (1.462 in)
If the misalignment exceeds the allowable limit, replace
Exhaust 38,46 mm
the camshaft.
valve (1.514 in)
Camshaft Allowable 0,01 mm

Figure 70-110-11
alignment limit (0.0004 in)
3EEABAC1P103A
Measure the cylinder block bore I.D. for camshaft with an

inside micrometer [Figure 70-110-11].

CAMSHAFT AND TIMING GEARS (CONTD) Idler Gear And Shaft - Servicing
Camshaft - Servicing (Contd) Figure 70-110-13
Figure 70-110-12
P-37189
P-37140
Bushing Replacing Tool
Measure the camshaft journal O.D. with an outside Application: Use to press out and press fit the bushing.

1. For idle gear bushing.
camshaft. A 196 mm (7.72 in)
B 37,5 mm (1.48 in)
Oil clearance Factory 0,050 - 0,091 mm C 150 mm (5.91 in)
of camshaft spec. (0.0020 - 0.0035 in) D 44,95 mm dia.
journal Allowable 0,15 mm (1.770 in dia.)
limit (0.0059 in) E 48,075 - 48,100 mm dia.
(1.8928 - 1.8937 in dia.)
F 20 mm dia. (0.79 in dia)
Camshaft Factory 45,934 - 45,950 mm
a 0,0000063 mm (0.00025 in)
journal O.D. spec. (1.8085 - 1.8090 in)
b 0,0000063 mm (0.00025 in)
Camshaft Factory 46,000 - 46,025 mm C1 Chamfer 1,0 mm (0.039 in)
journal I.D. spec. (1.8111 - 1.8120 in) C2 Chamfer 2,0 mm (0.079 in)

CAMSHAFT AND TIMING GEARS (CONTD) Figure 70-110-16
Idler Gear And Shaft - Servicing (Contd)
End Play
Figure 70-110-14
P-37141
Measure the idle gear bushing I.D. with an inside

micrometer, and calculate the oil clearance [Figure 70-
110-16].
If the oil clearance exceeds the allowable limit, replace

3EEABAC1P101A the bushing.
Clearance Factory 0,050 - 0,091 mm

Set a dial indicator with its tip on the idle gear [Figure 70-
110-14]. between idle spec. (0.0020 - 0.0035 in)
gear shaft Allowable 0,10 mm
Measure the end play by moving the idle gear to the front and idle gear limit (0.0039 in)
and rear. bushing
If the measurement exceeds the allowable limit, replace Idle gear Factory 45,025 - 45,050 mm
the idle gear collar. bushing I.D. spec. (1.7727 - 1.7736 in)
Idle gear Factory 44,959 - 44,975 mm
End play Factory 0,15 - 0,30 mm shaft O.D. spec. (1.7701 - 1.7706 in)
spec. (0.0059 - 0.011 in)
limit
Figure 70-110-15
P107436
Measure the idle gear shaft O.D. with an outside


CAMSHAFT AND TIMING GEARS (CONTD)
Idler Gear And Shaft - Servicing (Contd)
Figure 70-110-17
P-37177
Using an idle gear bushing replacing tool, press out the

used bushing.

Clean a new idle gear bushing and idle gear bore, and
apply engine oil to them.
Using an idle gear bushing replacing tool, press in a new

bushing to the specified dimension [Figure 70-110-17].


TURBOCHARGER
Description
The turbocharger is located between the exhaust and

intake manifolds. It is driven by hot exhaust gases and
supplies air at more than atmospheric pressure to the
intake. Lubrication for the turbocharger is supplied with
pressurized oil from the main engine oil galley.
Figure 70-120-1

P107826
The oil is delivered to the turbocharger through a tubeline

(Item 1) and returns to the engine block through a
drainage tubeline (Item 2) [Figure 70-120-1].
The turbocharger internal components are not

serviceable.

TURBOCHARGER (CONTD) Figure 70-120-3
Removal And Installation 6 2
5
1
WARNING
4
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
3
NOTE: Engine removed for photo clarity. P107403
Figure 70-120-2
Loosen the intake hose clamp (Item 1) and remove the
intake hose (Item 2) [Figure 70-120-3].
1
2 Loosen the air cleaner hose clamp (Item 3) and remove
the air cleaner hose (Item 4) [Figure 70-120-3].

Loosen the crankcase ventilation filter hose clamp (Item
5) and remove the hose (Item 6) [Figure 70-120-3].
3
Installation: Tighten the hose clamp (Item 3) [Figure 70-
4 120-3] to 3,4 - 4,0 Nm (30 - 35 in-lb) torque.
Figure 70-120-4
P107826
1
Remove the bolt (Item 1) and tubeline (item 2) [Figure

70-120-2].
Remove the bolts (Item 3) and tubeline (Item 4) [Figure

70-120-2].
NOTE: Always install new copper sealing washers on

the tubeline bolts.
1
P107824
Remove the four exhaust tube bolts (Item 1) [Figure 70-

120-4].

Removal And Installation (Contd) 1 4
Figure 70-120-5
1 1
3
2 3
1
1 P107404A
3 Remove the turbocharger mounting bolts (Item 1)

P107827 [Figure 70-120-7].
Remove the turbocharger assembly (Item 2) [Figure 70-

Move the clamp (Item 1) back on the hose. Remove the 120-7].
bolt (Item 2) [Figure 70-120-5] and set the cooling tube

aside. Remove the two bolts (Item 3) from the turbocharger
flange mount (Item 4) and remove flange [Figure 70-120-
Remove the four bolts (Item 3) [Figure 70-120-5] and 7].
remove the EGR tube.
Figure 70-120-6
P107366
Remove the two EGR heat shield mounting bolts (Item 1)

and remove the shield (Item 2) [Figure 70-120-6].

TURBOCHARGER (CONTD)
Testing
Turn the compressor wheel gently with a finger and check

for contact.
If the wheel does not turn smoothly, check the axial and
radial clearance.
If the compressor / turbine wheel and housing is

damaged, replace the turbocharger assembly with a new
one.
Figure 70-120-8

P-76099
Move the compressor / turbine wheel (up and down, right

and left) (Item 1) [Figure 70-120-8].
If the compressor / turbine wheel contacts the housing,

replace the turbocharger assembly.
Check the oil tubelines for leaks.

EGR Cooler Testing
Figure 70-120-9
2
1 P107610
3
4 Block the EGR cooler exhaust gas outlet (Item 1) [Figure

P107609 70-120-7].
Attach an air hose to the EGR cooler exhaust gas inlet

Block the EGR cooler exhaust gas inlet (Item 1), EGR (Item 2) [Figure 70-120-7] and submerge in water.
cooler exhaust gas outlet (Item 2) and the coolant outlet

(Item 3) [Figure 70-120-7]. The coolant passage must be filled with water.
Attach an air hose to the EGR cooler coolant inlet (Item Apply 290 kPa (2,9 bar) (43 psi) air pressure to the air
4) [Figure 70-120-7] and submerge in water. hose side and check for leaks in the EGR cooler.
Apply 250 kPa (2,5 bar) (36 psi) air pressure to the air Replace the EGR cooler if leaks are detected.
hose side and check for leaks in the EGR cooler.
Replace the EGR cooler if leaks are detected.


FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-130-2
Remove the drive belt. (See Belt Replacement on Page

30-60-2.) 1
Remove the belt tension pulley assembly. (See DRIVE

BELT on Page 30-60-1.)
Figure 70-130-1
P-37365
1
The ring gear (Item 1) [Figure 70-130-2] on the flywheel
is an interference fit. Heat the ring gear enough to
expand it and hit it with a hammer to remove it evenly.

Clean the outer surface of the flywheel to give it a smooth
P100238 fit.
Clean the new ring gear and heat it to a maximum

Remove the bolts (Item 1) [Figure 70-130-1] from the temperature of 220C (428F).
flywheel.
NOTE: The lead chamfer on ring gear tooth must face
Remove the flywheel from the engine crankshaft. the starter.
Installation: Apply engine oil to the bolts and tighten the Fit the ring gear over the flywheel. Make sure the gear is
flywheel bolts to 98 - 108 Nm (72 - 80 ft-lb) torque. seated properly.
Installation: There are two alignment pins that are used

to install the flywheel in the proper position for timing
purposes.

FLYWHEEL AND HOUSING (CONTD)
Housing Removal And Installation
Remove the drive belt. (See Belt Replacement on Page

30-60-2.)
Remove the hydrostatic pump. (See Removal And

Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Remove the starter. (See Removal And Installation on

Page 60-40-1.)
Figure 70-130-3
1
1

1
1
1
P100237
Remove the flywheel housing mounting bolts (Item 1)

[Figure 70-130-3].

(58 - 66P ft-lb) torque.
Remove the flywheel housing from the engine.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Electrical EGR consists of a water cooled EGR cooler, electric EGR valve, reed valve and EGR valve lift
sensor. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The degree the EGR valve is open is detected by the EGR valve lift sensor and a motor is used to set this to the degree
of open calculated using signals including the engine speed. Passing engine coolant through the housing enables
controlling temperature rise of the EGR valve. The reed valve between the EGR valve and the intake manifold prevents
fresh air from flowing into the EGR system.
Figure 70-140-1
7 1 1
2

11
9
10
4
13
10
12
14
11
13
3
6
12
P107525
The items listed below refer to Page 70-130-1 [Figure 7. Boost Pressure Sensor
70-140-1]. 8. Intake Throttle Valve
9. Intake Air Heater
1. EGR Valve Lift Sensor 10. Intake Air
2. Electrical EGR Valve 11. Exhaust Gas
3. Reed Valve 12. Coolant Inlet
4. Intake Manifold 13. Coolant Outlet
5. Exhaust Manifold 14. Turbo Charger
6. EGR Cooler

(CONT'D)
Testing WARNING
procedure: AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
MEL1563 - Remote Start Tool Kit system can be hot. Use caution when conducting
7024161 - Diagmaster (Service Tool) Kit diagnostic tests.
Allow the engine to cool before servicing.

WARNING W-2716-0208
Start Diagmaster (Service Tool).

When the engine is running during service, the Figure 70-140-2
steering levers or joysticks must be in neutral and
the parking brake engaged.
W-2717-0208 1
WARNING

MACHINE FALLING OR MOVING CAN CAUSE
2
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
P107603
1.)
Perform an EGR actuation test (Item 1) and follow all
Open the rear door. instructions and cautions (Item 2) [Figure 70-140-4].
Connect the Diagmaster (Service Tool).(See Diagmaster Based on the results, check that the EGR valve gas
(Service Tool) on Page 10-70-1.) passage and coolant passage are not clogged.
10-61-1.)
WARNING
fumes. If the engine is stationary, vent the exhaust
gases which can kill without warning.
W-2050-0807

(CONT'D)
Testing (Contd)
NOTE: EGR valve shown removed for photo quality.
Figure 70-140-3
2
1
P107604

Clean any soot from the gas passage (Item 1) [Figure
70-140-4] so it does not damage the EGR valve.
Clean the coolant passage (Item 2) [Figure 70-140-4] by

flushing it with water.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-140-5
(CONT'D)
WARNING 2
3
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting 1
diagnostic tests.
1
Allow the engine to cool before servicing. 2
W-2716-0208 P107415
Allow the engine to cool before working on the EGR Remove the retaining bolts and nuts (Item 1) and
system. disconnect the two cooler pipes (Item 2) [Figure 70-140-
5].
Figure 70-140-4
Remove the EGR valve assembly (Item 3) [Figure 70-
2 140-5].

1 4
gaskets.
P107360
Remove the bolts (Item 2) and disconnect the EGR pipe

(Item 1) [Figure 70-140-4].
Remove the connector (Item 3) from the EGR valve (Item

4) [Figure 70-140-4].

gaskets.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1

The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-7
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-17
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
CONDENSER (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

CONDENSER (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-61-1


RECEIVER / DRIER (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schraeder Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
RECEIVER / DRIER (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-71-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-71-1
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-71-3
Schraeder Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-71-4
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1


EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

EVAPORATOR / HEATER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil

and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6

1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R-134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
b-16691

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1
1
2
P-89545
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P100384 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3689 kPa (36 bar)
P-85824 (535 psi).
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
2
Figure 80-10-5 4
3
1
P101946
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P100889 10-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.

cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat and A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater / Evaporator Blower [Figure 80-10-7]: The blower
(Item 4) is used to push air through the heater and
evaporator coils and into the cab.
P100878
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

Components (Cont'd)
Figure 80-10-8
1
1
2
3
4 P-89545
Pressure Switch: The pressure switch (Item 1) [Figure

P-92638 80-10-10] will disengage the compressor clutch at high
pressure readings over 2648 kPa (26,5 bar) (384 psi) on
the high side, or at very low pressure of 193 kPa (1,9 bar)
Control Panel: The panel (Item 1) [Figure 80-10-8] has (28 psi) or less on the high side, which indicates loss of
three separate components. refrigerant.

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the key switch.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-9
P101968
Heater Valve: The heater valve (Item 1) [Figure 80-10-9]

is used to control the amount of engine coolant that flows
to the heater coil.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment WARNING

Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8C (21.6F)
INSTANTLY. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-12
WARNING

HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
P16399 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Recirculation Filter
Filters Figure 80-20-2
Fresh Air Filters
Figure 80-20-1
1
2 P100755
3
The recirculation filter is located behind the operators
seat inside the operator cab. The filter cover is held in
P-90489A
place with three clips. Pull the cover at each end (Item 1)
P-90492A
[Figure 80-20-2] to remove.

The fresh air filters are located behind the side windows Rinse the filter elements with water or use a vacuum to
outside the operator cab. (Right side shown) Remove the clean. Do not use solvents.
retaining screw (Item 3) and filter cover (Item 2) [Figure
80-20-1]. Line up the clips on the filter cover with the slots provided
and push the cover into place.
NOTE: Loosen the upper filter cover bolt (Item 1)
[Figure 80-20-1] to allow removal and
installation of the cover if equipped with the
High-Efficiency Particulate Air (HEPA) filter
kit.
Shake the filter (Item 4) [Figure 80-20-1] or use low

pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter,
filter cover and retaining screw.

REGULAR MAINTENANCE (CONTD) Move the air conditioning compressor toward the engine
as far as it will go and remove the belt from the pulleys.
Belt Adjustment
Inspect the pulleys for wear.
The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt Install new belt.
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your dealer for Figure 80-20-4
replacement parts.
Belt Replacement
Stop the engine and open the rear door (See REAR
DOOR (TAILGATE) on Page 50-70-1.).
Figure 80-20-3
P100271

Insert a breaker bar (Item 1) [Figure 80-20-4] into the
1 square opening provided in the air conditioning
compressor bracket as shown. Move the breaker bar
down until the bottom air conditioning compressor
mounting bolt (Item 1) [Figure 80-20-3] can be installed.
P100070
Tighten the mounting nut and bolts (Items 1 and 2)
[Figure 80-20-3].
Condenser
The condenser should be cleaned with the oil cooler and

the radiator.
2
Air Conditioning Lubrication
Operate the air conditioning for about 5 minutes every

week to lubricate the internal components.
P100071
NOTE: The engine is shown removed for photo

clarity.
Remove the bottom air conditioning compressor

mounting bolt (Item 1) [Figure 80-20-3].
Loosen the top air conditioning compressor mounting nut

and bolt (Item 2) [Figure 80-20-3].

REGULAR MAINTENANCE (CONTD)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

REGULAR MAINTENANCE (CONTD) Figure 80-20-7
Evaporator / Heater Coil

1
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 80-20-5
2
P109544
1 Clean the plenum drains (Item 1) [Figure 80-20-7] to

ensure they are not plugged by debris.
Inspect the cover seal (Item 2) [Figure 80-20-7] for

breaks and tears. Ensure the seal is firmly attached all
around the cover. See your dealer for a replacement seal.

P100756 Figure 80-20-8
Unhook cover latches (Item 1) [Figure 80-20-5] and

remove the cover.
2
Figure 80-20-6
P109411
2
NOTE: The bosses (Item 1) fit inside the core
supports (Item 2) [Figure 80-20-8] when the
cover is installed. Deformity of the cover
P100757 indicates they are out of position.
Use low pressure air or water to remove debris from the

heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-5].

REGULAR MAINTENANCE (CONTD) Figure 80-20-11
Evaporator / Heater Coil (Contd)
NOTE: Improper cover installation can damage the

seal, which may lead to HVAC component
failure. Perform the following steps in the
order given to prevent cover seal damage.
Figure 80-20-9 1
P100756
3. Fasten the two remaining latches (Item 1) [Figure 80-

20-11].
NOTE: Perform a thorough visual check to ensure

that the cover and the cover seal are not
deformed. The cover should seal tightly all

P109546
around without any gaps.

1. Hold the cover in place and fasten two latches (Item 3.)
1) [Figure 80-20-9].
Figure 80-20-10
1 2 3
P109543A P109545
2. Push the cover up in three places (Items 1, 2, and 3)

until the slots snap into place on the tabs. This slot
(Inset) [Figure 80-20-10] is correctly fastened.


TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch malfunc- Check power into and out of the fan switch. Replace Fan Switch.
tion.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly con- Repair or adjust.
nected and seals are not damaged.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.

(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor mal- The compressor is locked up and the belt slips. Replace compressor.
function.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness compo- Test the conductance of the pressure switch, ther- Check operation / thermostat
nents. mostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38C (86 - 96F)
and compressor speed of approximately 3200 rpm are:
High pressure side pressure: 1447,9 - 1827,1 kPa (210 - 265 psi) (14,5 - 18,3 bar)
Low pressure side pressure: 103,4 - 227,5 kPa (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equal- Replace compressor.
sor. ize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct

level.
2. Clogged or closed The expansion valves inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostats tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
P100890

Troubleshooting Tree (Contd)
p100892

Troubleshooting Tree (Contd)
P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP TEMP TEMP TEMP
kPa BAR PSIG kPa BAR PSIG
C F C F
-8,8 16 108,2 1,08 15.69 33,9 93 759,8 7,60 110.20
-7,8 18 117,5 1,17 17.04 34,4 94 773 7,73 112.10
-6,7 20 127,1 1,27 18.43 35 95 786,7 7,87 114.10
-5,6 22 137 1,37 19.87 37,8 100 857,1 8,57 124.30
-4,4 24 147,2 1,47 21.35 38,9 102 886 8,86 128.50
-3,3 26 157,8 1,58 22.88 40 104 916,3 9,16 132.90
-2,2 28 168,7 1,69 24.47 41,1 106 946,7 9,47 137.30
-1,1 30 180 1,80 26.10 42,2 108 978,4 9,78 141.90
0 32 191,6 1,92 27.79 43,3 110 1010.1 10,10 146.50
1,1 34 203,5 2,04 29.52 44,4 112 1043,2 10,43 151.30
2,2 36 216 2,16 31.32 45,6 114 1076,3 10,76 156.10
3,3 38 228,7 2,29 33.17 46,7 116 1110,7 11,11 161.10
4,4 40 241,8 2,42 35.07 47,8 118 1145,2 11,45 166.10
5,6 42 255,3 2,55 37.03 48,9 120 1181,1 11,81 171.30

6,7 44 269,3 2,69 39.05 50 122 1217,6 12,18 176.60
7,2 45 276,4 2,76 40.09 51,1 124 1254,8 12,55 182.00
10 50 313,6 3,14 45.48 52,2 126 1292,8 12,93 187.50
12,8 55 353,5 3,54 51.27 53,3 128 1331,4 13,31 193.10
15,6 60 396,3 3,96 57.47 54,4 130 1371,4 13,71 198.90
18,3 65 442 4,42 64.10 57,2 135 1473,4 14,73 213.70
21,1 70 490,8 4,91 71.19 60 140 1581,7 15,82 229.40
23,9 75 543 5,43 78.75 62,8 145 1694,7 16,95 245.80
26,7 80 598,5 5,99 86.80 65,6 150 1813,3 18,13 263.00
29,4 85 657,8 6,58 95.40 68,3 155 1938,1 19,38 281.10
32,2 90 719,8 7,20 104.40 71,1 160 2069,1 20,69 300.10
32,8 91 733 7,33 106.30 73,9 165 2207,1 22,07 320.10
33,3 92 746,1 7,46 108.20 76,7 170 2349,7 23,50 340.80

Temperature / Pressure Chart (Contd)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 4.5 - 5,5C (8 - 10F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4C (40F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature = 90F

90F
+40F
130F condenser temperature = 200 psig
Conditions and pressures will vary from system to system.

TROUBLESHOOTING (CONT'D) Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
Poor A/C Performance 60-1.)
Start the loader, lock the park brake, and engage the A/C Check the A/C evaporator coil for dirt or mud and clean if
system with the blower fan on High. Run the loader at full necessary. (See Removal And Installation on Page 80-
RPM for approximately 15 minutes, with the loader cab 110-1.)
door closed.
Check the engine coolant to see if it is bypassing the
Figure 80-30-1 heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-17.)

P-90356
Figure 80-30-2
N-22411
Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 7,2 - 11,7C

(45 - 53F) depending on the amount of humidity in the
air and ambient temperature.
If louver temperature is too high. (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower for proper operation, or noise, and

replace if necessary. (See Removal And Installation on
Page 80-130-1.)

HVAC Repair And Leaks
Figure 80-30-3
P-90361
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /

drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONTD) Figure 80-30-6
Electrical System
Check to see if the compressor clutch is engaging.

1
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN, without starting
the loader.
Figure 80-30-4
P-90357
Locate the loader harness and the compressor clutch

wire (Item 1) [Figure 80-30-6].
2
1 Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.

Figure 80-30-7
P-92638
Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON
position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
P-90358
With a multi meter, check the resistance to the

1 compressor clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor

clutch.
P107514A
If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.
Open the rear door (tailgate).

Electrical System (Contd)
Figure 80-30-8
P-90360
1
Using a multi meter check the loader wiring harness

P-90358 (Item 1) [Figure 80-30-10] for voltage.
The voltage should be battery voltage.

With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, check the

harness for broken wires.
The voltage reading should be battery voltage.
Figure 80-30-11
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Figure 80-30-9
1
P-90360
If there is voltage at the harness, check the resistance at

2
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, check for low refrigerant

1 P-90361 level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

Figure 80-30-12
1 P-90363
Disconnect the blower wiring connector (Item 1) [Figure

P100951 80-30-14] from the loader wiring harness.
Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
1
P-90362
2
Check the loader harness (Item 1) [Figure 80-30-15] for
1
voltage. The voltage should be battery voltage.
P-90362
If there is no voltage at the wiring harness, check the
Check the loader harness (Item 1) [Figure 80-30-13] for
voltage. The voltage should be battery voltage. If there is voltage at the wiring harness, check the
resistance to the blower at the blower wiring connector
If there is no voltage at the wiring harness, check the (Item 2) [Figure 80-30-15].
If there is no resistance value replace the blower. (See
If there is voltage at the wiring harness, check the
thermostat (Item 2) [Figure 80-30-13] for resistance.
If there is a resistance value check the climate controls at
The resistance value of the thermostat should be 10 ohm
the control panel inside the loader cab.
at 20C (68F).
If there is no resistance value, replace the thermostat.

(See Removal And Installation on Page 80-90-2.)
If there is a resistance value, check the blower.

Figure 80-30-16 C
H
B
1 M
N-22288
If there is voltage at the wiring harness, check the blower

P-90364 switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame

[Figure 80-30-18].
Figure 80-30-17
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the

blower switch.
If the above resistance tests are good, check the A/C

P-90365 switch.
Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.
Check the loader harness for voltage. The voltage should

be battery voltage.


TROUBLESHOOTING (CONTD) If no resistance value is found, replace the A/C switch.
Electrical System (Contd) If a resistance value is found, check the potentiometer.
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does

not work, check the potentiometer.
1
Figure 80-30-21
1
P-90367
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.

Check the harness for voltage. The voltage should be
P-90366
battery voltage.
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Figure 80-30-20 Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be battery voltage.

1
2
N-22289
If there is voltage at the wiring harness, check the A/C

switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no

continuity between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

continuity between terminal (Item 1) and terminal (Item 2)
[Figure 80-30-20].

Electrical System (Cont'd)
Figure 80-30-22
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0K
ohm.
If there is voltage at the wiring harness, check the Check the resistance between the wire terminal C and
potentiometer [Figure 80-30-22] for resistance. wire terminal B frame [Figure 80-30-24] should be

around 10K ohm.
The resistance should be 10K ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
P-90368
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

TROUBLESHOOTING (CONTD) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Raise the lift arms and install an approved lift arm
Figure 80-30-25
Figure 80-30-27
2 3
1
1
P-90369
P-90364A
To check the resistance of the white wire, turn the Push the A/C switch (Item 1) to the OFF position, turn the
potentiometer control (Item 1) [Figure 80-30-25] blower switch (Item 2) to position 1, then turn the

clockwise to the full Heater position. temperature control (Item 3) [Figure 80-30-27]
counterclockwise to the full A/C position, with the loader
Figure 80-30-26 key switch OFF.

C 10-61-1.)
A
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
B
N-22290
Check the resistance between the wire terminal A and

wire terminal B frame [Figure 80-30-26] should be
around 10K ohm. 1
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 80-30-26] should be
around 0K ohm.
P-90371
If the resistance is not found replace the potentiometer.
Check the heater hose (Item 1) [Figure 80-30-28] for

temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replace.

Heater Valve Not Opening Or Closing

Figure 80-30-29
P100896
NOTE: The HVAC assembly is removed for photo

2 3 clarity.
1
Place the remote start tool on the left fender of the
P-90364A loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of

the remote start is turned to the ON position without
Push the A/C switch (Item 1) to the OFF position, turn the starting the loader. The heater valve should rotate. Place
blower switch (Item 2) to position 1 and turn the a mark on the loader shaft.
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader key switch OFF. Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE Turn the temperature control (Item 3) [Figure 80-30-29]
START TOOL (SERVICE TOOL) KIT - 7217666 on Page to the High Heater position, with the loader key switch
10-61-1.) OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-11.)
Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)

SYSTEM CHARGING AND RECLAMATION Follow the steps displayed on the refrigerant identifier
screen.
Refrigerant Identification
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
WARNING and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.

If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
gas.
W-2371-0611
and properly and safely disposed of.
If R-134a is found, evacuate the system.

Figure 80-40-1

N-23024
NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

Connect the Refrigerant Identifier to the low pressure

hose.
Connect the Refrigerant Identifier to its power source.

SYSTEM CHARGING AND RECLAMATION (CONT'D) IMPORTANT: Only trained technicians should
perform the reclaiming and recharging.
Reclamation And Charging With Recovery / Charging
Unit

WARNING
Raise the operator cab. (See Raising on Page 10-30-2.) HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
Figure 80-40-2 blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
Gaseous R-134a becomes lethal (phosgene) gas
1 when it contacts open flame or very hot
substances.
NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
refrigeration equipment.
2 W-2373-0611

Use an approved recovery / charging unit [Figure 80-40-
P-90372 3] to evacuate the system.
Locate the low pressure port (Item 1), and high pressure
port (Item 2) [Figure 80-40-2].
WARNING
gas.
W-2371-0611
Figure 80-40-3
N-22291

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Unit (Cont'd)
Figure 80-40-4
N-22292
Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P100385
NOTE: The A/C system holds 0,91 kg (2 lb) of
refrigerant.
Figure 80-40-5

Figure 80-40-7
P100950
N-22381
Connect the reclaimer to the loader A/C charge ports

(Item 1) [Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 2) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 3) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.


COMPRESSOR Figure 80-50-2
NOTE: If compressor is being removed for engine

removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor. 1

Evacuate the A/C system. (See Reclamation And 2

Charging With Recovery / Charging Unit on Page 80-40-
P100070
2.)
Open the rear door. Remove the compressor bolt (Item 1) and the belt (Item
2) [Figure 80-50-2].
NOTE: The engine is removed for photo clarity.
Installation: Tighten the compressor mount bolt to 46
Figure 80-50-1 Nm (34 ft-lb) torque.

WARNING
gas.
W-2371-0611
1
P101512
Disconnect the loader harness (Item 1) [Figure 80-50-1]

from the compressor clutch wire.

COMPRESSOR (CONT'D)
Figure 80-50-3
1
2
P-89543
Remove the compressor hoses (Item 1) & (Item 2)

[Figure 80-50-3] from the compressor.

NOTE: A wrench must be used to hold the
compressor fittings when the compressor
hoses are being removed or damage will
occur to the compressor body.
Installation: Tighten the compressor hose (Item 1) to 30

Nm (22 ft-lb) torque. Tighten the compressor hose (Item
2) [Figure 80-50-3] to 45,4 Nm (33.5 ft-lb) torque.
Cap and plug the compressor hoses and the fittings with
Figure 80-50-4
P101247
Remove the compressor bolt and nut (Item 1) [Figure 80-

50-4].
Remove the compressor from the loader.

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
Oil RECLAMATION on Page 80-40-1.)
Figure 80-50-5 Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200

rpm.
Remove the compressor from the loader. (See Removal

1 And Installation on Page 80-50-1.)
P100384
The compressor (Item 1) [Figure 80-50-5] is factory filled

with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).

It is not necessary to frequently check or change the
compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
When ever the evaporator, condenser or receiver-

drier is replaced.
Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 100 oil should be used, and never

mix R-12 and R-134a Oils.
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check
Figure 80-50-6
1
1
P-90487
Add new compressor oil through the suction side

P-90487 connector (Item 1) [Figure 80-50-8].
Installation: Add 150 - 170 cc's of PAG 100 oil.

Drain the oil through the connectors (Item 1) [Figure 80-
50-6]. NOTE: The suction port on the compressor is marked

with an SUC and is the larger port on the
Figure 80-50-7 compressor.
P-90486
NOTE: After draining the oil, extract the remaining oil

through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
7] several times by hand.
Measure the drained oil in a measuring cylinder.
Inspect the oil for contamination, dirt, metal shavings, or

varnish color.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

CONDENSER (EARLY MODELS) Figure 80-60-2


1.)
1
Remove the refrigerant from the A/C system. (See
Unit on Page 80-40-2.)
P101510
Figure 80-60-1
Disconnect the hose (Item 1) on page 1 that routes

from the condenser to the receiver / drier.
1 Installation: Tighten the hose to 30 Nm (22 ft-lb) torque.
Cap and plug the hose and the condenser fittings with
2

the proper A/C caps and plugs.
Figure 80-60-3
1 1
P101651
1
Remove the bolts (Item 2) and brackets (Item 2) [Figure

80-60-1].
WARNING
P101511
contact with a flame, R-134a refrigerant gives a toxic Disconnect the hose (Item 1) [Figure 80-60-3] that
gas. routes from the condenser to the compressor.
W-2371-0611
Installation: Tighten the hose to 30 Nm (22 ft-lb) torque.
Remove the condenser.


CONDENSER (LATER MODELS) Figure 80-61-2


1.)

P114505
WARNING Unhook the two rubber straps (Item 1) [Figure 80-61-2].
Figure 80-61-3
gas.

W-2371-0611
1
Figure 80-61-1
P121217B
Raise the air conditioning condenser (Item 1) [Figure 80-

61-3].
NOTE: The air conditioning condenser fits into two

P114510 slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains
Remove the two hoses (Item 1) [Figure 80-61-1]. connected to the brackets when raising and
lowering.
Installation: Tighten the hose (Item 1) [Figure 80-61-1]

to 30 Nm (22 ft-lb) torque.

CONDENSER (LATER MODELS) (CONTD)
Figure 80-61-4
1
2
P121248
Remove the clips (Item 1) [Figure 80-61-4] and lift the

condenser out of the machine.

Installation: Ensure the air condenser is installed into
the two slotted brackets [Figure 80-61-4] (left side
shown).
Ensure the clips (Item 1) are properly installed over the

two slotted brackets (Item 2) [Figure 80-61-4] (left side
shown).
Figure 80-61-5
P114505
Fasten the two rubber straps (Item 1) [Figure 80-61-5]

(right side shown).

RECEIVER / DRIER (EARLY MODELS) Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Receiver / Drier Removal And Installation
Cap and plug the hoses and the receiver / drier fittings
WARNING NOTE: When replacing a receiver / drier in an A/C

system 1 fl. oz. (30 cc) of PAG 100 oil must be
added to the system when recharging.
Figure 80-70-2
W-2059-0598

1.)

Reclamation And Charging With Recovery / Charging 1

WARNING P-90493

Note the flow direction on the receiver / drier (Item 1)
[Figure 80-70-2] for proper installation.
gas.
W-2371-0611
Figure 80-70-1
P101513
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.
Installation: Tighten the hose to 30 Nm (22 ft-lb) torque.

RECEIVER / DRIER (EARLY MODELS) (CONTD) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Contd) Figure 80-70-5
Figure 80-70-3
1
1
N-22205
P101516
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver /
drier (Item 2) [Figure 80-70-3]. Figure 80-70-6

Figure 80-70-4
N-22206
P-89521
The pressure relief valve is designed to open and release
the A/C charge if the pressure reaches 3689 kPa (36,9
Remove the two mount bolts (Item 1) [Figure 80-70-4] bar) (535 psi) [Figure 80-70-6].
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.
The pressure relief valve is a secondary protection

device in the A/C system, with the pressure switch
shutting down the system at 2648 kPa (26,5 bar) (384
psi).
NOTE: If a pressure relief valve is found open, test

the A/C system for problems. Replace the
complete receiver / drier unit.

RECEIVER / DRIER (EARLY MODELS) (CONTD) Figure 80-70-8
Pressure Switch Removal And Installation
Figure 80-70-7
P101515
Remove the pressure switch (Item 1) [Figure 80-70-8]

P101509 from the A/C high pressure hose.
Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
70-7] from the pressure switch wire harness. Installation: Tighten the switch to 6,8 - 9,5 Nm (5 - 7 ft-

lb) torque.
NOTE: The pressure switch can be changed without
evacuating the A/C system.
WARNING
gas.
W-2371-0611

RECEIVER / DRIER (EARLY MODELS) (CONTD)
Schraeder Valve Removal And Installation
Figure 80-70-9
N-22166
The Schraeder valve (Item 1) [Figure 80-70-9] is

located in the A/C high pressure hose and is located

under the pressure switch.

Remove the pressure switch.
With a Schraeder valve removal tool, remove the valve

from the hose.

RECEIVER / DRIER (LATER MODELS) Installation: Tighten the two A/C hoses (Item 1) [Figure
80-71-1] to 30 Nm (22 ft-lb) torque.
Receiver / Drier Removal And Installation
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
WARNING Cap and plug the hoses and the receiver / drier fittings
NOTE: When replacing a receiver / drier in an A/C
system 30 cc of PAG 100 oil must be added to
the system when recharging.
W-2059-0598
Figure 80-71-2

1.)


WARNING
refrigerant can cause severe injuries to eyes. In P115342

gas.
Note the flow direction on the receiver / drier (Item 1)
W-2371-0611
[Figure 80-71-2] for proper installation.
Figure 80-71-1
P114493
NOTE: Mark the A/C hoses (Item 1) [Figure 80-71-1]

for proper installation.


RECEIVER / DRIER (LATER MODELS) (CONTD)
Receiver / Drier Removal And Installation (Contd)
Figure 80-71-3
P114491A
Loosen the two clamps (Item 1) and remove the receiver /

drier (Item 2) [Figure 80-71-3].

Figure 80-71-4
P114490A
Remove the two mount bolts (Item 1) from the receiver /

drier mount bracket (Item 2) [Figure 80-71-4].

RECEIVER / DRIER (LATER MODELS) (CONTD) Figure 80-71-6
Pressure Switch Removal And Installation
Figure 80-71-5 1
P114492A
Remove the pressure switch (Item 1) [Figure 80-71-6]

P114503 from the receiver / drier.
Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
71-5] from the pressure switch wire harness.

NOTE: The pressure switch can be changed without
evacuating the A/C system.
WARNING
gas.
W-2371-0611

RECEIVER / DRIER (LATER MODELS) (CONTD)
Schraeder Valve Removal And Installation
Figure 80-71-7
P115343
The Schraeder valve (Item 1) [Figure 80-71-7] is

located in the receiver / drier under the pressure switch.

The Schraeder valve is located on the receiver / drier.

Remove the pressure switch.
With a Schraeder valve removal tool, remove the valve


EVAPORATOR / HEATER UNIT Figure 80-80-3


1 2
2
2.)
Figure 80-80-1
P100900
1
NOTE: Support the evaporator / heater unit before
removing the mounting hardware.

1
Remove the two nuts (Item 2) [Figure 80-80-3].

Figure 80-80-4
1
3
P100879 3
Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1].
1
2
Figure 80-80-2
1 P100899
1
Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Installation: Tighten the A/C hoses to 29,8 Nm (22 ft-lb)

P100879 torque.

NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the Remove the two nuts (Item 3) [Figure 80-80-4].
system.
Remove evaporator / heater unit from the loader.
Remove the two hoses (Item 1) [Figure 80-80-2].


THERMOSTAT The EDT has the following protection built in:
4. Over temperature
Description
5. Over current from clutch output
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil 6. Voltage (Above and below operational limits or
temperature and cycles the compressor clutch to reverse voltage)
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 7. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before 8. Temperature sensor open and short detection
startup to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 2C (35.6F). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor
temperature is below -2C (28.4F), the EDT will turn off
Temperature At A/C startup 2x per second
the clutch and status LED.
sensor open and
short detection
Figure 80-90-1
Compressor Continuous 3x per second
clutch short to
battery

1
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

THERMOSTAT (CONTD) Figure 80-90-4
Remove the evaporator / heater cover. (See Removal on 1

Page 80-150-1.)
NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
Figure 80-90-2
P100893
2 Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-4].

P100889
Undo the four latches (Item 1) and remove the cover

(Item 2) [Figure 80-90-2].
Figure 80-90-3
P100894
Remove the thermostat probe (Item 1) [Figure 80-90-3]

from the A/C evaporator coil.

EXPANSION VALVE Figure 80-100-2

2.)
Remove the evaporator / heater cover. (See Removal on

2
Page 80-150-1.)
WARNING
1
P101948
contact with a flame, R-134a refrigerant gives a toxic NOTE: The evaporator / heater unit is removed for
gas. photo clarity.
W-2371-0611
Remove the two evaporator fittings (Item 1) [Figure 80-

Figure 80-100-1 100-2] from the expansion valve.

Installation: Tighten the two evaporator fittings to 30
Nm (22 ft-lb) torque.
Remove the expansion valve from the loader.
Cap and plug the evaporator tubelines (Item 1) [Figure

1 80-100-2] and the expansion valve fittings with the proper
1
A/C caps and plugs.
Figure 80-100-3
P103082

from the expansion valve.
Installation: Tighten the two A/C hose fittings to 30 Nm

(22 ft-lb) torque.
N-22085
The expansion valve [Figure 80-100-3] is replaced as a

complete unit.


EVAPORATOR COIL Figure 80-110-2

2.) 2 2
3
Page 80-150-1.)
1
WARNING
P100757
contact with a flame, R-134a refrigerant gives a toxic Remove the thermostat probe (Item 1) [Figure 80-110-2]
gas. from the evaporator coil.
W-2371-0611
Remove the two retaining clips (Item 2) [Figure 80-110-

Figure 80-110-1 2] that connect the evaporator coil, to the heater coil.

Remove the evaporator coil (Item 3) [Figure 80-110-2].
Figure 80-110-3
1
P101948
NOTE: The evaporator / heater unit is removed for

photo clarity. P-90424
Disconnect the two evaporator fittings (Item 1) [Figure

80-110-1] from the expansion valve. Inspect the evaporator coil [Figure 80-110-3] for leaks,
Installation: Tighten the two evaporator fittings to 29,8
Nm (22 ft-lb) torque. Clean with low pressure water or air.
Cap and plug the evaporator tubelines (Item 1) [Figure

80-110-1] and the expansion valve fittings with the proper
A/C caps and plugs.


HEATER COIL Figure 80-120-3
Remove the evaporator coil (If necessary). (See Removal

Remove the heater valve. (See Removal And Installation

on Page 80-140-1.)
1
NOTE: The evaporator / heater unit is removed for
photo clarity.
Figure 80-120-1
P100946
Figure 80-120-4

1
P100944
Figure 80-120-2
P100947

1
Remove the heater coil from the unit.
P101947
Remove the retainer clips (Item 1) [Figure 80-120-2]

from both sides.

HEATER COIL (CONT'D)
Figure 80-120-5
P100945
The heater coil [Figure 80-120-5] can be cleaned with

low pressure air or water.

BLOWER FAN Disassembly And Assembly
Removal And Installation Figure 80-130-2
Remove the evaporator / heater unit. (See Removal And

Remove the heater coil. (See Removal And Installation

on Page 80-120-1.)
Figure 80-130-1
1 1
P-90458
1 1 Remove the eight screws (Item 1) [Figure 80-130-2]

from the blower wheel cover.
2
Figure 80-130-3

P-90457
1
Remove the blower fan (Item 2) [Figure 80-130-1] from

the evaporator / heater unit.
2
P-90465
Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].
Repeat for other side.
Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

BLOWER FAN (CONT'D) Figure 80-130-6
Figure 80-130-4
P-90463
1 Check the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
Remove the two wires (Item 1) [Figure 80-130-4] from
the blower motor.

NOTE: Mark the wires for proper installation.
Figure 80-130-5
1
1
P-90461
1
Remove the blower wheel outside clamp (Item 1) [Figure
80-130-7] from the blower wheel.
P100887
Remove the two screws (Item 1) [Figure 80-130-5] from

the resistor.
Remove the blower motor from the blower housing.

BLOWER FAN (CONT'D)
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-

8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.


HEATER VALVE Figure 80-140-2

Page 80-150-1.)
2
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly. 1
Remove any tie straps that hold the heater hoses.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
Figure 80-140-1 P100948
NOTE: Cap the heater hoses and the heater valve

with plugs to prevent coolant loss from the
1
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-

2].

Remove the heater hose from the heater valve.
Remove the heater hose clamp (Item 2) [Figure 80-140-

2].
P101961 Remove the heater hose from the heater coil.
Disconnect the loader wiring harness (Item 1) [Figure

80-140-1] from the heater valve.


EVAPORATOR / HEATER COVER Installation
Removal Inspect the cover seal for breaks and tears. Ensure the
seal is firmly attached all around the cover. Replace the
Raise the lift arms and install an approved lift arm seal if necessary.
Figure 80-150-2
Figure 80-150-1
2
P109411

P100756 NOTE: The bosses (Item 1) fit inside the core
supports (Item 2) [Figure 80-150-2] when the
cover is installed. Deformity of the cover
Unhook cover latches (Item 1) and remove the cover indicates they are out of position.
(Item 2) [Figure 80-150-1].
NOTE: Improper cover installation can damage the
seal, which may lead to HVAC component
failure. Perform the following steps in the
order given to prevent cover seal damage.
Figure 80-150-3
P109546
Hold the cover in place and fasten two latches (Item 1)

[Figure 80-150-3].

EVAPORATOR / HEATER COVER (CONTD)
Installation (Contd)
Figure 80-150-4
1 2 3
P109543A P109545
Push the cover up in three places (Items 1, 2 and 3) until

the slots snap into place on the tabs. This slot (Inset)

[Figure 80-150-4] is correctly fastened.
Figure 80-150-5
P100756
Fasten the two remaining latches (Item 1) [Figure 80-

150-5].
NOTE: Perform a thorough visual check to ensure

that the cover and the cover seal are not
deformed. The cover should seal tightly all
around without any gaps.

3.)

SPECIFICATIONS
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
TECHINCAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Loader Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic / Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2

TORQUE SPECIFICATION FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1

Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Mainframe And Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-4
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
977 of 1010 SPEC-01 A770 Service Manual

978 of 1010 SPEC-02 A770 Service Manual

LOADER SPECIFICATIONS
Machine Dimensions
Dimensions are given for loader equipped with standard tires and 74 in. Construction and Industrial bucket and may
vary with other bucket types.
Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
20.3 1880 mm
(74 in)
2179 mm
3848 mm (85.8 in)
(151.5 in)
11.6

3386 mm
(133.3 in) 1770 mm
(69.7 in)
1572 mm
(61.9 in)
1897 mm
(74.7 in)
98
4232 mm
42
(166.6 in)
800 mm
(31.5 in)
3353 mm
(132.0 in)
2649 mm
2065 mm (104.3 in)
(81.3 in)
25.1
31.9
207 mm 1227 mm
(8.1 in) (48.3 in)
2903 mm
(114.3 in)
3597 mm
(141.6 in) NA5996
Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.
979 of 1010 SPEC-10-1 A770 Service Manual

LOADER SPECIFICATIONS (CONTD)
Performance
Rated Operating Capacity 1508 kg (3325 lb)

with 200 Pound Frame Mounted
1576 kg (3475 lb)
Counterweight Kit
1599 kg (3525 lb)
Counterweight Kit
1644 kg (3625 lb)
Counterweight Kit
Tipping Load 3016 kg (6650 lb)
Operating Weight 4291 kg (9460 lb)
Breakout Force - Lift 2434 kg (5365 lb)
Breakout Force - Tilt 2495 kg (5500 lb)
Push Force 2829 kg (6237 lb)
Travel Speed:
- Low Range / High Range 0 - 11,4 km/h (0 - 7.1 mph) / 0 - 19,8 km/h (0 - 12.3 mph)
Engine
Make / Model Kubota / V3800-CR-TE4CB Interim Tier 4

Fuel / Cooling Diesel / Liquid
Horsepower:
- ISO 9249 EEC / SAE J1349 Net 65,6 kW (88.0 hp) @ 2400 rpm
- ISO 14396 Gross 67,6 kW (90.7 hp) @ 2400 rpm
- SAE J1995 Gross 68,6 kW (92.0 hp) @ 2400 rpm
Torque:
- ISO 9249 EEC / SAE J1349 Net 330,0 Nm (243.4 ft-lb) @ 1500 rpm
- SAE J1995 Gross 335,0 Nm (247.1 ft-lb) @ 1500 rpm
Low Idle rpm 1275 - 1325
High Idle rpm 2400
Number of Cylinders 4
Displacement 3769 cm3 (230.0 in3)
Bore / Stroke 100 mm / 120 mm (3.94 in / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Open Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Air Intake Heater - Automatically activated as needed in RUN position

Drive System
Main Drive Fully hydrostatic, 4-wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive Pre-stressed #120 HSOC endless roller chain (no master link) and sprockets in
sealed chaincase with oil lubrication (Chains do not require periodic
adjustments) Two chains per side with no idler sprocket
Axle Size 69,85 mm (2.75 in), Heat treated
Wheel Bolts Eight - 9/16 in. Wheel bolts fixed to axle hubs
Controls
Vehicle Steering
All-Wheel Steer Mode Direction and speed controlled by Left Hand joystick (C pattern)
Skid-Steer Mode Direction and speed controlled by Left Hand joystick (S pattern)
Loader Hydraulics
- Lift and Tilt Controlled by Right Hand joystick
- Front Auxiliary Controlled by electrical switch on Right Hand joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand joystick

Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control with additional foot operated speed control pedal; key-
type start switch or optional Keyless Start Panel or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Air Intake Heater automatically activated as needed in RUN position
Service Brake Two independent hydrostatic systems controlled by left hand joystick
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel

Hydraulic System
Pump Type Engine driven, gear type

Pump Capacity - Standard 87,1 L/min (23.0 U.S. gpm)
Pump Capacity - High-Flow Option 138,2 L/min (36.5 U.S. gpm)
System Relief at Quick Couplers 23,8 - 24,5 MPa (238 - 245 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Filter (Steering) Replaceable 40 micron
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on lower, tilt cylinders have
Bore Diameter:Lift Cylinder (2) cushioning feature on dump and rollback
Tilt Cylinder (2) 76,2 mm (3.00 in)
Steering Cylinder (4) 76,2 mm (3.00 in)
Rod Diameter: Lift Cylinder (2) 50,8 mm (2.00 in)
Stroke: Lift Cylinder (2) 25,4 mm (1.00 in)
123,0 mm (4.86 in)

Control Valve 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 4.2 Seconds
Lower Lift Arms 3.1 Seconds
Bucket Dump 2.6 Seconds
Bucket Rollback 2.5 Seconds
Wheel Cycle (Full Left - Full Right) 0.9 Seconds

Electrical System
Alternator Belt driven, 90 amperes, open frame

Battery 12 volts, 950 cold cranking amperes @ -18C (0F),
180 Minute reserve capacity @ 25 amperes
Starter 12 volts, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, Diesel Particulate Filter (PDF) / Diesel Exhaust
Fluid (DEF), General Warning.
Indicators:
BICS Functions, Two-Speed, 3-Point Shoulder Belt, Turn Signals, Engine
Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown,
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.

Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;
System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.
Capacities
Fuel 90,5 L (23.9 U.S. gal)

Engine Oil with Filter Change 11,4 L (12.0 qt)
Engine Cooling System
with Heater 15,1 L (4.0 U.S. gal)
without Heater 14,4 L (3.8 U.S. gal)
Hydraulic / Hydrostatic Reservoir 9,8 L (2.6 U.S. gal)
Hydraulic / Hydrostatic System 37,9 L (10.0 U.S. gal)
Chaincase Reservoir 39,7 L (10.5 U.S. gal)
Air Conditioning Refrigerant (R-134a) 0,91 kg (2.0 lb)
Tires
Heavy Duty (Standard) 12.00 - 16.5, 12 Ply Rating

Severe Duty (Option) 12.00 - 16.5, 12 Ply Rating
Severe Duty Poly Fill (Option) 12.00 - 16.5, 12 Ply Rating
Solidflex (Option) 33 x 6 x 11
Super Float Offset (Option) 33 x 15.5 - 16.5, 12 Ply Rating
Turf and Sand (Option) 33 x 15.5 - 16.5, 10 Ply Rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.


TECHINCAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Oil Pressure at Low Idle 48 - 97 kPa (0,48 - 1,0 bar) (7 - 14 psi)
Engine Oil Pressure at High Idle 200 - 390 kPa (2,0 - 4,0 bar) (29 - 56 psi)
Firing Order 1-3-4-2
Location of Number 1 Cylinder Closest to water pump
Injection Timing Not applicable for iT4 engines, ECU controlled
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Compression at Cranking Speed 10% variance between pistons. 3090 - 3280 kPa (31-33 bar) (448 - 476 psi)
Valve Clearance (Cold) Intake 0,23 - 0,27 mm (0.0091 - 0.010 in)
Valve Clearance (Cold) Exhaust 0,23 - 0,27 mm (0.0091 - 0.010 in)
NOTE: For additional engine specifications, (See Specifications on Page 70-10-2.)
Engine Torques
Engine Oil Drain Cap 54,2 Nm (40 ft-lb)

Fuel Injection Tubeline Nuts 23 - 36 Nm (17 - 26 ft-lb)
Supply Pump Mounting Nuts 24 - 27 Nm (18 - 20 ft-lb)

Upper Head Cover Bolts 9,8 - 11,2 Nm (7 - 8 ft-lb)
Intermediate Head Cover Bolts 6,9 - 11,2 Nm (5 - 8 ft-lb)
NOTE: For additional engine torques, (See Torque Values on Page 70-10-8.)
Cooling System
Coolant Type and Mix 47% Water and 53% Propylene Glycol
Radiator Cap Pressure 97 kPa (1,0 bar) (14 psi)
Thermostat Fully Open at 90C (194F)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM (EARLY MODELS) on Page
70-50-1.)

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONTD)
Loader Torques
Bob-Tach Pivot Pin Retainer Bolt 240 - 255 Nm (175 - 190 ft-lb)
Lift Arm Pivot Pin Retainer Bolt 48 - 54 Nm (35 - 40 ft-lb)
Tilt Cylinder Pivot Pin Retainer Bolt 48 - 54 Nm (35 - 40 ft-lb)
Control Valve Mounting Bolts 125 - 135 Nm (90 - 100 ft-lb)
Hydraulic Pump Mounting Bolts 88 - 95 Nm (65 - 70 ft-lb)
Hydrostatic Motor Mounting Bolts 123 - 137 Nm (91 - 110 ft-lb)
Hydrostatic Pump Pulley Nut 257 - 325 Nm (190 - 240 ft-lb)
Main Frame Mounting Bolts 542 - 583 Nm (400 - 430 ft-lb)
Wheel Nuts (Installing) 217 Nm (160 ft-lb)
Wheel Nuts (Checking) 190 Nm (140 ft-lb)
NOTE: Additional loader torques can be found in the relevant section of this manual.
Hydraulic / Hydrostatic System
Pump Capacity at High Idle

- Standard Flow 87,1 L/min (23.0 U.S. gpm)
- High Flow 115,5 L/min (30.5 U.S. gpm)

- Charge 51,1 L/min (13.5 U.S. gpm)
Charge Pressure at High Idle Fluid
2482 - 2827 kPa (25 - 28 bar) (360 - 410 psi)
Temp at 60C (140F):
Check Charge Pressure See Loader Service Manual
Maximum Cylinder Drift Allowed
33 mm (1.3 in)
Without Bucket in 10 Minutes
NOTE: For additional hydraulic / hydrostatic system information, (See HYDRAULIC SYSTEM INFORMATION on
Page 20-10-1.) and (See HYDROSTATIC SYSTEM INFORMATION on Page 30-10-1.)
Fuel Consumption
Engine Load Full - 100% High - 70% Medium - 50% Low - 30%
19,7 L 16,3 L 13,6 L 11,7 L
Fuel Consumption Rate Per Hour
(5.2 U.S. gal) (4.3 U.S. gal) (3.6 U.S. gal) (3.1 U.S. gal)
NOTE: The engine fuel consumption chart is to be used as a guideline only. The actual results may vary.
High - Continuous loading or digging or load / carrying cycles; little idling.

Medium - Average loading or load / carrying cycles; some idling.
Low - Light loading or carrying - not much digging or pushing; considerable idling.

TORQUE SPECIFICATION FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9,0 - 10,2 12,4 - 13,6
Nm (80 - 90) (110 - 120)
(in-lb) 0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
0.375 34 - 38 47 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
Nm. 0.750 300 - 330 410 - 450
(ft-lb) (220 - 245) (300 - 330)

0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 5830 - 6500
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONTD)
Torque For General Metric Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- Nm ft-lb Nm ft-lb Nm ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100

M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 2900 - 2600
NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-40-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until

the washer is tight against the surface [Figure SPEC-40-
1].
Figure SPEC-40-2
O-ring Boss
Tightening Torque
x TORQUE
x Nm
Thread Size (ft-lb)
7/16 - 20 18 (13)
9/16 - 18 30 (22)
3/4 -1 6 54 (40)
7/8 - 14 81 (60)
1-1/16 - 12 114 (84)
1-3/16 - 12 133 (98)
1-5/16 - 12 160 (118)
1-7/16 - 12 209 (154)
1-5/8 - 12 221 (163)

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONTD)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.
Figure SPEC-40-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
P-85926
Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-40-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-40-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x Nm
Diameter Thread Size (ft-lb)
1/4 7/16 - 20 18 (13)
5/16 1/2 - 20 23 (17)
3/8 9/16 - 18 30 (22)
1/2 3/4 - 16 54 (40)
5/8 7/8 - 14 81 (60)
3/4 1-1/16 - 12 114 (84)
7/8 1-3/16 - 12 133 (98)
1 1-5/16 - 12 160 (118)
1-1/4 1-5/8 - 12 209 (154)
1-1/2 1-7/8 - 12 221 (163)
2 2-1/2 - 12 342 (252)

SPECIFICATIONS
Specifications WARNING
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0C [32F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30C (-20F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18C (0F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid

[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18C (0F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart


SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing loaders.
Remote Start Tools
TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool S70 This tool has been replaced by
S450 - S850 the new remote start tool
T450 - T870 7003031, see below. MEL1563
A770 includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness S70 Used with MEL1563 to connect
S450 - S850 remote start tool to machine
T450 - T870
MEL1566 Service Tool Harness S70 Used with MEL1563 to connect

Communicator S450 - S850 remote start tool to PC
T450 - T870
A770
7217666 Remote Start Tool S70 This tool replaced the original
KIT S450 - S850 remote start tool kit MEL1563
(Was 7003031) T450 - T870 and 7003031. Kit 7217666

A770 includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.
7022042 Remote Start Tool This tool replaces remote start

tool 6689778 and 7003030.
(Was 7003030)
(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to loader
6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.
6689745 BOSS Service Tool Included with 7003031 but only

Harness used on early model loaders
equipped with BOSS.
7152935 Service Tool Harness Loaders with the Used to connect the 7 pin
7 pin attachment attachment harness to remote
harness. start tool.
See BobcatNET for parts ordering information. (For Europe dealers, see the Bobcat Special Tools Catalogue for additional
information and part numbers.)
ST LDR-0815

SERVICE TOOLS REQUIRED (CONTD)
Hydraulic Tools
TOOL PART MODELS

NUMBER USED ON
MEL10003 Hydraulic Tester S70 Either hydraulic tester, MEL10003 or
(Flow Meter) S450 - S850 TWX-RFIK200-S-6 can be used for
T450 - T870 hydraulic testing.
A770
TWX-RFIK200- Hydraulic Tester TWX-RFIK200-S-6 is no longer

S-6 (Flow Meter) available, order MEL10003.
MEL1074 O-Ring Seal Hook
MEL1075 Adjustable Gland Includes MEL1075-1 and MEL1075-2

NUt Wrench

MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2
MEL1396-2 Piston Ring

Compressor
MEL1033 Rod Seal Installation

Tool
MEL1418 Cylinder Hone = S510 - S850

2.00 in T550 - T870
OEM6275 Cylinder Hone =
2.75 - 3.00 in
3.00 - 3.50 in
3.50 - 4.00 in
ST LDR-0815

Hydraulic Tools (Contd)
TOOL PART MODELS

NUMBER USED ON
MEL10006 Hydraulic Test Kit S70 This test kit includes various adapters
S450 - S850 and couplers that are used when
T450 - T870 testing hydraulic functions. MEL10006
A770 Includes: MEL10006-1 thru
MEL10006-7
MEL1278 Detent Tool S70

S450 - S850
T450 - T870
MEL1285 Detent Spring Tool S70

S450 - S850
T450 - T870
A770
MEL1355-2 Pressure Gauge, S450 - S850
1000 psi T450 - T870

MEL1355-3 Pressure Gauge, A770
5000 psi
MEL1723 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.
MEL1173A Hydraulic Test Kit S70 This test kit includes various adapters
and couplers that are used when
testing hydraulic functions.
MEL1723A Includes: MEL1723-1 thru
MEL1723-17
Mainframe And Drive Tools
TOOL PART MODELS

NUMBER USED ON
MEL1407 Seal Driver Tool S510 - S770
MEL1399 Seal Driver Tool S450
MEL1525 Seal Driver Tool S70
ST LDR-0815

Mainframe And Drive Tools (Contd)
TOOL PART MODELS

NUMBER USED ON
MEL1242 Power Ram S450 - S850
MEL1202 Axle Bearing Service S70 MEL1202 Includes:

Set S450 - S770 MEL1202-1 thru MEL1202-13
MEL1714 Axle Seal Installation S750 - S850

Tool
6675936 Bleed Tool T110 - T870 Machines with two track tension
(MEL1560) fittings.
7277225 Bleed Tool T110 - T870 Machines with one track tension

(MEL1745) fitting.
MEL1246 Chain Link Tool S450 - S850

A770
MEL1604 Seal Driver A770
MEL1269 Chain Breaker S450 - S595
MEL1364 Chain Link Tool S450 - S595
MEL1685 Pivot Point Tapered S630 - S850

Reamer T630 - T870
MEL1734 Pivot Point Tapered S450 - S595

Reamer T450 - T595
MEL1605 Bearing Race A770

Installer
MEL1730 Bearing Race S850

Remover
ST LDR-0815

Mainframe And Drive Tools (Contd)
TOOL PART MODELS

NUMBER USED ON
MEL1731 Bearing Race S850
Installer
MEL1606 Seal Installer A770
MEL1420 Carrier Seal S510 - S595

installation Tool
MEL1612 Bearing Removal T550 - T595

Tool
MEL1562 Bearing Installation T630 - T870

Tool

MEL1431 Seal Driver Tool S630 - S770
A770
Electrical Tools
TOOL PART MODELS

NUMBER USED ON
MEL1609 Wheel Speed S630 - S850
T630 - T870
A770
MEL1428 Sensor Tester S70

S450 - S850
T450 - T870
A770
MEL1567 Seat Bar Adapter S450 - S850

T450 - T870
A770
ST LDR-0815

Engine Tools (Contd)
TOOL PART MODELS

NUMBER USED ON
7024161 Diagmaster Kit S750 - S850 Includes:
(iT4 engine only) T750 - T870 DST-i (Diagmaster Service Tool)
A770 Vehicle cable (7024272)
USB cable (7024271)
Diagmaster Diagnostic Software
MEL10630 Engine Compression S70 Includes: MEL1352, MEL1433,

Test Kit S450 - S650, MEL1489, MEL1546, MEL1551,
T450 - T650 MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14
MEL1655 Compression S450 - S650, Used in glow plug port for testing
Adapter T550 - T650 compression, NOT included with
MEL10630
MEL1614 Compression S750 - S850 Used in glow plug port for testing
Adapter T750 - T870 compression, NOT included with

A770 MEL10630
MEL1656 Fuel Injection Pump

Degree Restoring
Tool
MEL1657 Timing Gear Puller

Tool
7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool

Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357)

7031370 Rear Main Seal T4 Bobcat Used for installing rear main seal
Installer Engine
Applications
7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications
ST LDR-0815

TOOL PART MODELS

NUMBER USED ON
7031371 Valve Spring T4 Bobcat Used for compressing valve springs
Compressor Engine
Applications
MEL1733 Pivot Bushing S510 - S850 Use to install pivot bushing into
Installer T550 - T870 flywheel housing
4200 Injector Nozzle S70,

Tester S450 - S850
T550 - T870
A770

4201 Injector Nozzle
Tester Adapter Kit
MEL1173-1 Pressure Gauge S450 - S850

10000 psi T550 - T870
MEL1637 Governor Connecting S750 - S850

Rod Tool T750 - T870
A770
MEL1667 Governor Connecting S510 - S590,

Rod Tool S750 - S850
T550, T590,
T750 - T870
MEL1660 Crankshaft S510 - S650,
Replacement Tool T550 - T650
MEL1237 Fuel Line Adapter S450 - S550

T450 - T590
MEL1724 Crankshaft Position S750 - S850 For checking crankshaft sensor on

Sensor Measuring T750 - T870 IT4 Kubota engine
Tool A770
ST LDR-0815

TOOL PART MODELS

NUMBER USED ON
MEL1725 Compression S750 - S850 For checking compression on IT4
Adapter T750 - T870 Kubota engine
A770
MEL1666 Camshaft Gear S510 - S550
Puller T550 - T590
MEL1653-1 Engine Removal Tool S450 - S850,

T450 - T870,
A770
MEL1653-2 Engine Removal Tool S750 - S850, Kubota V3800 Engines

T750 - T870,
A770

MEL1653-3 Engine Removal Tool S450 - S530, Kubota V2203 and V2403 Engines
T450
MEL1653-4 Engine Removal Tool S550 - S590, Kubota V2607 Engines

T550 - T590
MEL1653-5 Engine Removal Tool S630, S650, Kubota V3307 Engines

T630, T650
MEL1653-6 Engine Removal Tool S750 - S850 iT4 Engines

T750 - T870,
A770
MEL1653-7 Engine Removal Tool S740 - S850 Used with MEL1653-1

Handle T740 - T870
A770
ST LDR-0815

TOOL PART MODELS

NUMBER USED ON
MEL1686 Engine Removal Tool S750 - S850 Used with MEL1653-2
T750 - T870
A770
MEL1653-8 Engine Removal Tool S740 - S850 Used with MEL1653-1

T740 - T870
A770
MEL1653-9 Engine Removal Tool S510 - S595, 2.4L Bobcat Engine Tier 4
S630, S650,
T550 - T595,
T630, T650
MEL1653-11 Engine Removal Tool S750 - S850, 3.4L Bobcat Engine Tier 4
T750 - T870,

A770
MEL1712 Push Button Starter S450 - S850,

Switch T450 - T870,
A770
MEL1270 Fuel Line Removal S70
Tool
MEL1271 Delivery Valve

Removal Tool
MEL1485 Injector Removal

Socket
MEL1616 Radiator Tank Test

Adapter
MEL1642 Radiator Cap Test

Adapter
ST LDR-0815

TOOL PART MODELS

NUMBER USED ON
7267635 Urea (DEF/AdBlue) Bobcat 3.4L Includes: Filter Disassembly Tool
Filter Disassembly Engine (7267635), Filter and Equalizer.
Tool Models Tier 4
SCR
Equipped
7267635 Urea (DEF/AdBlue) Bobcat 3.4L
Filter Disassembly Engine
Tool Models Tier 4
SCR
Equipped
7268212 Valve Lash Adjusting All Bobcat
Wrench Engine
Models
7255632 Valve Stem Seal Tool

MEL1742 Seal Installer S450 Drive motor seal installer
MEL1607 Snap Ring Installer
ST LDR-0815

HVAC Tools
TOOL PART MODELS

NUMBER USED ON
MEL1581 HVAC Recover, S450 - S850 MEL1581 is no longer available,
Recycling, T450 - T870 order MEL1735 or MEL1736
Recharging Machine A770
MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine
MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine
MEL1592 HVAC Refrigerant

Identification Tool
MEL1595 AC Compressor S630 - S850

Pulley Puller T630 - T870
ST LDR-0815


ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14

AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 DIAGMASTER (SERVICE TOOL) KIT -
AIR CONDITIONING SYSTEM FLOW . 80-10-1 7024161 . . . . . . . . . . . . . . . . . . . . . . . .10-70-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DIAGMASTER DIAGNOSTIC TROUBLE
CODES (DCT) . . . . . . . . . . . . . . . . . .60-110-1
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1
DIAGNOSTIC SERVICE CODES . . . .60-100-1
BACK-UP ALARM SYSTEM . . . . . . . 60-220-1
DIESEL PARTICULATE FILTER (DPF)
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .70-30-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-80-1
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-60-1
BOBCAT CONTROLLER (DRIVE PLUS) DRIVE COMPONENTS . . . . . . . . . . . .40-30-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLERS (GATEWAY AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-150-1
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1
ELECTRICAL SYSTEM INFORMATION
BOBCAT INTERLOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
(BICS) . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
EMERGENCY EXIT . . . . . . . . . . . . . .10-210-1
BOB-TACH (HAND LEVER) . . . . . . 10-150-1
ENGINE AIR CLEANER . . . . . . . . . . . .10-90-1
BOB-TACH (HAND LEVER) . . . . . . . 50-40-1
ENGINE CONTROL UNIT (ECU) . . . . .60-80-1

BOB-TACH (POWER) BLOCK (EARLY
MODELS) . . . . . . . . . . . . . . . . . . . . . . 20-120-1 ENGINE COOLING SYSTEM (EARLY
MODELS) . . . . . . . . . . . . . . . . . . . . . . .70-50-1
BOB-TACH (POWER) BLOCK (LATER
MODELS) . . . . . . . . . . . . . . . . . . . . . . 20-121-1 ENGINE COOLING SYSTEM (LATER
MODELS) . . . . . . . . . . . . . . . . . . . . . . .70-51-1
BOB-TACH (POWER) . . . . . . . . . . . 10-151-1
ENGINE COOLING SYSTEM . . . . . .10-100-1
BOB-TACH (POWER) . . . . . . . . . . . . 50-41-1
ENGINE INFORMATION . . . . . . . . . . .70-10-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
ENGINE LUBRICATION SYSTEM . . .10-120-1
BUCKET POSITION VALVE . . . . . . . . 20-100-1
ENGINE SPEED CONTROL (FOOT) . .70-21-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1
ENGINE SPEED CONTROL (HAND) . .70-20-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-170-1
EVAPORATOR / HEATER COVER . .80-150-1
CAMSHAFT AND TIMING GEARS . . 70-110-1
EVAPORATOR / HEATER UNIT . . . . . .80-80-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . 40-40-1
EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-40-1
EXHAUST GAS RECIRCULATION (EGR)
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-140-1
CONDENSER (EARLY MODELS) . . . . 80-60-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CONDENSER (LATER MODELS) . . . . 80-61-1 FINAL DRIVE TRANSMISSION
CONTROL PANEL SETUP . . . . . . . . 60-190-1 (CHAINCASE) . . . . . . . . . . . . . . . . . .10-140-1
CONTROL PANEL . . . . . . . . . . . . . . . 50-100-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 FLOOR PAN . . . . . . . . . . . . . . . . . . . . .50-90-1
CRANKSHAFT AND PISTONS . . . . . . 70-90-1 FLYWHEEL AND HOUSING . . . . . . .70-130-1
CRANKSHAFT POSITION SENSOR . 70-100-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CYLINDER (BOB-TACH) . . . . . . . . . . 20-22-1 FRONT AUXILIARY HYDRAULIC COUPLER
CYLINDER (LIFT) . . . . . . . . . . . . . . . . 20-20-1 BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
CYLINDER (STEERING) . . . . . . . . . . . 20-23-1 FRONT HORN . . . . . . . . . . . . . . . . . .60-230-1
CYLINDER (TILT) . . . . . . . . . . . . . . . . . 20-21-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-110-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 70-80-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
1007 of 1010 INDEX-01 A770 Service Manual

FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1 LOADER STORAGE AND RETURN TO
HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1 SERVICE . . . . . . . . . . . . . . . . . . . . . 10-190-1
HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1 LUBRICATING THE LOADER . . . . . 10-160-1
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1 LUBRICATION SYSTEM . . . . . . . . . . 70-60-1
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-1 MAIN RELIEF VALVE (EARLY MODELS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
HYDRAULIC / HYDROSTATIC FILTERS
(EARLY MODELS) . . . . . . . . . . . . . . . .20-70-1 MAIN RELIEF VALVE (LATE MODELS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
HYDRAULIC / HYDROSTATIC FILTERS
(LATER MODELS) . . . . . . . . . . . . . . . .20-71-1 MAINTENANCE CLOCK . . . . . . . . . 60-210-1
HYDRAULIC / HYDROSTATIC FLUID MAINTENANCE SAFETY . . . . . . . . . . . . . . 1-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-50-1 OIL COOLER (EARLY MODELS) . . . . 20-90-1
HYDRAULIC / HYDROSTATIC SYSTEM OIL COOLER (LATER MODELS) . . . . 20-91-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1 OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
HYDRAULIC CONNECTION OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1
OPERATOR SEAT (SUSPENSION) . . 50-30-1
HYDRAULIC CONTROL VALVE (EARLY
MODELS) . . . . . . . . . . . . . . . . . . . . . . .20-40-1 PASSWORD SETUP (DELUXE
INSTRUMENTATION PANEL) . . . . . . 60-200-1
HYDRAULIC CONTROL VALVE (LATE
MODELS) . . . . . . . . . . . . . . . . . . . . . . .20-41-1 PASSWORD SETUP (KEYLESS START
PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
HYDRAULIC FLUID RESERVOIR (EARLY

MODELS) . . . . . . . . . . . . . . . . . . . . . . .20-80-1 PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-180-1
HYDRAULIC FLUID RESERVOIR (LATER REAR AUXILIARY DIVERTER VALVE
MODELS) . . . . . . . . . . . . . . . . . . . . . . .20-81-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1 REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1 REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC SYSTEM INFORMATION 20-10-1 RECEIVER / DRIER (EARLY MODELS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
HYDROSTATIC DRIVE MOTOR (TWO-
SPEED) (S/N ATDW11599 & BELOW) 30-20-1 RECEIVER / DRIER (LATER MODELS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-71-1
HYDROSTATIC DRIVE MOTOR (TWO-
SPEED) (S/N ATDW11600 AND ATDY11001 & REGULAR MAINTENANCE . . . . . . . . 80-20-1
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 REMOTE START TOOL (SERVICE TOOL) KIT
HYDROSTATIC MOTOR CARRIER . . .30-30-1 - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1 REMOTE START TOOL KIT-MEL1563 10-60-1
HYDROSTATIC SYSTEM INFORMATION RIGHT SIDE LOWER PANEL . . . . . . 50-170-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SEAT BAR SENSOR . . . . . . . . . . . . 60-130-1
JOYSTICK CONTROL . . . . . . . . . . . .50-110-1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
LEFT SIDE LOWER PANEL . . . . . . . .50-160-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-220-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 SERVICE PC (LAPTOP COMPUTER)
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
LIFTING AND BLOCKING THE LOADER SERVICE SCHEDULE . . . . . . . . . . . . 10-80-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 SERVICE TOOLS REQUIRED . . . .SPEC-70-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-15 STEERING BLOCK . . . . . . . . . . . . . . 40-20-1
LOADER SPECIFICATIONS . . . . . SPEC-10-1 STEERING DRIFT COMPENSATION 60-180-1

STOPPING THE ENGINE AND LEAVING THE
LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
TECHINCAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . 80-90-1
TIRE MAINTENANCE . . . . . . . . . . . . 10-170-1
TORQUE SPECIFICATION FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TOWING THE LOADER . . . . . . . . . . . . 10-50-1
TRACTION LOCK . . . . . . . . . . . . . . . 60-140-1
TRANSPORTING LOADER ON A TRAILER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . 80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-120-1
TWO-SPEED / BRAKE VALVE (S/N
ATDW11599 & BELOW) . . . . . . . . . . . . 30-70-1
TWO-SPEED / BRAKE VALVE (S/N
ATDW11600 & ABOVE AND ATDY11001 &

ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . 30-71-1
WHEEL POSITION SENSORS . . . . . . 60-90-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1


A770 6990245 enUS SM 08-15

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

A770 6990245 enUS SM 08-15

Enviado por

Direitos autorais:

Formatos disponíveis

Service Manual

A770 All-Wheel Steer Loader

S/N ATDW11001 & Above

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 NA1694 NA1693

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1682 NA1683 B-6589

3 of 1010 1-1 A770 Service Manual

4 of 1010 1-2 A770 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 1010 1-3 A770 Service Manual

6 of 1010 1-4 A770 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 1010 1-5 A770 Service Manual

8 of 1010 1-6 A770 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 1010 1-7 A770 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 1010 1-8 A770 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT The AEM Safety Manual delivered with the machine

The Skid-Steer Loader Operator Training Course is

The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

11 of 1010 1-9 A770 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

12 of 1010 1-10 A770 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

13 of 1010 1-11 A770 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale