s175 6987035 SM 11-10

Service Manual
S175 Skid-Steer Loader
File has expired.

S/N A3L520001 & Above
Dealer Copy -- Not for Resale

Use updated files from Bobcat
Publications.
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6987035 (11-10) Printed in U.S.A. © Bobcat Company 2010
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15535 B-15524
WRONG
File has expired.
Never service the Bobcat Skid-
Steer Loader without instructions.
Use the correct procedure to lift or
lower operator cab.
WRONG
Cleaning and maintenance are
required daily.
WRONG

B-15734 B-15732 B-15525
parts. Publications.
Have good ventilation when
welding or grinding painted
Wear dust mask when grinding

Disconnecting or loosening any
hydraulic tubeline, hose, fitting,
component or a part failure can
cause lift arms to drop. Do not go
Never work on loader with lift
arms up unless lift arms are held
by an approved lift arm support
device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15733 B-15523 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW07-0409
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ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) ..................................... 50-01 ELECTRICAL SYSTEM INFORMATION.................60-01

ACCESS PANEL (INSIDE) (SJC) ........................... 50-01 ELECTRICAL / HYDRAULIC CONTROLS..............60-01
AIR CLEANER .................................................... 70-01 ELECTRICAL / HYDRAULIC CONTROLS (ACS) ...60-01
AIR CLEANER SERVICE ....................................... 10-01 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....60-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EMERGENCY EXIT ................................................10-01
ALTERNATOR ........................................................ 60-01 ENGINE COOLING SYSTEM ......................10-01, 70-01
ENGINE INFORMATION .........................................70-01
BATTERY................................................................ 60-01 ENGINE LUBRICATION SYSTEM ..........................10-01
BLOWER FAN ........................................................80-01 ENGINE SPEED CONTROL (SJC) .........................70-01
BOBCAT INTERLOCK CONTROL EVAPORATOR ........................................................80-01
SYSTEM (BICS) .................................................. 60-01 EVAPORATOR / HEATER UNIT..............................80-01
BOBCAT CONTROLLER (ACS) ..........................60-01 EXPANSION VALVE ................................................80-01
BOBCAT CONTROLLER
(GATEWAY AND AUXILIARY)............................. 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 FLYWHEEL AND HOUSING ................................ 70-01
BOB-TACH (HAND LEVER) ........................ 10-01, 50-01 FLYWHEEL RPM SENSOR ....................................60-01
BOB-TACH (POWER)............................................. 50-01 FRONT AUXILIARY HYDRAULIC
File has expired.

BRAKE (SINGLE SPEED) ...................................... 40-01
BRAKE (TWO-SPEED)........................................... 40-01
BUCKET POSITION VALVE ................................20-01
COUPLER BLOCK ...............................................20-01
FUEL SYSTEM.............................................10-01, 70-01
FUEL TANK .............................................................50-01
CALIBRATION ........................................................ 60-01 HEATER COIL .........................................................80-01

CAMSHAFT AND TIMING GEARS.........................70-01 HEATER VALVE ......................................................80-01
CHAINCASE ........................................................... 40-01 HIGH FLOW VALVE ................................................20-01
CHARGE PRESSURE ............................................ 30-01
COMPRESSOR ...................................................... 80-01
CONDENSER ......................................................... 80-01
HYDRAULIC CONNECTION
SPECIFICATIONS.......................................... SPEC-01
HYDRAULIC CONTROL VALVE .............................20-01
Publications.
CONTROL HANDLE / LEVER ................................ 50-01
CONTROL HANDLE / LEVER (ACS) ..................... 50-01
CONTROL HANDLE / LEVER (SJC) ...................... 50-01
HYDRAULIC FLUID RESERVOIR ..........................20-01
HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS.......................................... SPEC-01
CONTROL PANEL .................................................. 50-01 HYDRAULIC / HYDROSTATIC FILTERS ................20-01
CONTROL PANEL (SJC)........................................ 50-01 HYDRAULIC / HYDROSTATIC SYSTEM ................10-01
CONTROL PEDALS AND LINKAGE ...................... 50-01 HYDRAULIC PUMP (STANDARD)..........................20-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01
CONTROL SYSTEM (ACS) .................................... 60-01 HYDRAULIC PUMP (HIGH FLOW) (SJC)...............20-01
CONVERSIONS ............................................SPEC-01 HYDARULIC PUMP (SJC) ......................................20-01
CRANKSHAFT AND PISTONS .............................. 70-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CYLINDER (LIFT) ................................................... 20-01 HYDROSTATIC DRIVE MOTOR ......................... 30-01
CYLINDER (BOB-TACH) ........................................ 20-01 HYDROSTATIC DRIVE MOTOR (TWO SPEED) ....30-01
CYLINDER (TILT) ................................................ 20-01 HYDROSTATIC MOTOR CARRIER
CYLINDER HEAD ................................................... 70-01 (SINGLE ANDTWO-SPEED WITH MANUAL
CONTROLS) ........................................................30-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 HYDROSTATIC MOTOR CARRIER
DRIVE BELT ........................................................... 30-01 (SINGLE ANDTWO-SPEED WITH SJC
DRIVE COMPONENTS .......................................... 40-01 CONTROLS) ........................................................30-01
HYDROSTATIC PUMP ........................................ 30-01
HYDROSTATIC PUMP (SJC) ............................. 30-01
HYDROSTATIC SYSTEM INFORMATION ..........30-01
INSTRUMENT PANELS ..........................................60-01
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ALPHABETICAL INDEX (CONT’D)
LIFT ARMS ..........................................................50-01 THERMOSTAT ........................................................ 80-01

LIFT ARM BYPASS CONTROL VALVE .............. 20-01 TIRE MAINTENANCE ............................................. 10-01
LIFT ARM SUPPORT DEVICE ............................10-01 TORQUE SPECIFICATIONS FOR BOLTS ....... SPEC-01
LIFTING AND BLOCKING THE LOADER...............10-01 TOWING THE LOADER.......................................... 10-01
LIGHTS ............................................................... 60-01 TRACTION LOCK ................................................... 60-01
(S175) LOADER SPECIFICATIONS ................. SPEC-01 TRANSPORTING LOADER ON A TRAILER .......... 10-01
LOADER STORAGE AND RETURN TO SERVICE 10-01 TROUBLESHOOTING ............................................ 80-01
LUBRICATING THE LOADER .................................10-01 TURBOCHARGER.................................................. 70-01
LUBRICATION SYSTEM .........................................70-01 TWO-SPEED VALVE............................................... 30-01
MAIN RELIEF VALVE ..............................................20-01 WINDOW (FRONT DOOR) ..................................... 50-01

MUFFLER................................................................70-01 WINDOW (REAR) ...................................................50-01
WINDOW (SIDE)..................................................... 50-01
OIL COOLER...........................................................20-01 WINDOW (TOP) ...................................................... 50-01
OPERATOR CAB..........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
PASSWORD SETUP (DELUXE INSTRUMENTATION File has expired.

PANEL).................................................................60-01
PASSWORD SETUP (KEYLESS START PANEL) ..60-01
PIVOT PINS.............................................................10-01

POWER BOB-TACH BLOCK...................................20-01

REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...................................................... 50-01
REAR GRILLE .........................................................50-01
Publications.
RECEIVER/DRIER ..................................................80-01
REGULAR MAINTENANCE ................................... 80-01
REMOTE START TOOL KIT-MEL1563 ...............10-01
REMOTE START TOOL (SERVICE TOOL)
KIT-6689779 .........................................................10-01
SEAT BAR ...............................................................50-01

SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER ............................. 10-01
SPEED SENSORS (SJC)....................................... 60-01
STARTER ................................................................60-01
STEERING DRIFT COMPENSATION .....................60-01
STOPPING THE ENGINE AND
LEAVING THE LOADER ......................................10-01
SYSTEM CHARGING AND RECLAMATION ......... 80-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

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

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

SYSTEM
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
File has expired.

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

MAINFRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
SYSTEM &
MAINFRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
Publications.
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
SERVICE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER
SPECIFICATIONS
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including 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

File has expired. 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. Publications.
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
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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).
File has expired.

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,
21. Inspect for loose or broken
lift kits, etc.).
27. Recommend to the owner
Publications.
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
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
File has expired.

warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

operator. The handbook is available from your dealer
in an English edition or one of many other languages.

IMPORTANT
See your Bobcat dealer for more information on
translated versions.
Publications.
This notice identifies procedures which must be
followed to avoid damage to the machine.
• The AEM Safety Manual delivered with the machine
gives general safety information.
I-2019-0284 • The Service Manual and Parts Manual are available

from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at

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

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1008 SM
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.
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.
File
Call Before You Dig
has expired.
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.).
Publications.
SI SSL-1008 SM
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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
File has expired.

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are
flammable. Flammable fluids that are leaking or spilled
Do not use ether or starting fluids on any engine that has
glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
cause a fire. Publications.
onto hot surfaces or onto electrical components can
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Operation
Do not use the machine where exhaust, arcs, sparks or

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

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-1008 SM
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FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

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

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

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

Publications.
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-1008 SM
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Figure 1
P-76728
File has expired. The engine serial number is located on the side of the
engine (Item 1) [Figure 2] above the oil filter.

P-31843B

Loader Serial Number
Publications.
The loader serial number plate [Figure 1] is located on
the outside of the loader frame.
Explanation of loader Serial Number:

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

Combination
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.
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DELIVERY REPORT
Figure 3
B-16315
File has expired.

The delivery report [Figure 3] must be filled out by the
dealer and signed by the owner or operator when the
Bobcat loader is delivered. An explanation of the form
must be given to the owner. Make sure it is filled out

completely.

Publications.
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LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
GRAB OPERATOR’S
HANDLES HANDBOOK
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
File has expired.

†BUCKET

STEP
Use updated files from Bobcat BUCKET

STEPS
● OPERATOR CAB
Publications. LIFT
CYLINDER
(ROPS AND FOPS)
LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
TAIL LIGHT *TIRES B-16606B
DOOR B-16607B
* TIRES - The Bobcat loader is factory equipped with standard tires

† BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I. Level II
is available.
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SAFETY &
SAFETY & MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1
SAFETY &
INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . .10-140-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . .10-140-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-141-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . .10-141-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-210-1

Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-210-1 DRIVE
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-210-1 SYSTEM
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .10-90-1
File has expired.

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

ELECTRICAL
Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM &
Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
ANALYSIS
Publications.
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . .10-130-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1
ENGINE
SERVICE
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . .10-130-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-1

Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-1 SPECIFICATIONS
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . .10-100-3
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . .10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-7
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . .10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . .10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . .10-120-2
Removing And Replacing Hydraulic Case Drain Filters (Single
Speed Loaders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter. . . . . . . .10-120-6
Continued On Next Page
10-01 S175 Service Manual

19 of 928
SAFETY & MAINTENANCE (CONT’D)
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

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

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

Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
File has expired.

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-30-1
10-30-1
10-30-3
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Special Applications Kit Inspection And Maintenance . . . . . . . . 10-30-3
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

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

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . 10-60-2
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . 10-61-1

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

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

20 of 928
SAFETY & MAINTENANCE (CONT’D)
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
File has expired.

TRANSPORTING LOADER ON A TRAILER . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION)
UNLESS OTHERWISE SPECIFIED.
Publications.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND
STANDARD ITEMS MAY VARY.

21 of 928
File has expired.

Publications.

22 of 928
LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
N-18877
Put the floor jack under the front of the loader [Figure 10-
File has expired.

B-7023A 10-2].
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-2].
WARNING

NOTE: Make sure the jackstands do not touch the
tires. Make sure tires clear floor or any
AVOID INJURY OR DEATH
Instructions are necessary before operating or
obstacles.
Figure 10-10-3
servicing machine. Read and understand the
Publications.
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Always park the loader on a level surface.
WARNING P-31849
Put jackstands under the front axles and rear corners

Put the floor jack under the rear of the loader [Figure 10-
of the frame before running the engine for service.
10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Lift the rear of the loader and install jackstands [Figure
W-2017-0286
10-10-3].
10-10-1 S175 Service Manual

23 of 928
File has expired.

Publications.

24 of 928
LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing 1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts P-43747 P-31266

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death. Put jackstands under the rear corners of the loader frame
File has expired.

W-2572-0407 (Inset) [Figure 10-20-1]
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from storage position.

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

Installation on Page 50-40-1.) OR (See Removal And
Installation on Page 50-41-1.)
P-31854A
Have a second person install the lift arm support device

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

cylinder rod.

25 of 928
LIFT ARM SUPPORT DEVICE (CONT’D)
Installing (Cont’d)
Figure 10-20-3
P-10136
File has expired.

P-31855A
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure

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

Publications.
The operator must be in the operator's seat, with the seat
belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, 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.
Return the lift arm support device to storage position and

secure with clamping knobs.
Remove the jackstands.

26 of 928
OPERATOR CAB Figure 10-30-1
Description
The Bobcat loader has an operator cab (ROPS and

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

for damage. Never modify the ROPS / FOPS cab.
Replace the cab and hardware if damaged. See your
Bobcat dealer for parts.
P-43747
ROPS / FOPS - Roll Over protective Structure per ISO

3471, and Falling Object Protective Structure per SAE
Install jackstands under the rear of the loader frame
J1043 and ISO 3449, Level I. Level II is available.
[Figure 10-30-1].
Level I
File has expired.

Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
Figure 10-30-2
construction sites.

Level II

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

27 of 928
OPERATOR CAB (CONT’D)
Raising (Cont’d)
WARNING
Figure 10-30-3
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
P-31858A
File has expired.

Lift on the grab handles and bottom of the operator cab
Support the cab and release the latching mechanism
(Inset) [Figure 10-30-4]. Remove your hand from the
latch mechanism when the cab is past the latch stop. Use
[Figure 10-30-3] slowly until the cab is all the way up and both hands to lower the cab all the way down.
the latching mechanism engages.

Lowering
WARNING
Always stop the engine before raising or lowering the
cab.
Figure 10-30-4
Publications.
NOTE: Always use the grab handles to lower the cab. PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
N-20120 P-31859A
Pull down on the bottom of the operator cab until it stops

P-31288 P-31289
at the latching mechanism [Figure 10-30-4].
NOTE: The weight of the cab increases when Install the plates and nuts (both sides) [Figure 10-30-5].
equipped with options and accessories such
as cab door, heater, air conditioning, etc. In Tighten the nuts to 40 - 45 ft.-lb. (54 - 61 N•m) torque.
these cases, the cab may need to be raised
slightly from the latch to be able to release the
latch.

28 of 928
OPERATOR CAB (CONT’D) Special Applications Kit
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.

WARNING
Figure 10-30-6
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
3 openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
S3999A
W-2737-0508
Figure 10-30-8
1
2
File has expired. P-68116
P-68115

Cab doors have a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the

door is open.
A decal is located on the latch mechanism (Item 2)
Publications.
[Figure 10-30-6].
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]

B-25286A
will be OFF when the door is closed, the key switch is Available for special applications to restrict material from
turned to RUN or the RUN / ENTER button is pressed, entering cab openings. Kit includes 1/2 inch thick
the seat bar is lowered and the PRESS TO OPERATE polycarbonate front door, top and rear windows [Figure
LOADER button is pressed. 10-30-8].
Figure 10-30-7 See your Bobcat 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.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]
will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.
[DOOR] will appear in the data display [Figure 10-30-7].

29 of 928
File has expired.

Publications.

30 of 928
TRANSPORTING LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. N-19048A P-73276
W-2058-0807
Be sure the transport and towing vehicles are of

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

Use updated files from Bobcat Alternate Front Tie Down
Publications.
P-31828B
P-24480B
1
P-31913A
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
• Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader • Stop the engine.
to prevent the front end of the trailer from raising up.
• Engage the parking brake.
• Install chains at the front and rear loader tie down

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

31 of 928
File has expired.

Publications.

32 of 928
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.)
File has expired.

Publications.

33 of 928
File has expired.

Publications.

34 of 928
REMOTE START TOOL KIT-MEL1563 The maximum flow/variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
Remote Start Tool - MEL1563 Pressing the switch once will activate maximum flow.
Pressing the switch again will activate variable flow. The
Tools that will be needed to complete the following steps switch will illuminate to indicate which flow rate is active.
are: Pressing the switch a third time will turn the flow OFF.
The switch is used when checking pressures and flow
MEL1563 - Remote Start Tool rate.
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator The auxiliary pressure release (Item 3) [Figure 10-60-2]
(Computer Interface) is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
Figure 10-60-1 hold the switch for a few seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
1
engine to stop. To relieve the pressure; press
the switch until the engine stops.
File has expired.

Use updated files from Bobcat P16114
Publications.
The remote start tool (Item 1) [Figure 10-60-1] is
required when the service technician is checking the
hydraulic/hydrostatic system or adjusting the steering
linkage.
Figure 10-60-2
2
3
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.

35 of 928
REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
File has expired.

P16116
The service tool harness control (Item 1) [Figure 10-60-
5] is used to connect the remote start tool (Item 2)
Figure 10-60-4 [Figure 10-60-5] to the electrical system on the loader.

1 Figure 10-60-6

Publications. 1
P16120
N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
The panel must be removed from inside the operator cab

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

36 of 928
REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Control - MEL1565 (Cont’d)
Figure 10-60-7
File has expired.N-19631
Loaders equipped with an attachment harness (Item 1)

[Figure 10-60-7] must disconnect the attachment

harness from the loader harness (Item 2) [Figure 10-60-
7].
Connect the service tool harness to the ACD connector
and the loader harness connector.
Publications.
NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool Switch.
Service Tool Harness Communicator - MEL1566
Figure 10-60-8
P16119
The service tool harness communicator (Item 1) [Figure

10-60-8] is required to connect remote start tool to the
Service PC (Item 2) [Figure 10-60-8].

37 of 928
REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-11
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit
1
Figure 10-60-9
N-19150
Remove the plug (Item 1) [Figure 10-60-10] or

disconnect the attachment control harness (Item 1)
File has expired. [Figure 10-60-11] if connected.

Figure 10-60-12
P16115


required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Publications.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See LIFT
ARM SUPPORT DEVICE on Page 10-10-1.) P13861
Raise the operator cab (if required by the procedure).

Connect the remote start tool to the engine harness
(See Raising on Page 10-30-1.)
connector [Figure 10-60-12].
Open the rear door of the loader.
NOTE: The key switch on the right-hand side
Figure 10-60-10 operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
1
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
N-19151 is important to remove the operator panel keys.
W-2357-0899

38 of 928
REMOTE START TOOL KIT-MEL1563 (CONT'D) The auxiliary pressure release (Item 3) [Figure 10-60-14]
is used to release hydraulic pressure to the front and/or
Remote Start Procedure (Cont'd) rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
Figure 10-60-13
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
WARNING
• Use traction lock override switch for service
work with seat bar raised.
File has expired. P16116
•
•
Traction lock is engaged when light is OFF.
Lift and block the loader. Check that wheels are
clear.
The remote start tool (Item 1) [Figure 10-60-13] has
• Traction lock is disengaged when light is ON.
three rocker switches.
• See Service Manual for more instruction.

W-2785-0209
Figure 10-60-14
Publications.
2
3 1
P16118
The traction lock switch (Item 1) [Figure 10-60-14] is

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

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

39 of 928
REMOTE START TOOL KIT-MEL1563 (CONT'D)
Remote Start Procedure (Cont'd)

engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
Figure 10-60-15
File has expired.

Use updated files from Bobcat P-34661
Publications.
Push the couplers on the front auxiliary block toward the
block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].

40 of 928
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL 1563 Remote Start Tool and
MEL 1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,

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

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

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

Publications.

41 of 928
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7003031 (CONT'D)
2
Remote Start Tool (Service Tool) - 7003030
Tools that will be needed to complete the following steps

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

Tool (Service Tool) Kit
Kit Includes:
1
7003030 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS® Service Tool Harness
Figure 10-61-1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
File has expired. 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
1
the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to
indicate the service tool is active.
Publications. 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
required when the service technician is checking the
disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system or adjusting the steering
linkage.
The auxiliary button (Item 6) [Figure 10-61-2] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

42 of 928
7003031 (CONT'D)
Loader Service Tool Harness - 6689747 2
Figure 10-61-3
P-76452
2
Loaders with an attachment control harness (7 pin or 14
File has expired.

P-76678
pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
10-61-5].
The loader service tool harness (Item 1) [Figure 10-61-3] When the remote start procedure is completed, replace

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

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

43 of 928
REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7003031 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
3 2
1 P-76450
File has expired.

P-76453 The computer service tool harness (Item 1) [Figure 10-
61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item

1) and (Item 3). The main connector (Item 1)

[Figure 10-61-6] is always used for connection
to the loader harness.
Publications.
The second connector (Item 3) [Figure 10-61-
6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector

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

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

44 of 928
REMOTE START TOOL (SERVICE TOOL) KIT - Open the rear door of the loader.
7003031 (CONT'D)
Figure 10-61-9
Remote Start Procedure
1
WARNING
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
Pressing the RUN button on the Remote Start Tool

disconnects the operator panel from the start circuit. P-76451
If the service technician will be working in the engine
File has expired.

area it is important to remove the operator panel key
or lock the keypad with a unique password.
W-2647-0707
Loaders without an attachment control harness, remove
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:
Figure 10-61-10
7003031: Remote Start Tool (Service Tool) Kit
2
Figure 10-61-8
Publications.
1
P-76452
Loaders with an attachment control harness (7 pin or 14

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

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

45 of 928
7003031 (CONT'D)
2
Figure 10-61-11
5 3
2
6 4
1
P-76439
3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
File has expired.

P-76453
61-12] has five buttons.
The STOP button (Item 2) [Figure 10-61-12] is used to

stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item

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

46 of 928
7003031 (CONT'D)
Figure 10-61-13
1 2
P-34661
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is

pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)
Publications.
[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
NOTE: To relieve the pressure at the rear or

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

47 of 928
File has expired.

Publications.

48 of 928
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

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

Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS) bar raised. See details in this Manual.

Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
Operator Cab
safety treads that are damaged or worn.
Check the fastening bolts, washers and nuts. Check the condition of the cab.
(If Equipped)
Publications.
Indicators and Lights
Heater and A/C Filters
Hydraulic Fluid, Hoses and

Check for correct operation of all indicators and lights.
Clean or replace filters as needed.
Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed.
conditioning, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. ▲ ✶
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed
or as scheduled.
✶ Change oil and filter every 100 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.

49 of 928
File has expired.

Publications.

50 of 928
AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-3
Figure 10-80-1
1
1
P-76460G
P-76732
Figure 10-80-2
File has expired. Remove the wing nut and remove the dust cover (Item 1)
[Figure 10-80-3].
Figure 10-80-4

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

necessary. The Service indicator (Item 1) will FLASH and
P-76730
service code [M0117] (Air Filter Plugged) will show in the
Data Display (Item 2) when the Information button (Item
3) [Figure 10-80-1] is held for two seconds. Remove the wing nut and remove the outer filter element
(Item 1) [Figure 10-80-4] out and discard.
The Air Cleaner icon on the Deluxe Instrumentation
Panel, if equipped, will be ON (Item 1) [Figure 10-80-2]. NOTE: Make sure all sealing surfaces are free of dirt
and debris. DO NOT use compressed air.
Replace the inner filter every third time the outer filter is
replaced or as indicated. Install a new filter. Push all the way in until it contacts the
base of the housing. Install wing nut.
Install the dust cover and the wing nut [Figure 10-80-3].

51 of 928
AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

conditions: 1
• Replace the inner filter element every third time the

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

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [M0117] (Air Filter Plugged),
replace the inner filter element. P-76732
Figure 10-80-5
Install the dust cover and the wing nut (Item 1) [Figure
File has expired. 10-80-6].

Publications.
P-76731
Remove the wing nut and remove the inner filter element
(Item 1) [Figure 10-80-5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris. DO NOT use compressed air.
Install the new inner element.
Install the outer element.

52 of 928
ENGINE COOLING SYSTEM Figure 10-90-2
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
2
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present. 1
• Engine is running.
P-76190
• Tools are being used.
W-2019-0907
NOTE: Be careful when raising and lowering the oil
Cleaning
File has expired.
Open the rear door and remove the rear grille. (See
cooler so that the oil cooler does not fall on
the radiator and damage the fins.
REAR GRILLE on Page 50-60-1.) Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)

Figure 10-90-1 [Figure 10-90-2].
Use updated files from Bobcat Lower the oil cooler.
Check the cooling system for leaks.

1
Publications. Lower the rear grille and close the rear door.
P-45101
Use low air pressure or water pressure to clean the top of

the oil cooler (Item 1) [Figure 10-90-1].

53 of 928
ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant
Checking Level Open the rear door and remove the rear grille.
Open the rear door and raise the rear grille. Figure 10-90-4
Check coolant level using the level markers (Item 2)

[Figure 10-90-2] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
hot.
Close the rear door before operating the loader.
1
3
IMPORTANT
2
AVOID ENGINE DAMAGE
File has expired.

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

P-54299 P-76738
Remove the coolant fill cap (Item 1) [Figure 10-90-4].

efficiency and may cause serious premature engine Connect a hose to the engine block drain valve (Item 3)
damage. [Figure 10-90-4]. Open the drain valve and drain the

coolant into a container.
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
After all the coolant is removed, close the drain valve and
remove the hose. Recycle or dispose of coolant in an
environmentally safe manner.
Publications.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-4.)
I-2124-0497
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
Figure 10-90-3
propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank. (See Checking Level.)
The correct mixture of coolant to provide a -37° C (-34°

1 F) freeze protection is 5L propylene glycol mixed with
4,4L of water OR 1 U.S. gal propylene glycol mixed with
3.5 U.S. qt of water.
Fill the tank until it is at the lower marker on the tank.
Use a refractometer to check the condition of propylene

glycol in your cooling system and replace the coolant fill
cap.
P-76780
NOTE: When installing the coolant fill cap, the cap
must be tightened until it clicks.
NOTE: All access covers (Item 1) [Figure 10-90-3]
(both sides) must be in place to ensure Run the engine until it is at operating temperature. Stop
correct air flow through the oil cooler which the engine. Check the coolant level when cool. Add
will ensure cooling for engine and hydraulic coolant as needed.
system.
Install the rear grille and close the rear door.

54 of 928
FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE F° (C°) NO. 2 NO. 1 corrosion and plugging of fuel system components.
+15°(-9°) 100% 0% • Use of biodiesel blend fuel may result in premature

Down to -20° (-29°) 50% 50% failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals may be required, such

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
as cleaning the fuel system and replacing fuel filters
must be used in this machine.
and fuel lines.
File has expired.

The following fuels may also be used in this machine:
• Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
deterioration of hoses, tubelines, injectors, injector
pump and seals.

• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low

sulfur petroleum based diesel. This is commonly
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or
Apply the following guidelines if biodiesel blend fuel is
used:
• Ensure the fuel tank is as full as possible at all times
Publications.
EN590 (EU Standard) 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
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term

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

55 of 928
FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1 B-15650
Use a clean, approved safety container to add fuel of the
1
File has expired. correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-

100-1].

WARNING
Publications. P-76799 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

56 of 928
Fuel Filter
See the SERVICE SCHEDULE for the service interval for 1

removing water from, or replacing the fuel filter. (See
SERVICE SCHEDULE on Page 10-70-1.)
Removing Water
Figure 10-100-3
3
2
P-76735
Open the vent (Item 3) [Figure 10-100-4] on the fuel filter
File has expired. housing.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

2 10-100-4] until fuel flows from the vent with no air
1 bubbles.

P-76734
Close the vent (Item 3) [Figure 10-100-4] on the fuel

Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the
filter.
filter housing.
Open the vent (Item 1) [Figure 10-100-4] on the fuel
Publications.
Replacing Element
Remove the filter element (Item 2) [Figure 10-100-3].

injection pump.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

10-100-4] until the pump feels solid.
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Remove the air from the fuel system. (See Removing Air
WARNING
From The Fuel System below.)
Removing Air From The Fuel System Always clean up spilled fuel or oil. Keep heat, flames,
After replacing the filter element or when the fuel tank Failure to use care around combustibles can cause
has run out of fuel, the air must be removed from the fuel explosion or fire.
system before starting the engine. W-2103-0508
Tighten the vent plug (Item 1) [Figure 10-100-4] and start

WARNING the engine.
It may be necessary to open the vent plug (Item 1)

[Figure 10-100-4] briefly while the engine is running.
Diesel fuel or hydraulic fluid under pressure can
Close the vent when the engine runs smoothly.
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

57 of 928
File has expired.

Publications.

58 of 928
ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)
1 File has expired.

P-76736

Park the machine on level ground. Open the rear door TEMPERATURE RANGE ANTICIPATED BEFORE

and remove the dipstick (Item 1) [Figure 10-110-1]. Keep
the oil level between the marks on the dipstick. Do not
overfill.
NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
[1]Synthetic Oil - Use recommendation from Synthetic Oil
Manufacturer.
Publications. Use a good quality motor oil that meets API Service
Classification of CI-4 or better See Oil Chart [Figure 10-
110-2].

59 of 928
ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter WARNING

For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Run the engine until it is at operating temperature. Stop sparks or lighted tobacco away from fuel and oil.
the engine. Failure to use care around combustibles can cause
explosion or fire.
Figure 10-110-3 W-2103-0508
2
3
P-24679
File has expired.

1

P-76737

Open the rear door and remove the drain hose from its
storage position (Item 1) [Figure 10-110-3].
Publications.
Remove the oil drain cap (Item 2) [Figure 10-110-3] and
drain the oil into a container. Recycle or dispose of used
oil in an environmentally safe manner.
Install the oil drain cap.
Remove the oil filter (Item 3) [Figure 10-110-3] and clean

the filter housing surface.
Use genuine Bobcat filter only.
Put clean oil on the new oil filter gasket, install new filter
and hand tighten.
Remove the fill cap (Item 2) [Figure 10-110-3].
Put oil in the engine. For the correct quantity (See

Capacities on Page SPEC-10-4.) Do not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the oil filter.
Remove the dipstick (Item 1) [Figure 10-110-3] and

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

dipstick. Install the dipstick and close the rear door.

60 of 928
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-2
Check the hydraulic / hydrostatic fluid level everyday HYDRAULIC / HYDROSTATIC FLUID
before starting the work shift. RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms and
tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
1 TEMPERATURE RANGE ANTICIPATED

1
File has expired. 2
DURING MACHINE USE
[1] VG 100; Minimum VI 130
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic

Fluid (Unlike biodegradable fluids that are vegetable

P-45224A
P-45224A P-48011
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
10-120-1]. Publications.
Check the fluid level in the sight gauge (Item 1) [Figure
Use only recommended fluid in the hydraulic system
[Figure 10-120-2]. (See Hydraulic System on Page
SPEC-10-3.
Open the rear door and raise the rear grille. Remove the
fill cap (Item 2) [Figure 10-120-1].
Add fluid [Figure 10-120-2] as needed to bring the level

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

61 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Replace the fill cap, install the rear grille and close the
rear door.
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic
For the correct service interval (See SERVICE Filter
SCHEDULE on Page 10-70-1.).
Replace the fluid if it becomes contaminated or after For the correct service interval (See SERVICE
major repair. SCHEDULE on Page 10-70-1.)
Always replace the hydraulic / hydrostatic filter, the case Open the rear door.
drain filters and the hydraulic charge filter whenever the
hydraulic fluid is replaced. (See Removing And Figure 10-120-4
Replacing Hydraulic / Hydrostatic Filter on Page 10-120-
2.)
Open the rear door and remove the rear grille. Remove
the fill cap.
Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 10-120-3
File has expired. 1

1
Remove the filter (Item 1) [Figure 10-120-4].
Publications. Clean the surface of the filter housing where the seal
contacts the housing.
Put clean oil on the seal of the new filter element. Install
P-24751 and hand tighten the filter element.
Remove the plug from the top of the reservoir (Item 1)

[Figure 10-120-3]. Pump the fluid out of the reservoir
and into a container. Recycle or dispose of used fluid in
WARNING
an environmentally safe manner.
WARNING sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
AVOID INJURY OR DEATH W-2103-0508
sparks or lighted tobacco away from fuel and oil. Close the rear door before operating the loader.
explosion or fire. Start the engine and operate the loader hydraulic
W-2103-0508
controls.
Install the plug in the top of the reservoir. Lower the Stop the engine and check for leaks at the filter.
operator cab. (See Lowering on Page 10-30-2.) Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)

62 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Case Drain

Filters (Single Speed Loaders) WARNING
For the correct service interval (See SERVICE
SCHEDULE on Page 10-70-1.)
Figure 10-120-5
Left Side Shown Use a piece of cardboard or wood to find leaks. Do
1
W-2072-0807
Stop the engine and check for leaks at the filter

assemblies.
File has expired. Check the fluid level in the reservoir and add as needed.
P-45492

Remove both hydrostatic motor covers (Item 1) [Figure
10-120-5].
Figure 10-120-6
Publications.
1
P-45499 P-45493
Remove the case drain filter assemblies (Item 1) [Figure

10-120-6] near the hydrostatic motors. Install the fittings
from the old filter assembly onto the new filter assembly.
Install new filter assemblies. Install motor covers.
Recycle or dispose of used fluid in an environmentally

safe manner.
Start the engine and operate the loader hydraulic

controls.

63 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-8

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

P-90328
10-120-8].
Install the fittings from the old filter assembly onto the
AVOID DEATH new filter assembly.

Install new case drain filter assembly and replace the
can cause lift arms to drop. side access cover.
•
Keep out of this area when lift arms are raised
safe manner.
Publications. D-1009-0409

SJC equipped machines skip ahead to [Figure 10-120-
10].
Figure 10-120-9
Figure 10-120-7
1
2 2
1
1
P-76174
P-76171
Scribe a mark across the top of the steering linkage bars

Remove the left side access cover (Item 1) [Figure 10-
(Item 1) [Figure 10-120-9] which are connected to the
120-7] near the rear tire.
steering shaft on the control panel.
Remove the four steering linkage mounting bolts (Item 2)

[Figure 10-120-9].

64 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Start the engine and operate the loader hydraulic
controls.
Filters (Two-Speed Loaders) (Cont’d)
Figure 10-120-10
WARNING
1 Diesel fuel or hydraulic fluid under pressure can
W-2072-0807

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

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

10-120-10]. Install the fittings from the old filter assembly
onto the new filter assembly.

Install new case drain filter assembly.
Publications.
WARNING
explosion or fire.
W-2103-0508
Standard Controls and ACS only: Align the marks on the

steering linkage bars. Install the steering linkage
mounting bolts (Item 2) [Figure 10-120-9] in the proper
orientation (two bolts facing up and two bolts facing
down). Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 N•m).
Recycle or dispose of the used fluid in an

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

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

65 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-13
Removing And Replacing Hydraulic Charge Filter

SCHEDULE on Page 10-70-1.). 1
For Machines With (SN A3L529999 and Below)

P-76553A
Figure 10-120-11
Remove and discard the filter element (Item 1) [Figure
10-120-13].
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
1 File has expired. the element on the filter base. Install and hand tighten the
filter housing to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
All Models

WARNING

Publications.
Clean the surface of the filter housing where the filter
seal contacts the housing.
explosion or fire.
Put clean oil on the seal of the new filter. Install and hand W-2103-0508
tighten the new filter.
For Machines With (SN A3L530001 and Above) Lower the cab. (See Lowering on Page 10-30-2.)
Figure 10-120-12 Start the engine and operate the loader hydraulic
controls.
WARNING
1
P-76676 W-2072-0807
Place a suitable container below the filter housing and Stop the engine and check for leaks at the filter.
remove the filter housing (Item 1) [Figure 10-120-12].
Check the fluid level in the reservoir and add as needed.
safe manner.

66 of 928
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Breather Cap

SCHEDULE on Page 10-70-1.)
Figure 10-120-14
File has expired.

P-76673

Remove the breather cap (Item 1) [Figure 10-120-14]
and discard. (Blower housing removed for clarity.)
Publications.
Install new breather cap.

2.)

67 of 928
File has expired.

Publications.

68 of 928
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil
Checking And Adding Oil Figure 10-130-2
The chaincase contains the final drive sprockets and

chains. Use the same type of oil as the hydraulic/
hydrostatic system. (See Hydraulic System on Page
SPEC-10-3.)
1
Stop the loader on a level surface and stop the engine.
Figure 10-130-1
1
P-76684
File has expired. Remove the check plug (Item 1) [Figure 10-130-2] from
the front of the chaincase housing.
Figure 10-130-3

Publications.
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
oil flows from the hole.
Install and tighten the plug. P-31287A
Remove the oil from the chaincase [Figure 10-130-3].
Recycle or dispose of the used oil in an environmentally

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

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File has expired.

Publications.

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BOB-TACH (HAND LEVER) The wedges (Item 1) [Figure 10-140-2] must extend
through the holes in the attachment mounting frame.
Inspection And Maintenance
The spring loaded wedge (Item 1) must contact the lower
Figure 10-140-1 edge of the hole in the attachment (Item 2) [Figure 10-
140-2].
If the wedges do not contact the lower edge of the holes

[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
File has expired.

P-31693
Move the Bob-Tach levers down to engage the wedges

[Figure 10-140-1].

The levers and wedges must move freely.

Publications.
WARNING
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208
Figure 10-140-2
B-17460
2
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
Wedge must contact damaged, bent, or missing. Keep all fasteners tight.
lower edge of hole in the
attachment. Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
P-31233 B-15177
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) (See Lubrication Locations on Page 10-
150-1.)

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Publications.

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

[Figure 10-141-1] until wedges are fully raised. Push and
File has expired.

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

Use WARNING
updated files from Bobcat
Publications.
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208
Figure 10-141-2
B-17460
2
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts including
Wedge must contact decals and lever that are damaged, bent, or missing.
lower edge of hole in the Keep all fasteners tight.
attachment.
Look for cracked welds. Contact your Bobcat dealer for
B-15177
repair or replacement parts.
P-31233
Lubricate the wedges. (See SERVICE SCHEDULE on

The wedges must extend through the holes in the Page 10-70-1.) (See Lubrication Locations on Page 10-
attachment mounting frame (Item 2) [Figure 10-141-2]. 150-1.)

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LUBRICATING THE LOADER 4. Lift Cylinder Base End (Both Sides) [Figure 10-150-
2].
Lubrication Locations
Figure 10-150-3
Lubricate the loader as specified for the best
performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
Record the operating hours each time you lubricate the

Bobcat Loader.
Always use a good quality lithium based multi-purpose 5

grease when you lubricate the loader. Apply lubricant
until extra grease shows.
Lubricate the following:
Figure 10-150-1
File has expired.

N-18510
5. Tilt Cylinder Base End (Both Sides) [Figure 10-150-

3].
1

Figure 10-150-4

Publications.
N-18505
6
1. Stabilizer Rod - Front (Both Sides) [Figure 10-150-1] 7
Figure 10-150-2
N-18509
3
2 6. Tilt Cylinder Rod End (Both Sides). [Figure 10-150-
4 4].
N-18506 7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-4].

Access
Hole
P-31852A
2. Stabilizer Rod - Rear (Both Sides) [Figure 10-150-2].
3. Lift Cylinder Rod End (Both Sides) [Figure 10-150-2].

75 of 928
LUBRICATING THE LOADER (CONT’D) Figure 10-150-7
Lubrication Locations (Cont’d)
Figure 10-150-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-150-
9 7].
File has expired.

P-16045 Figure 10-150-8
8. Bob-Tach Wedge (Both Sides) [Figure 10-150-5].

9. Power Bob-Tach Cylinder (Both Sides) [Figure 10-
150-5].

Figure 10-150-6
Publications.
10
12
P-24703
12. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-

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

76 of 928
TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-160-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Mounting
Tires are to be repaired only by an authorized person

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

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

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

SERVICE SCHEDULE on Page 10-70-1.) cause serious injury or death.

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

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SPARK ARRESTOR MUFFLER
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for
WARNING
cleaning the spark arrestor muffler. (See SERVICE
SCHEDULE on Page 10-70-1.) When the engine is running during service, the
driving and steering controls must be in neutral and
Do not operate the loader with a defective exhaust
the parking brake engaged. Failure to do so can
system.
cause injury or death.
W-2006-1209
IMPORTANT Start the engine and run for about 10 seconds while a
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
This machine is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor exhaust This will force contaminants out through the cleanout
system. hole.
File has expired.

The spark arrestor muffler, if equipped, must be
cleaned to keep it in working condition. The spark
arrestor muffler must be serviced by dumping the
Stop the engine.
Install and tighten the plug.

spark chamber every 100 hours of operation.
Close the rear door.
On some models, the turbocharger functions as the

spark arrestor and must operate correctly for proper
Use updated files from WARNING

spark arrestor function.
Bobcat
If this machine is operated on flammable forest,
brush, or grass covered land, it must be equipped AVOID INJURY OR DEATH
Publications.
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
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
be in violation of California State Law, Section 4442.
PRC. Refer to local laws and regulations for spark outside. Exhaust fumes contain odorless, invisible
arrestor requirements. gases which can kill without warning.
I-2284-0409 W-2050-0807
Stop the engine. Open the rear door.
Figure 10-170-1
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
1
WARNING
Never use machine in atmosphere with explosive
P-76801
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
Remove the plug (Item 1) [Figure 10-170-1] from the W-2068-1285
bottom of the muffler.

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File has expired.

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PIVOT PINS
Inspection And Maintenance
Figure 10-180-1
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 35 - 40 ft.-lb. (48
- 54 N•m) torque.
Publications.

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Publications.

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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.
• File has expired.

Put blocks under the frame to remove weight from the
tires.
• Check tire inflation and remove blocks from under
frame.
• Remove cover from exhaust pipe opening.

• Put grease on any exposed cylinder rods.

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

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

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

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

condition.

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

P-68124B P-68125B

P-31864

Pull the engine speed control fully backward [Figure 10-
Exit the loader using grab handles, safety tread and
steps (maintaining a 3-point contact) [Figure 10-200-3].
200-1] to decrease the engine speed.
Publications.
Engage the parking brake.
Figure 10-200-2
WARNING
2 AVOID INJURY OR DEATH
1
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
2 • Engage the parking brake.
• Raise the seat bar.
P-76603 P-90809A B-15553L
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
Turn the key switch to the STOP position (Item 1) or drive functions are deactivated.
press the STOP button (Item 2) [Figure 10-200-2].
The seat bar system must deactivate these functions
NOTE: If the loader lights are ON, they will remain ON when the seat bar is up. Service the system if
for approximately 90 seconds after turning controls do not deactivate.
the loader OFF. W-2463-0610
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to

prevent operation of the loader by unauthorized
personnel.

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EMERGENCY EXIT NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
The front opening on the operator cab and rear window NOT an emergency exit.
provide exits.
Figure 10-210-3
Rear Window
Figure 10-210-1
P-64994 Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-210-3].

Pull on the tag on the top of the rear window to remove Figure 10-210-4
the rubber cord [Figure 10-210-1].
Push the rear window out of the rear of the operator cab.
Publications.
Figure 10-210-2
X X
X X
S0363
Push the window out with your foot at any corner of the
window [Figure 10-210-4].
P-43752
Exit through the front door.
Exit through the rear of the operator cab [Figure 10-210-

2].
Front Door
This machine may be equipped with a front door.
NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be
used as an emergency exit. [Figure 10-210-3]

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

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

each year or more often if the machine is exposed to
severe environmental conditions or applications.
File has expired.
Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware or any other obvious

problem should be replaced immediately.
The items below are referenced in [Figure 10-220-1].

B-22283
Publications.
1. Check the webbing. If the system is equipped with a
retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.
2. Check the buckle and latch for correct operation.

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

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

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have deteriorated.
See your Bobcat dealer for seat belt system replacement

parts for your machine.

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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 HYDRAULIC
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4 SAFETY
SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 SYSTEM
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
File has expired.

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2

ELECTRICAL
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SYSTEM &
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . 20-21-4
ANALYSIS
Publications.
Rod End Pivot Pin Bushing And Seal Removal And Installation . . . 20-21-3
ENGINE
SERVICE
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1 SPECIFICATIONS
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
High Flow Relief Valve Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

91 of 928
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1

Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . 20-41-12
Auxiliary Solenoid Removal And Installation (S/N A3L534999 & Below). . . . . 20-41-26
Auxiliary Solenoid Removal And Installation (S/N A3L535001 & Above) . . . . 20-41-27
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . .20-41-11
File has expired.

Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . 20-41-13

Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2
Publications.
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22

92 of 928
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . .20-40-10
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-28
Auxiliary Solenoid Removal And Installation (S/N A3L534999 & Below). . . . . .20-40-30
Auxiliary Solenoid Removal And Installation (S/N A3L535001 & Above) . . . . .20-40-31
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-36
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-15
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-35
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . 20-40-9
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
File has expired.

Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-35
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . .20-40-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . .20-40-11

Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . .20-40-12
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-2
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-14
Publications.
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-32
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
HYDRAULIC PUMP (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

93 of 928
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
File has expired.

Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8

HYDRAULIC PUMP (SJC) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Publications.
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-11
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

94 of 928
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
File has expired.

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Publications.


95 of 928
File has expired.

Publications.

96 of 928
HYDRAULIC/HYDROSTATIC SCHEMATIC
S175 (S/N A3L520001 AND ABOVE)
Printable Version Click Here
(PRINTED MARCH 2008)

V-1122legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
2 SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL
3 File has expired.
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar)
CONTROL VALVE - BICS CONTROL
17 PILOTED ACTIVATED DIRECTIONAL

32 FILTER - CASE DRAIN (SINTERED
BRONZE)
45
46
RESTRICTION - 0.089 inch (2,26 mm)

Normally Closed
CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
4 DRIVE MOTOR SHUTTLE VALVE (SCREEN)
CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
5 RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
34 CHECK VALVE - BUCKET POSITION
VALVE
49 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
6 RELIEF VALVE - CHARGE INLET: ARM BY-PASS 35 RESTRICTION
Publications. 360 PSI (24,8 Bar)
at High Engine Idle
With 140 degrees F. (60 degrees C.) Fluid
CONTROL VALVE - UNLOADING
36 VARIABLE CAPACITY DISPLACEMENT
50 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 51 ANTICAVITATION VALVE
7 FRONT AUXILIARY MANUAL PRESSURE 37 SHUTTLE RELIEF VALVE
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL (Not Adjustable - Factory Set) 52 PROPORTIONAL RELIEF VALVE –
SPOOL 65 PSI (4,5 Bar) (Fan Speed Regulator):
8 HYDRAULIC PUMP . . . . . . . Gear Type 1566 - 1784 PSI (108 - 123 bar)
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT
53 FILTER - BOB-TACH VALVE
BIDIRECTIONAL HYDROSTATIC
9 RELIEF VALVE - MAIN: MOTOR 54
23 SOLENOID ACTIVATED DIRECTIONAL RESTRICTION - 0.343 inch (8,73 mm)
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
at Front Quick Couplers 55 SENSOR – CHARGE PRESSURE – Fan
24 SOLENOID ACTIVATED DIRECTIONAL Filter
10 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
PORT 3500 PSI (241,3 Bar) 56 SENSOR – HYD. TEMP. – Hyd. Filter
CONTROL VALVE - BUCKET POSITION
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF)
26 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE

CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
42 CHARGE PUMP -
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL 12.8 GPM (48,5 L/min) at High Engine Idle
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY
28 43 CHECK VALVE - With 300 PSI (20,7 Bar)
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE Spring And With 0.016 inch (0,40 mm) Orifice
29 RESTRICTOR - 0.031 inch (0,8 mm) NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1122legend (2-27-08)

97 of 928
(REAR QUICK
FEMALE COUPLERS) MALE
S175 (S/N A3L520001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(PRINTED MARCH 2008) INTEGRATED QUICK
V-1122 23 24 COUPLER BLOCK
25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
File has expired. 32 BUCKET POSITION VALVE (OPTIONAL)
38
D
HYDRAULIC FILTER 34
31
56 OIL
2 22

COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
Publications.
6 3 40 C
21
Dealer Copy -- 13Not for Resale

20
AUXILIARY
CHARGE
SPOOL
INLET 12
54 12
13 B
B A
55
3 14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
LIFT ARM BY PASS VALVE
32
19
98 of 928
Printed in U.S.A. V-1122 (2-27-08)
WITH 2 SPEED OPTION

V-1123legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 47 RELIEF VALVE - 2000 PSI (137 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) 48 RELIEF VALVE - 1200 PSI (83 Bar)
3 File has expired.
36-44 PSI (2,5-3,0 Bar)

BRONZE)
33 FILTER - BICS CONTROL VALVE
Normally Closed (SCREEN) HYDRAULIC MOTOR
CONTROL VALVE - TILT CONTROL
4 DRIVE MOTOR SHUTTLE VALVE 34 CHECK VALVE - BUCKET POSITION
18 PILOTED ACTIVATED DIRECTIONAL 51 ANTICAVITATION VALVE
CONTROL VALVE - LIFT CONTROL VALVE

35 RESTRICTION

52 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
6 RELIEF VALVE - CHARGE INLET: ARM BY-PASS
at High Engine Idle
Dealer Copy --37NotCHECK
for Resale
VALVE - With 5 PSI (0,34 Bar) Spring
53
54
FILTER - BOB-TACH VALVE

SPOOL 38 BIDIRECTIONAL HYDROSTATIC
MOTOR – 2 SPEED 55 SENSOR – CHARGE PRESSURE – Fan
7 FRONT AUXILIARY MANUAL PRESSURE 21 PILOTED ACTIVATED DIRECTIONAL
Filter
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL
SPOOL 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 56 SENSOR – HYD. TEMP. – Hyd. Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 57 HIGH PRESSURE SHUTTLE
9 RELIEF VALVE - MAIN: 23 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 58 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE CONTROL VALVE – WARM UP
at Front Quick Couplers 41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL 59 SOLENOID ACTIVATED DIRECTIONAL
10 RELIEF/ANTICAVITATION VALVE - 42 CHARGE PUMP -
CONTROL VALVE - ROD CONTROL VALVE – 2 SPEED
PORT 3500 PSI (241,3 Bar) 12.8 GPM (48,5 L/min) at High Engine Idle
60 PILOT ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE – HIGH / LO SPEED
43 CHECK VALVE - With 300 PSI (20,7 Bar)
Spring And With 0.016 inch (0,40 mm) Orifice 61 CHECK VALVE – With 125 PSI (8,6 bar) Spring
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY
45 RESTRICTION - 0.089 inch (2,26 mm)
28 RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE
pressure value.

99 of 928
(REAR QUICK
WITH 2 SPEED OPTION

INTEGRATED QUICK
(PRINTED MARCH 2008) 23 24 COUPLER BLOCK
V-1123 25 MALE
26
DRIVE MOTOR MALE
38 7 LEFT SIDE LIFT ARM)
(2 SPEED)
29
61 4 1 30
FEMALE
27
57
P-OUT P-IN T
File has expired.

60
32 BUCKET POSITION VALVE (OPTIONAL)
D
HYDRAULIC FILTER 34
31
56 OIL
2 22

COOLER
5 36
5
A
Publications.
6 3 40 C
21

20
AUXILIARY
CHARGE
SPOOL
INLET 12 12
13 B
B A
54
3
31 14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
55
2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
52 (OPTIONAL) 11
HYDRAULIC
51 POWERED 14
DRIVE MOTOR BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
(2 SPEED)
38 18
39
60 DR B A
37 13 LIFT
58
CYLINDER
43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
57 PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
59
4 32
19
61
100 of 928
Printed in U.S.A. V-1123 (2-27-08)
WITH HIGH FLOW OPTION

V-1124legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
3 File has expired.
36-44 PSI (2,5-3,0 Bar)

BRONZE)
45
46

Normally Closed
CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
4 DRIVE MOTOR SHUTTLE VALVE (SCREEN)
CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE
6 RELIEF VALVE - CHARGE INLET: ARM BY-PASS 35 RESTRICTION
at High Engine Idle
50
51
RELIEF VALVE - 3300 PSI (228 Bar)
DUMP VALVE - (ON/OFF)

SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 37 SHUTTLE RELIEF VALVE 52 CHECK VALVE
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL (Not Adjustable - Factory Set)
65 PSI (4,5 Bar) 53 FILTER - BOB-TACH VALVE
SPOOL
8 HYDRAULIC PUMP . . . . . . . Gear Type
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT 54 AUXILIARY HYDRAULIC PUMP -
BIDIRECTIONAL HYDROSTATIC 9.5 GPM (36 L/min) at High Engine Idle
9 RELIEF VALVE - MAIN: MOTOR
23 SOLENOID ACTIVATED DIRECTIONAL 55 FIXED CAPACITY DISPLACEMENT
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
at Front Quick Couplers HYDRAULIC MOTOR
24 SOLENOID ACTIVATED DIRECTIONAL 56 ANTICAVITATION VALVE
10 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
PORT 3500 PSI (241,3 Bar)
CONTROL VALVE - BUCKET POSITION 57 PROPORTIONAL RELIEF VALVE –
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF) (Fan Speed Regulator):
1566 - 1784 PSI (108 - 123 bar)
26 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 58 RESTRICTION - 0.343 inch (8,73 mm)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
42 CHARGE PUMP -
13 27 PILOT ACTIVATED DIRECTIONAL 12.8 GPM (48,5 L/min) at High Engine Idle 59 SENSOR – CHARGE PRESSURE – Fan
RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - REAR AUXILIARY Filter
PORT (OPTIONAL) 3500 PSI (241,3 Bar)
28 43 CHECK VALVE - With 300 PSI (20,7 Bar) 60 SENSOR – HYD. TEMP. – Hyd. Filter
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE Spring And With 0.016 inch (0,40 mm) Orifice
pressure value.

101 of 928
(REAR QUICK
WITH HIGH FLOW OPTION

V-1124 23 24 COUPLER BLOCK
25 MALE
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
60 2 22

COOLER
5 36
5
A
Publications.
6 3 40 C
21

20
AUXILIARY
CHARGE
SPOOL
INLET 12
58 12
13 B
B A
3
14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
59 2
51
8
50
52
55 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
54 (OPTIONAL) 11
HYDRAULIC
57 56 POWERED 14
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
32
19
102 of 928
Printed in U.S.A. V-1124 (2-27-08)
WITH HIGH FLOW & 2 SPEED OPTION

V-1125legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 50 RELIEF VALVE - 3300 PSI (228 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
51 DUMP VALVE - (ON/OFF)
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 Bar) (SCREEN)
3 File has expired.
36-44 PSI (2,5-3,0 Bar)
CONTROL VALVE - TILT CONTROL
CONTROL VALVE - LIFT CONTROL
VALVE
52
53
CHECK VALVE
FILTER - BOB-TACH VALVE

Normally Closed 35 RESTRICTION 54
19 PULL BUTTON ACTIVATED AUXILIARY HYDRAULIC PUMP -
4 DRIVE MOTOR SHUTTLE VALVE DIRECTIONAL CONTROL VALVE - LIFT 9.5 GPM (36 L/min) at High Engine Idle
ARM BY-PASS BIDIRECTIONAL HYDROSTATIC PUMP
PRESSURE: 5000 PSI (345 Bar) 20 PILOTED ACTIVATED DIRECTIONAL
37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring
56
HYDRAULIC MOTOR
ANTICAVITATION VALVE
6 RELIEF VALVE - CHARGE INLET: SPOOL
at High Engine Idle
CONTROL VALVE - FLOW CONTROL
38 BIDIRECTIONAL HYDROSTATIC
21 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not MOTOR – 2 SPEED
for Resale
SPOOL 1566 - 1784 PSI (108 - 123 bar)
7 FRONT AUXILIARY MANUAL PRESSURE 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 58 RESTRICTION - 0.343 inch (8,73 mm)
BLEED-OFF VALVE CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF) 59 SENSOR – CHARGE PRESSURE – Fan
8 HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL
Filter
16.9 GPM (64 L/min.) at High Engine Idle CONTROL VALVE - BASE 41 CHECK VALVE - BICS CONTROL VALVE
60 SENSOR – HYD. TEMP. – Hyd. Filter
9 RELIEF VALVE - MAIN: 42 CHARGE PUMP -
CONTROL VALVE - ROD
3250-3350 PSI (224-231 Bar) 12.8 GPM (48,5 L/min) at High Engine Idle 61 HIGH PRESSURE SHUTTLE
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 43 CHECK VALVE - With 300 PSI (20,7 Bar) 62 SOLENOID ACTIVATED DIRECTIONAL
10 RELIEF/ANTICAVITATION VALVE - Spring And With 0.016 inch (0,40 mm) Orifice CONTROL VALVE – WARM UP
PORT 3500 PSI (241,3 Bar) 26 SOLENOID ACTIVATED DIRECTIONAL
44 PILOT ACTIVATED DIRECTIONAL 63 SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
CONTROL VALVE - HYDRAULIC CONTROL VALVE – 2 SPEED
27 PILOT ACTIVATED DIRECTIONAL POWERED BOB-TACH
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 64 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 45 RESTRICTION - 0.089 inch (2,26 mm) CONTROL VALVE – HIGH / LO SPEED
13 RELIEF/ANTICAVITATION VALVE - 65 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
PORT (OPTIONAL) 3500 PSI (241,3 Bar) 29 RESTRICTOR - 0.031 inch (0,8 mm)
14 LOAD CHECK VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
30 RELIEF VALVE: 3300 PSI (228 Bar)
15 LIFT CYLINDER SPOOL - MADE TO 48 RELIEF VALVE - 1200 PSI (83 Bar) NOTE: Unless otherwise specified
RESTRICT FLOW DURING BOOM 31 FILTER - HYDRAULIC (CANISTER) springs have NO significant
DOWN BUT NOT DURING BOOM UP CONTROL VALVE (TWO COIL) pressure value.

103 of 928
(REAR QUICK
WITH HIGH FLOW & 2 SPEED OPTION
V-1125 INTEGRATED QUICK
23 24 COUPLER BLOCK
25 MALE
26
DRIVE MOTOR (2 SPEED) MALE
29
65 4 1 30
FEMALE
27
61
P-OUT P-IN T
File has expired.

64
32 BUCKET POSITION VALVE (OPTIONAL)
D
HYDRAULIC FILTER 34
31
OIL
60 2 22

COOLER
5 36
5
A
Publications.
6 3 40 C
21
Dealer Copy -- Not

13
for Resale
20
AUXILIARY
CHARGE
SPOOL
INLET 12 12
13 B
B A
58
3
14
31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
59 2
51
8
50
52
55 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
54 (OPTIONAL) 11
57
HYDRAULIC
56 POWERED 14
DRIVE MOTOR (2 SPEED) (OPTIONAL) 10
38 18
39
64 DR B A
13 LIFT
62 37
CYLINDER
43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
53
PILOT CIRCUITS
61
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
63 LIFT ARM BY PASS VALVE
32
4 19
65
104 of 928
Printed in U.S.A. V-1125 (2-27-08)
WITH SJC OPTION

V-1126legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3
File has expired.
36-44 PSI (2,5-3,0 bar)
Normally Closed
VALVE
19 PULL BUTTON ACTIVATED HYDRAULIC MOTOR
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 PROPORTIONAL RELIEF VALVE –
6
PRESSURE: 5075 PSI (350 bar)
RELIEF VALVE - CHARGE INLET:

SPOOL 37
BI-DIRECTIONAL HYDROSTATIC PUMP
SHUTTLE RELIEF VALVE
1566 - 1784 PSI (108 - 123 bar)
Publications. 360 PSI (24,8 bar)

at High Engine Idle
(Not Adjustable - Factory Set)
Dealer Copy -- Not for Resale 65 PSI (4,5 bar)
53
54
CHARGE PUMP -
12.8 GPM (48,5 L/min) at High Engine Idle
CHECK VALVE - With 300 PSI (20,7 bar) Spring
SPOOL 38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL with 0.016 inch (0,40 mm) orifice
22 FLOW DIVIDER ADJUSTMENT VALVE BI-DIRECTIONAL HYDROSTATIC
PRESSURE BLEED-OFF VALVE MOTOR 55 SOLENOID ACTIVATED CONTROL
8 VALVE - FORWARD/REVERSE
HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 56 SERVO PISTON -Swash Plate
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE
40 SOLENOID ACTIVATED DIRECTIONAL 57 POSITION SENSOR -Swash Plate
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar) 58 CHARGE PRESSURE SENSOR
VALVE (ON/OFF)
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE
10 PORT RELIEF/ANTICAVITATION VALVE 59 SENSOR – CHARGE PRESSURE – Fan
3500 PSI (241,3 bar) 26 Filter
SOLENOID ACTIVATED DIRECTIONAL
42 RESTRICTION - 0.343 inch (8,7 mm) 60 SENSOR – HYD. TEMP. – Hyd. Filter
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 FILTER - Bob-Tach Valve
CONTROL VALVE - AUXILIARY
13 PORT RELIEF/ANTICAVITATION VALVE: 44 PILOT ACTIVATED DIRECTIONAL
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
3500 PSI (241,3 bar) POWERED BOB-TACH
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-1126legend (2-27-08)
Printed in U.S.A.
105 of 928
(REAR QUICK
WITH SJC OPTION BASE ROD REAR AUX VALVE (OPTIONAL)
(V-1126) 23 24 COUPLER BLOCK
Printable Version Click Here 25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
38 HYDRAULIC FILTER 34
31
B HYDROSTATIC PUMPS A OIL

60 22

2 COOLER
55
56 A
HYDRAULIC CONTROL VALVE
Publications.
5 5 3 40 C
57
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
59 57 14
36
10 TILT CYLINDERS
31 BICS CONTROL VALVE
5 56 5
55
3 2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
50 LIFT CYLINDERS
52 51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P2 LIFT ARM BY PASS VALVE
P1
32 44 19
Printed in U.S.A.
106 of 928
DRIVE MOTOR
V-1126 (2-27-08)
WITH SJC & 2 SPEED OPTION
V-1127legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 51 ANTICAVITATION VALVE
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE (Fan Speed Regulator):
VALVE: 45-55 PSI (3,1-3,8 bar) 17 PILOTED ACTIVATED DIRECTIONAL (SCREEN)
CONTROL VALVE - TILT CONTROL 1566 - 1784 PSI (108 - 123 bar)
3
File has expired.
36-44 PSI (2,5-3,0 bar)
Normally Closed
VALVE
53 CHARGE PUMP -
35 RESTRICTION
4 19 PULL BUTTON ACTIVATED 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - 36 VARIABLE CAPACITY DISPLACEMENT with 0.016 inch (0,40 mm) orifice
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS BI-DIRECTIONAL HYDROSTATIC PUMP 55 SOLENOID ACTIVATED CONTROL

6

SPOOL
56
VALVE - FORWARD/REVERSE
SERVO PISTON -Swash Plate
38 BI-DIRECTIONAL HYDROSTATIC

at High Engine Idle
MOTOR – 2 SPEED
39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
57
58
POSITION SENSOR -Swash Plate
CHARGE PRESSURE SENSOR

SPOOL
7 FRONT AUXILIARY MANUAL 22 FLOW DIVIDER ADJUSTMENT VALVE 40 SOLENOID ACTIVATED DIRECTIONAL 59 SENSOR – CHARGE PRESSURE – Fan
PRESSURE BLEED-OFF VALVE CONTROL VALVE - BUCKET POSITION Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type VALVE (ON/OFF) 60 SENSOR – HYD. TEMP. – Hyd. Filter
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE 41 CHECK VALVE - BICS CONTROL VALVE
61 HIGH PRESSURE SHUTTLE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD 62 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers 43 CONTROL VALVE – WARM UP
25 FILTER - Bob-Tach Valve
LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE 63 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) 44 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – 2 SPEED
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 64 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH
CONTROL VALVE – HIGH / LO SPEED
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 65 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
CONTROL VALVE - AUXILIARY 46 RESTRICTION - 0.025 inch (0,6 mm)
13 PORT RELIEF/ANTICAVITATION VALVE:
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) 47 RELIEF VALVE - 2000 PSI (137 bar)
3500 PSI (241,3 bar)
14 LOAD CHECK VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
30 RELIEF VALVE: 3300 PSI (228 bar)
15 LIFT CYLINDER SPOOL - MADE TO 49 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE (TWO COIL)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP 50 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR - FAN V-1127legend (2-27-08)
Printed in U.S.A.
107 of 928
(REAR QUICK
WITH SJC & 2 SPEED OPTION

(V-1127) INTEGRATED QUICK
24 COUPLER BLOCK
Printable Version Click Here 23
25 MALE
26
DRIVE MOTOR (2 SPEED) 38 MALE
4 29
65 1 30
FEMALE
27
61
P-OUT P-IN T
File has expired.

64 32 BUCKET POSITION VALVE (OPTIONAL)
34
D
HYDRAULIC FILTER
31

60 22
2 COOLER
55
Use updated files from Bobcat 5

56
57 5 3
A
40 C
21
Publications. 6 36 Dealer Copy -- Not

13 for Resale
12
20
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
57 14
3 36
10 TILT CYLINDERS
5 56 5
55
59 2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
52
50 LIFT CYLINDERS
51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
DRIVE MOTOR (2 SPEED) 38 BOB-TACH
(OPTIONAL) SPOOL
64 35
39 47
62 15
DR
37 14
54
48 33 41
46 33 16
9
49 45
PP
61 43
P1
44 19
63
4
108 of 928 65
32 V-1127 (2-27-08)
Printed in U.S.A.
WITH SJC AND HIGH FLOW OPTION
V-1128legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 qt. (18,2 L) BRONZE) CONTROL VALVE (TWO COIL)
2 SPRING LOADED FILTER BY-PASS 50 RELIEF VALVE - 3300 PSI (228 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 51 DUMP VALVE - (ON/OFF)
3
File has expired.
36-44 PSI (2,5-3,0 bar)
Normally Closed
VALVE
52 CHECK VALVE
4 DRIVE MOTOR SHUTTLE VALVE 19 PULL BUTTON ACTIVATED 53 AUXILIARY HYDRAULIC PUMP -
35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 9.5 GPM (36 L/min) at High Engine Idle
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
6

SPOOL 37
BI-DIRECTIONAL HYDROSTATIC PUMP
SHUTTLE RELIEF VALVE
55
with 0.016 inch (0,40 mm) orifice
SOLENOID ACTIVATED CONTROL
VALVE - FORWARD/REVERSE

at High Engine Idle
(Not Adjustable - Factory Set)
Dealer Copy -- Not for Resale 65 PSI (4,5 bar)
56
57
SERVO PISTON -Swash Plate
POSITION SENSOR -Swash Plate

SPOOL 38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL BI-DIRECTIONAL HYDROSTATIC
22 FLOW DIVIDER ADJUSTMENT VALVE MOTOR 58 CHARGE PRESSURE SENSOR
PRESSURE BLEED-OFF VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
23 SOLENOID ACTIVATED DIRECTIONAL 59 CHARGE PUMP -
16.9 GPM (64 L/min.) at High Engine Idle 12.8 GPM (48,5 L/min) at High Engine Idle
CONTROL VALVE - BASE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION 60 FIXED CAPACITY DISPLACEMENT
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD VALVE (ON/OFF) HYDRAULIC MOTOR
at Front Quick Couplers 41 CHECK VALVE - BICS CONTROL VALVE 61 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 26 42 RESTRICTION - 0.343 inch (8,7 mm) 62 PROPORTIONAL RELIEF VALVE –
SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL (Fan Speed Regulator):
43 FILTER - Bob-Tach Valve 1566 - 1784 PSI (108 - 123 bar)
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 44 PILOT ACTIVATED DIRECTIONAL 63 SENSOR – CHARGE PRESSURE – Fan
CONTROL VALVE - AUXILIARY CONTROL VALVE - HYDRAULIC Filter
28 RESTRICTOR - 0.140 inch (3,6 mm) POWERED BOB-TACH
13 PORT RELIEF/ANTICAVITATION VALVE: 64 SENSOR – HYD. TEMP. – Hyd. Filter
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm)
3500 PSI (241,3 bar) 46 RESTRICTION - 0.025 inch (0,6 mm)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar)
47 RELIEF VALVE - 2000 PSI (137 bar)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 48
RESTRICT FLOW DURING BOOM RELIEF VALVE - 1200 PSI (83 bar) NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-1128legend (2-27-08)
Printed in U.S.A.
109 of 928
(REAR QUICK
WITH SJC AND HIGH FLOW OPTION
(V-1128) 23 24 COUPLER BLOCK
25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
38 HYDRAULIC FILTER 34
31

64 22

2 COOLER
55
56 A
Publications.
5 5 3 40 C
57
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
63 57 14
36
3 10 TILT CYLINDERS
HIGH FLOW VALVE
5 56 5
55 51
2 50
52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
60 LIFT CYLINDERS
62 61 59 10
FAN MOTOR 18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P1
32 44 19
Printed in U.S.A.
110 of 928
DRIVE MOTOR
V-1128 (2-27-08)
WITH SJC, 2 SPEED AND HIGH FLOW OPTION

V-1129legend
LEGEND
1 RESERVOIR: 17 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 56 SERVO PISTON -Swash Plate
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - TILT CONTROL
36 VARIABLE CAPACITY DISPLACEMENT 57 POSITION SENSOR -Swash Plate
2 SPRING LOADED FILTER BY-PASS 18 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP
VALVE: 45-55 PSI (3,1-3,8 bar) CONTROL VALVE - LIFT CONTROL 58 CHARGE PRESSURE SENSOR
3
File has expired.
36-44 PSI (2,5-3,0 bar)
Normally Closed
19 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE -
LIFT ARM BY-PASS
38 BI-DIRECTIONAL HYDROSTATIC
59 CHARGE PUMP -
MOTOR – 2 Speed
4 DRIVE MOTOR SHUTTLE VALVE 20 PILOTED ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 60 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING HYDRAULIC MOTOR
5 RELIEF/REPLENISHING VALVE - HIGH SPOOL 40 SOLENOID ACTIVATED DIRECTIONAL

6
41
VALVE (ON/OFF)
61 ANTICAVITATION VALVE

360 PSI (24,8 bar) SPOOL CHECK VALVE - BICS CONTROL VALVE
Publications. at High Engine Idle

22 FLOW DIVIDER ADJUSTMENT VALVE Dealer Copy 42
-- Not for Resale - 0.343 inch (8,7 mm)
RESTRICTION
1566 - 1784 PSI (108 - 123 bar)
7 FRONT AUXILIARY MANUAL 23 SOLENOID ACTIVATED DIRECTIONAL 43 FILTER - Bob-Tach Valve 63 SENSOR – CHARGE PRESSURE – Fan
PRESSURE BLEED-OFF VALVE CONTROL VALVE - BASE Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type 24 SOLENOID ACTIVATED DIRECTIONAL 64 SENSOR – HYD. TEMP. – Hyd. Filter
16.9 GPM (64 L/min.) at High Engine Idle CONTROL VALVE - ROD
POWERED BOB-TACH
25 LOAD SHUTTLE VALVE - BLEED OFF 45 65 HIGH PRESSURE SHUTTLE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 bar) 26 SOLENOID ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm) 66 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE - TWO COIL CONTROL VALVE – WARM UP
47 RELIEF VALVE - 2000 PSI (137 bar)
10 PORT RELIEF/ANTICAVITATION VALVE 27 67 SOLENOID ACTIVATED DIRECTIONAL
PILOT ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) CONTROL VALVE - REAR AUXILIARY 48 RELIEF VALVE - 1200 PSI (83 bar) CONTROL VALVE – 2 SPEED
11 ANTICAVITATION VALVE 28 68 PILOT ACTIVATED DIRECTIONAL

RESTRICTOR - 0.140 inch (3,6 mm) 49 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) CONTROL VALVE – HIGH / LO SPEED
12 SOLENOID ACTIVATED DIRECTIONAL 69
29 RESTRICTOR - 0.031 inch (0,8 mm) 50 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
CONTROL VALVE - AUXILIARY RELIEF VALVE - 3300 PSI (228 bar)
13 PORT RELIEF/ANTICAVITATION VALVE: 30 RELIEF VALVE: 3300 PSI (228 bar) 51 DUMP VALVE - (ON/OFF)
. . . . . (Optional)
3500 PSI (241,3 bar) 31 FILTER - HYDRAULIC (CANISTER) 52 CHECK VALVE
14 LOAD CHECK VALVE
32 FILTER - CASE DRAIN (SINTERED 53 AUXILIARY HYDRAULIC PUMP -
15 LIFT CYLINDER SPOOL - MADE TO BRONZE) 9.5 GPM (36 L/min) at High Engine Idle
RESTRICT FLOW DURING BOOM 33 FILTER - BICS CONTROL VALVE 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring NOTE: Unless otherwise specified, springs have
DOWN BUT NOT DURING BOOM UP (SCREEN) with 0.016 inch (0,40 mm) orifice NO significant pressure value.
16 SOLENOID ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 55 SOLENOID ACTIVATED CONTROL
CONTROL VALVE - BICS CONTROL VALVE VALVE - FORWARD/REVERSE V-1129legend (2-27-08)
Printed in U.S.A.
111 of 928
(REAR QUICK
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
INTEGRATED QUICK
(V-1129) COUPLER BLOCK
23 24
25 MALE
26
DRIVE MOTOR (2 SPEED) 28 7 (FRONT AUXILIARY
MALE
69 4
29
1 30
FEMALE
27
65
P-OUT P-IN T
File has expired.

68 32 BUCKET POSITION VALVE (OPTIONAL)
34
D
HYDRAULIC FILTER
31

64 22
2 COOLER
55

56
57 5 3
A
40 C
21
Publications. 6 36 Dealer Copy -- Not

13 for Resale
12
20
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
57 14
3 36
31 10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
63 2 50
52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
62
60 LIFT CYLINDERS
61 59 10
FAN MOTOR 18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
DRIVE MOTOR (2 SPEED) 38
35
68 39 47
66 37
15
DR
14
54
48 33 41
46 33 16
9
49 45
PP
43
P1
44 19
67
112 of 928 4 V-1129 (2-27-08)

69 32
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).
File has expired.

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

FILTER (strainer or screen) - For fluid

COMPONENTS - Long Chain Line -
Enclosure outline for several
conditioning.
VENTED AND FILTERED

components assembled in one unit.
Publications.
MECHANICAL CONNECTIONS -
RESERVOIR
atmosphere).
(reservoir open to
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.

113 of 928
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY
DISPLACEMENT and CUSHION ON A PUSH-PULL BUTTON (manual).
File has expired.

ONE END - With single piston rod.
CONTROL VALVE ACTIVATED BY

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

energy.

FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
A PEDAL (manual).
Publications.
direction of flow.
VARIABLE CAPACITY
CONTROL VALVE WITH SPRING
RETURN (mechanical).
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

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

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

114 of 928

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the 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
File has expired.
Valve) - Opens if the Inlet pressure is
greater than the Outlet pressure plus
the spring pressure.
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE (Two Position) -
controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

RETURN VALVE- It is possible to MANUALLY ACTIVATED
DIRECTION CONTROL VALVE
OUT
IN
open the valve by pilot pressure. T
P
(Variable Position) Joystick
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
IN
OUT
Publications.
IN connected to the higher pressure is
automatically connected to the Outlet
port while the other Inlet port is
valve spool.
MANUALLY ACTIVATED FLOW

CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRON T
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.

115 of 928

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
File has expired.

the opposing force of the spring, the
IN OUT
valve opens permitting flow from the

Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes

the opposing force of the spring, the
IN OUT
valve opens permitting flow from the

Outlet port. Pilot pressure provides a
second pressure value.
Publications.
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).

116 of 928
HYDRAULIC SYSTEM INFORMATION (CONT'D)
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light come ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
File has expired.

Hydraulic action is not smooth.
Lift arms go up slowly at full engine RPM
1, 4, 5, 6, 7
1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down when the pedal is in neutral position 4, 9, 10, 11

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

117 of 928
File has expired.

Publications.

118 of 928
CYLINDER (LIFT) Figure 20-20-2
Testing
WARNING 2
1
enters skin or eyes, get immediate medical attention N-18786
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
Figure 20-20-1
File has expired. tighten.
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the

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

lift cylinder base end port.

119 of 928
CYLINDER (LIFT) (CONT’D) Roll the lift arm link back.
Removal And Installation Figure 20-20-5
Figure 20-20-3
P-34048
File has expired.

N-18785
Remove the retainer bolt (Item 1) [Figure 20-20-5] and
nut from the lift cylinder rod end pivot pin (both sides).
Stop the engine. Pull up on the lift arm bypass control to
release the hydraulic pressure. Installation: Tighten the bolt and nut to standard torque.

Open the rear door.

Disconnect the negative ground cable to the battery.
Publications.
lift cylinder base end port.
Install a plug in the hose and tighten.
Figure 20-20-4
N-18806

nut from the lift arm pin (both sides).
Installation: Tighten the bolt and nut to standard torque.
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-4] (both sides).

120 of 928
CYLINDER (LIFT) (CONT’D) Figure 20-20-8
Removal And Installation (Cont’d)
Figure 20-20-6
1
1 2
N-18782
File has expired. P-34049 nut from the lift cylinder pivot pin.
Installation: Tighten the bolt and nut to standard torque.

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

(Item 2) [Figure 20-20-8].
Figure 20-20-7

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

cylinder in place.

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

121 of 928
CYLINDER (LIFT) (CONT’D)
Figure 20-20-9
File has expired.

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

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

122 of 928
CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring
File has expired. 9
7 8

1 6
15
4
5
Publications. 14
1 13
2 12
3
11
10
B-13593

123 of 928
CYLINDER (LIFT) (CONT’D) Figure 20-20-11
Disassembly And Assembly

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

damage. Replace any damaged parts. Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
File has expired.

Always install new O-rings and seals during assembly.
and head (Item 4) [Figure 20-20-11].
Assembly: Tighten the nut (Item 1) [Figure 20-20-11] to

Lubricate all O-rings and seals with hydraulic oil during 850 ft.-lb. (1152 N•m) torque.
installation.

NOTE: Clean and dry the threads before installing the
Hold the hydraulic cylinder over a drain pan and move nut. Install the new nut from the kit.
cylinder. Use updated files from Bobcat

the rod in and out slowly to remove the fluid from the
Figure 20-20-12
Figure 20-20-10
Publications.
Put the base end of the cylinder in a vise.
2
2 1
1
P-48038
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

P-48033
20-12] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-12]

Use a spanner wrench to loosen the head (Item 1) on the piston head, becomes damaged, the
[Figure 20-20-10] from the cylinder case. complete piston head must be replaced.
Assembly: Tighten the head with a spanner wrench until

the head is seated all of the way into the cylinder (Item 2)
[Figure 20-20-10].

124 of 928
CYLINDER (LIFT) (CONT'D) Figure 20-20-15
Disassembly And Assembly (Cont'd)
Figure 20-20-13
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-15] from
File has expired. P7424 the cylinder head.
Figure 20-20-16
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-13]. Allow

the seal to stretch for 30 seconds before installing it on
the piston. 2
Once the seal is installed on the piston, a piston ring
compressor can be used on the piston for 3 minutes to
Publications.
compress the seal into place.
Figure 20-20-14
1
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-20-
2 16].
P-48039
Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-14] from the cylinder head.

125 of 928
CYLINDER (LIFT) (CONT'D) Figure 20-20-19
Figure 20-20-17
P7425
Assembly: Install the rod seal in the head. Rotate the
File has expired.

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

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

Figure 20-20-18

1 Publications.
P-48043A P7427
a
Assembly: Install the rod seal on the rod seal tool

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

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

126 of 928
CYLINDER (TILT) Figure 20-21-2
Testing
WARNING 1
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 N-18802
Remove the attachment. Roll the Bob-Tach fully back. Install a cap (Item 1) [Figure 20-21-2] on the fitting and
Figure 20-21-1
File has expired.
Stop the engine. Raise the seat bar. tighten.
Engage the parking brake. Lower the seat bar.
Start the engine and push the Press to Operate button.

Push the bottom (heel) of the tilt pedal.
Use updated files from Bobcat If there is leakage from the open port, remove the tilt
cylinder for repair.
Publications.
1
N-18801
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the base end of the tilt cylinder.

127 of 928
CYLINDER (TILT) (CONT'D) Figure 20-21-4
Removal And Installation
WARNING 1

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

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

the engine. Raise the seat bar.
P-34137
nut from the rod end pin.
Remove the retainer bolt (Item 1) [Figure 20-21-5] from
Installation: Tighten the bolt and nut to standard torque. the tilt cylinder rod end pivot pin.
Installation: Tighten the bolt and nut to 125 - 140 ft.-lb.

(170 - 190 N•m) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.

128 of 928
Figure 20-21-6
N-18555
2
Remove and replace bushing with a driver tool and
File has expired. P-34228 hammer [Figure 20-21-8].
Figure 20-21-9
cylinder.

Remove the cylinder (Item 2) [Figure 20-21-6] from the

rod end pivot pin.
Remove the cylinder from the loader.
Publications.
Rod End Pivot Pin Bushing And Seal Removal And
Installation
Figure 20-21-7
N-18554
Reverse the removal procedure to install the pivot pin

bushing and seal.
1
1
N-18556
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Removal And Installation, Page 20-21-2.)
Use a seal pick to remove the seals (Item 1) [Figure 20-

21-7] on both sides of the pivot bushing.

129 of 928
CYLINDER (TILT) (CONT'D)
Base End Pivot Pin Removal And Installation
Figure 20-21-10
File has expired.

P-24709
Remove the tilt cylinder from the Bob-Tach. (See

Removal And Installation, Page 20-21-2.)

Loosen the retainer bolt (Item 1) [Figure 20-21-10] from

the tilt cylinder rod base end pin.
Installation: Tighten the retainer bolt to 175 - 190 ft.-lb.
Publications.
(240 - 260 N•m) torque.
Strike the head of the bolt (Item 1) [Figure 20-21-10] to

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

130 of 928
CYLINDER (TILT) (CONT'D)
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing
3
MC-01688A
File has expired.

1

Publications. 4
10
7
12
6 13
5 11
MC-01688D
14
MC-01688C
15
16
15
PE-1056A

131 of 928

3
Use the following tools to service the cylinder: 2

1
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.

damage. Replace any damaged parts.
P-48071
Lubricate all O-rings and seals with hydraulic oil during Remove the nut (Item 1), piston (Item 2) and head (Item
installation.
File has expired.
Hold the hydraulic cylinder over a drain pan and move
3) [Figure 20-21-12].
Assembly: Tighten the nut (Item 1) [Figure 20-21-12] to

the rod in and out slowly to remove the fluid from the 100 ft.-lb. (136 N•m) torque.
cylinder.

NOTE: Clean and dry the threads before installing the
Put the base end of the cylinder in a vise. nut. Install the new nut from the kit.
Figure 20-21-11 Figure 20-21-13
Publications.
1
2
P-48034 P-48088 P-48089
Use a spanner wrench to loosen the head (Item 1) Assembly: Mark the end of the shaft and nut. Tighten
[Figure 20-21-11] from the cylinder case. the nut an additional 135 degrees or 2-1/4 flats [Figure
20-21-13].
Assembly: Tighten the head with a spanner wrench until
[Figure 20-21-11].

132 of 928

1
Figure 20-21-14
2
2
P-48039
File has expired. P-48073 (Item 2) [Figure 20-21-16] from the cylinder head.
Figure 20-21-17
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.

Figure 20-21-15
Publications.
P-48040

P7424 the cylinder head.

stretch it until it fits the piston [Figure 20-21-15]. Allow
the seal to stretch for 30 seconds before installing it on
the piston.


133 of 928
Figure 20-21-18
1
P-48043 P7427

P-48041
File has expired.
P-48042 [Figure 20-21-20].

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

18].
Figure 20-21-21
Figure 20-21-19
Publications.
1
P7425
P-48042

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

134 of 928
CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING
explosion or fire.
W-2103-0508 1
P16330
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the
File has expired.

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

from a physician familiar with this injury. 2
Figure 20-22-1
Publications. W-2072-0807
1 P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and

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

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

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

135 of 928
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
1 2
File has expired.

N-21401
Disconnect the hoses from the cylinder fittings (Item 1

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

Install plugs and cap on fittings.

NOTE: Connect the hose with the 45 degree end (Item
1) [Figure 20-22-4] to the base end fitting on
the cylinder.
Figure 20-22-5
Publications.
1 1
N-21400
Remove the bolts (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the washers and cylinder from the lever pivots.

136 of 928
CYLINDER (BOB-TACH) (CONT’D)
1. Cylinder
2. Plug
3. O-ring
4. Nut
5. Piston
6. O-ring
7. Ring
8. Spacer
9. O-ring
10. Ring
11. O-ring
12. Head
13. Seal
14.
15.
Seal
Rod File has expired. 1

Publications.
14
2
3
13 12
11
10
9
8 7 6
5
4
15
PE1064

137 of 928
CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-7

4 3 2
Use the following tools to service the cylinder:
1
Spanner Wrench

Wash the cylinder parts in solvent and air dry them.

damage. Replace any damaged parts. P16294

Remove the head and rod assembly from the cylinder
File has expired.

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

cylinder. Assembly: Grease the piston where the nut contacts the
piston. do not get grease on the threads. Install the new
Put the base end of the cylinder in a vise.
Figure 20-22-6
nut (Item 1) [Figure 20-22-7].
Assembly: Tighten the nut to 90 ft.-lb. (122 N•m) torque.
Publications. 2
Figure 20-22-8
3
2
1
4
1
P-43212
P16295
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-22-6].
Remove the O-ring (Item 1), and seal (Item 2) from the
Assembly: Tighten the head with a spanner wrench until piston (Item 3) [Figure 20-22-8].
[Figure 20-22-6]. NOTE: The piston center hole (Item 4) [Figure 20-22-
8] has a bevel on one end. The bevel goes
toward the rod when assembling.

138 of 928
Disassembly And Assembly (Cont’d)
Figure 20-22-9
1
P-48040
File has expired. P7424 the cylinder head.
Figure 20-22-12
stretch it until it fits the piston [Figure 20-22-9]. Allow the

seal to stretch for 30 seconds before installing it on the
piston. 2
Figure 20-22-10
Publications.
1
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 12].
P-48039

(Item 2) [Figure 20-22-10] from the cylinder head.

139 of 928
Figure 20-22-13
P7425
File has expired.

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

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

Figure 20-22-14

1 Publications.
P-48043A P7427
a

[Figure 20-22-14].

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

140 of 928
MAIN RELIEF VALVE Lift and block the loader. (See Procedure on Page 10-10-
1.)
Description
Figure 20-30-1
The main relief valve limits the hydraulic system pressure
by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader. 2
1
Testing
IMPORTANT
File has expired.
P-34480
The hydraulic tester must be in the fully open

position before you start the engine. Connect the IN port (Item 1) [Figure 20-30-1] of the
I-2024-0284 hydraulic tester to the bottom (female) quick coupler on
the loader.

Connect the OUT port (Item 2) [Figure 20-30-1] of the
Use WARNING
updated files from Bobcat hydraulic tester to the top (male) quick coupler on the
loader.
Publications.
When the engine is running during service, the
driving and steering controls must be in neutral and
Figure 20-30-2
the parking brake engaged. Failure to do so can

W-2006-1209
WARNING 2
1

fall or move and cause injury or death. P-76460C
W-2017-0286
The tools listed will be needed to do the following Start the engine and run at low idle.
procedure:
• Press the AUXILIARY HYDRAULICS Button (Item 1)
MEL10003 - Hydraulic Tester [Figure 20-30-2] once to engage the auxiliary
MEL10006 - Hydraulic Test Kit hydraulics.
Turn the key switch to the OFF position. To release the NOTE: The light (Item 2) [Figure 20-30-2] will be on.
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds.

141 of 928
MAIN RELIEF VALVE (CONT’D) Turn the restrictor control, on the tester, until the main
relief valve opens. Check the relief pressure.
Testing (Cont’d)
If the relief pressure is not correct, stop the engine and
Figure 20-30-3 adjust the main relief valve.
Right
Steering
Lever
Control
1
File has expired.
P-31833
Figure 20-30-4

SJC Option Only

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

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

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

sure the flow is correct. Increase the engine speed to full
RPM.
Refer to Specifications, (See Hydraulic System on Page

SPEC-10-3.) for both flow and pressure specifications of
the hydraulic system.
Check the free flow specification.

142 of 928
MAIN RELIEF VALVE (CONT’D)
Adjusting
Figure 20-30-5
O-ring
Back-up
File has expired. B-6764
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 1) [Figure 20-30-5].

Turn the adjusting screw in or out until the pressure is

correct.
NOTE: If the correct pressure can not be reached,
Publications.
replace the main relief valve. Check the
pressure setting of the new relief valve.

143 of 928
MAIN RELIEF VALVE (CONT’D) Installation: Tighten the main relief valve to 35 - 40 ft.-lb.
(47 - 54 N•m) torque.
Figure 20-30-6
IMPORTANT
When repairing hydrostatic and hydraulic systems,
1 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
File has expired.

P-48872
Remove the four motor cover mounting screws (Item 1)

[Figure 20-30-6].

Installation: Tighten the mounting screws to 15 - 20 ft.-

lb. (20 - 27 N•m) torque.
Figure 20-30-7
Publications.
P-48874
Clean the area around the control valve. Loosen and

remove the main relief valve (Item 1) [Figure 20-30-7].
Remove the O-rings and back-up washers [Figure 20-

30-5].
Clean the main relief valve in clean solvent. Use air

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

relief valve (Item 1) [Figure 20-30-7] and tighten. Check
the pressure again. (See Testing on Page 20-30-1.)

144 of 928
HYDRAULIC CONTROL VALVE (STANDARD) The auxiliary function is operated by pilot pressure.
There is one solenoid located by each side of the spool.
Description Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid
Figure 20-40-1 sends pilot pressure oil to one side of the spool and
forces the spool to shift.
The hydraulic control valve contains a main relief valve

which is adjustable.
Figure 20-40-2

Publications.
P-85528
NOTE: The hydraulic control valve can be equipped

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

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

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

linkages to connect the foot pedals to the lift and tilt
spools.

145 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Raise the operator cab. (See Raising on Page 10-30-1.)
(CONT’D)
Clean the area around the control valve.
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
DANGER Remove the control panel. (See Removal And Installation

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


Use updated files from Bobcat D-1009-0409
Remove the right rear tire.

P-34004
Publications.
WARNING Locate and remove the access covers (Item 1) [Figure
20-40-3] on the right side of the machine.
Never work on a machine with the lift arms up unless Figure 20-40-4
to fall and cause injury or death. 3
W-2059-0598
2
1
IMPORTANT
1
clean the work area before disassembly and keep all
tubelines and ports to keep dirt out. Dirt can quickly P-66963
damage the system.
I-2003-0888
Mark and disconnect the five electric solenoid connectors
Lift and block the loader. (See Procedure on Page 10-10- for correct installation (Item 1) [Figure 20-40-4].
1.)
Disconnect and cap the supply hose (Item 2). Remove
Raise the lift arms and install an approved lift arm the supply hose clamp (Item 3) [Figure 20-40-4].
support device (See Installing on Page 10-20-1.)

146 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-7
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-40-5
1
1
P-66969
2 Remove the crossbar linkage bolt (Item 1) [Figure 20-40-

7].
Remove the control pedal crossbar linkage and tilt

linkage. (See Linkage Removal And Installation on Page
Disconnect and cap the tubelines (Item 1) [Figure 20-40- 50-90-2.)
5] from the lift arm bypass valve to the hydraulic control

valve. Figure 20-40-8
Disconnect and cap the hose (Item 2) [Figure 20-40-5]
from the lift arm bypass valve to the drive motor case
drain.
Figure 20-40-6
Publications. 1
P-66965
1
Remove the two lift arm bypass valve bracket mounting
bolts (Item 1) [Figure 20-40-8].
P-66967 Remove the lift arm bypass valve and mounting bracket.
Remove the connector pins (Item 1) [Figure 20-40-6].

147 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Remove the throttle rod (Item 5) [Figure 20-40-10] from
(CONT’D) the engine, then pull the throttle rod out of the loader from
the rear.
Figure 20-40-11
Figure 20-40-9
File has expired.

P-66968
P-66961
Disconnect and cap the supply tubeline (Item 1) [Figure

Remove tubeline clamp screw (Item 1) [Figure 20-40-9] 20-40-11] from the hydraulic control valve.
from the auxiliary tubelines in the left rear upright.

Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m)
torque.
Figure 20-40-10
Publications.
3
5
2 1
1
P-66970
Remove and cap both tubelines (Item 1) [Figure 20-40-

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

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

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

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

148 of 928
(CONT'D)
Figure 20-40-12
1 1
2
P-66957
Mark all tubelines and hoses for correct installation.
File has expired. P-66973 The fixed end main valve hose (Item 1) [Figure 20-40-
14] is connected to a fixed end fitting on the control valve.
The hose is routed to the back upright where the hose is
Remove the supply tubeline clamp screw (Item 1) connected to a tee fitting that feeds the base end of both
[Figure 20-40-12].

lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
torque.Use updated files from Bobcat

NOTE: Remember the hose routing for ease of
control valve installation.
Publications.
Remove supply tubeline (Item 2) [Figure 20-40-12] from
loader.
Figure 20-40-13
P-66971
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-40-13] from the tilt section of the control
valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-40-

13] from the lift section of the control valve.

149 of 928
(CONT'D)
Figure 20-40-15
1
1
P-66974
Connect a hoist to the lifting brackets (Item 1) [Figure 20-
File has expired.

P-66962
40-17] on the control valve.
Figure 20-40-18
Remove any tie-straps (Item 1) [Figure 20-40-15]

securing the fixed end main valve hose.

1

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

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

Remove the fixed-end main valve hose (Item 1) [Figure
20-40-16] from the main control valve fitting. Reverse removal procedure to install the hydraulic
control valve.

150 of 928
HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-19
J2
C2 J4 C3
D5 E3 B3
E3
G1 G2
F2 B2 A3 D3
D4 F4 C4 E2
A2
D1 File has expired. D2

A1
E1
F1 H2 B1
F3

H3
MR C1
Use updated files from Bobcat H1
J1
J3
MS1937
ITEM
A1
Publications.
S175/S185 LOADER
Lift Cylinder Base End
ITEM
E1
S175/S185 LOADER
Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Valve Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End) J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve – 3300 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

151 of 928
(CONT'D)
Mount Bracket Removal And Installation
Remove the control valve and mount bracket from the

loader. 1
Figure 20-40-20
2
1
2
P-68014
Remove the fitting (Item 1) [Figure 20-40-22] from the
File has expired. check valve.
Remove the lift load check valve (Item 2) [Figure 20-40-

3 22].
P-68011

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

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

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

control valve.

152 of 928
(CONT'D)
Lift Load Check Valve Removal And Installation

(Cont’d)
4
Figure 20-40-24
1 1
3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure

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

poppet to be sure it is not plugged.
Check for free movement of the load check valve (Item 1)

Installation: Install a new O-ring (Item 4) [Figure 20-40-
[Figure 20-40-24]. 26] on the plug and lightly lubricate with oil before
Load Check Valve Removal And Installation (Tilt And
Auxiliary)
installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.
Publications.
Figure 20-40-25
P-68007
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-25].
At the front side of the control valve locate the auxiliary

section load check valve (Item 2) [Figure 20-40-25].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

153 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Installation: Always use new O-ring (Item 1) [Figure 20-
(CONT'D) 40-28] on the anti-cavitation valve plug. Tighten the plug
to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Anti-Cavitation Valve Removal And Installation
(Lift, Rod End) Figure 20-40-29
Figure 20-40-27
1
3
2
File has expired.

P-68015
P-51453

20-40-29].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-40-27]. Check the orifice (Item 3) [Figure 20-40-29] in the
Use updated files from Bobcat poppet to be sure it is not plugged.

IMPORTANTPublications. 29] on the plug and lightly lubricate with oil before
torque.
damage the system.
I-2003-0888
Figure 20-40-28
P-51693

154 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-32

Installation (Lift, Base End)
Figure 20-40-30
File has expired.

P-68015
P-68015 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-32] from the base end of the tilt section.
Loosen the lift circuit port relief/anti-cavitation valve (Item

Figure 20-40-33
1) [Figure 20-40-30].

Figure 20-40-31
Publications.
1
P-51454
1
P-51451 Replace the O-ring (Item 1) [Figure 20-40-33] before

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

torque.

155 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-36
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-40-34
P-68015
File has expired.

P-68015
Remove the port relief plug (Item 1) [Figure 20-40-36]
from the auxiliary circuit of the control valve.
Figure 20-40-37
Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-34] from the rod end of the tilt section.

Figure 20-40-35
Publications.
P-51695
1
Installation: Always use new O-rings (Item 1) [Figure

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

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

torque.

156 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Plug Removal And Installation
(CONT'D)
Figure 20-40-40
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-38
1
1
P-68016
File has expired.P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-40].
The control valve may be equipped with an optional Figure 20-40-41

auxiliary port relief valve (Item 1) [Figure 20-40-38].

Remove the auxiliary port relief valve.
Figure 20-40-39
Publications.
1
P-51460

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

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

157 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Rubber Boot Removal And Installation
(CONT'D)
Figure 20-40-44
Plug Removal And Installation (Cont’d)
1
Figure 20-40-42
P-51506
File has expired.

1
P-51461 Remove the three screws (Item 1) [Figure 20-40-44] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
(Item 1) [Figure 20-40-42].

11,3 N•m) torque.

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

158 of 928
(CONT'D)
End Cap / Spool Lock Block Removal And

Installation
Figure 20-40-46
1 1
2
1
P-51699A
1
Remove the four end cap/spool lock block mount screws

(Item 1) [Figure 20-40-48].
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt

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

Disconnect the tube line (Item 1) [Figure 20-40-47] from 20-40-49] from the control valve.
the end cap/spool lock block.

159 of 928
(CONT'D)
Lift Spool And Detent Removal And Installation

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap/spool lock block from the control

valve.
Figure 20-40-50
P-51513
Remove the end cap (Item 1) [Figure 20-40-52].
1
File has expired. Figure 20-40-53

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

with oil before installation of the end cap/spool lock block.
P-51514
Figure 20-40-51
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-53].
Remove the washer (Item 2) [Figure 20-40-53].
P-51512A
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-51] from the lift spool.

160 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Put a rag around the detent assembly [Figure 20-40-55].
(CONT'D) This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
(Cont'd) Figure 20-40-56
Figure 20-40-54
2 1
3
1
1 File has expired.

2
P-51515
2 P-51517
Remove the detent sleeve (Item 1), detent balls (Item 2)

Remove the screws (Item 1) [Figure 20-40-54] from the and spring (Item 3) [Figure 20-40-56].

detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-40-54].
Installation: Lubricate the screws and tighten to 90 - 100
Publications.
in.-lb. (10 - 11,3 N•m) torque.
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-55
P-51516

161 of 928
(CONT'D)

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

1
File has expired.
P-51518
40-59].
NOTE: Protect spool before clamping in vise.
Figure 20-40-60
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-57] from the control valve. 2

Figure 20-40-58
Publications. 3
1
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-60] over the

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

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

is white on all 700 series loaders.

162 of 928
(CONT'D)
Lift Spool And Detent Removal And Installation 1

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

1
2 File has expired. N-18916
spring assembly.
Figure 20-40-64
Put a rag around the detent assembly [Figure 20-40-61]. 1

2
This will prevent the detent balls and spring from being

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

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

from the spring assembly.

163 of 928
HYDRAULIC CONTROL VALVE (STANDARD) NOTE: DO NOT USE Loctite® ON THE STUD
(CONT'D) THREADS.
Lift Spool And Detent Removal And Installation Figure 20-40-67

(Cont'd)
Figure 20-40-65
2
1
File has expired.

N-18961
N-18918 Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-67].
Remove the stud from the end of the spool [Figure 20-

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

N-18963
Make a center point in the plug using a 1/16 in. drill.
Drill a hole all the way through the plug using a 7/64 in. Install the plastic plug and O-ring in the spool [Figure 20-
tap drill 40-68].
Turn a 6-32 tap (Item 1) [Figure 20-40-66] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.

164 of 928
(CONT'D)

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

the adapter (Item 3) [Figure 20-40-71] and compress
with the detent pliers (Item 1) [Figure 20-40-72].
Install the stud and tighten until the other end of the stud

is out about 0.600 in. (15,2 mm) from the spool [Figure Figure 20-40-72
20-40-69].
Figure 20-40-70
Publications.
1
N-18968
N-18967 Install the detent adapter to the collar [Figure 20-40-72].
NOTE: The collar and the detent adapter are held

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

165 of 928
(CONT'D)

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

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


washer.
washer, spring, collar and detent adapter.

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

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

166 of 928
(CONT'D)

(Cont'd)
Figure 20-40-77
2
P-51515
Install the lift spool assembly in the spool bore [Figure
File has expired. N-19007

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

Hold the detent balls in place with the detent pliers

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

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

167 of 928
(CONT'D)

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

P-51513
20-40-83] on the lift spool.
Figure 20-40-84
Install the end cap (Item 1) [Figure 20-40-81].

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

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

linkage end of the valve.

168 of 928
(CONT'D)

(Cont'd)
Figure 20-40-85
2
1
P-51697
3
Use an ohm meter to measure the lock solenoid coils
File has expired.

4
P-51701
resistance.
The correct resistance for the coil is 5.5 ± 0.28 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap/spool lock block (Item 1) and the

(Item 2) [Figure 20-40-87] lock solenoids and tighten to
mount bolt (Item 2) [Figure 20-40-85]. 35 - 45 ft.-lb. (52 - 61 N•m) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
Publications.
[Figure 20-40-85].
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Figure 20-40-86
P-68017
Connect the tubeline (Item 1) [Figure 20-40-86].

169 of 928
(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap / Spool Lock Block Removal And Installation on
Page 20-40-15.)
2
Figure 20-40-88
1
P-68023
Remove the spool centering block (Item 1) [Figure 20-

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

before replacing the spool centering block.

P-51521A Figure 20-40-91

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

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

the spool centering block.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.

170 of 928
(CONT'D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-92
3
4
1
N-18944A

Figure 20-40-95
Put the linkage end of the spool in the vice [Figure 20-
40-92]. 2

1

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

washer (Item 2) [Figure 20-40-95].
Installation: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-93] holding the

centering spring to the spool.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.
Remove spring tool from the spring assembly.

171 of 928
(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-96
2
2
1
1
P-68022

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

from the spool centering block.

N•m) torque.
Publications.
2 1
Figure 20-40-97
P-51549A
Remove the spring (Item 1) and center spring retainer

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

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

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

retainer on the opposite end also.

172 of 928
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-100
1 2
File has expired.

P-51550A


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

173 of 928
(CONT'D)
Auxiliary Solenoid Removal And Installation (S/N

A3L534999 & Below)
Figure 20-40-102 1
1
1
P-68008
Remove the solenoid stem (Item 1) [Figure 20-40-104].
File has expired.

P-68007
Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19
N•m) torque.
Figure 20-40-105
Remove the nut (Item 1) [Figure 20-40-102] from both

solenoids.

Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)
torque.
Figure 20-40-103 Publications. 1
1
2
2
P-51555
Remove the O-rings (Item 1) [Figure 20-40-105] from

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

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

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

resistance.

174 of 928
HYDRAULIC CONTROL VALVE (STANDARD)
(CONT’D)

A3L535001 & Above)
Figure 20-40-106
2
1
2 1
Remove the screws (Item 1) [Figure 20-40-106] from

both solenoids.

Remove the solenoids (Item 1) [Figure 20-40-106] from
the control valve.
Publications.
Installation: Tighten the nut to 21.6 - 26.4 in.-lb. (2,44 -
2,98 N•m) torque.
Figure 20-40-107
P-85556
Check and remove the O-rings (Item 1) [Figure 20-40-

107] from the solenoid stem.

resistance.

175 of 928
(CONT'D)
Solenoid Removal And Installation
Figure 20-40-108
2
P-68009
File has expired.

P-68006 Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Remove the nut (Item 1) [Figure 20-40-108] from the Figure 20-40-111
solenoid stem.

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-108]. 3
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

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

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

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

176 of 928
(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-112 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-40-114] from the lift lock valve, and replace
with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-112] is for the lift

circuit.

Figure 20-40-113
Publications.
P-51443
Remove the lift lock valve (Item 1) [Figure 20-40-113]

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

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

177 of 928
(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-115
1
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-40-117]
File has expired.

P-51705
from the front of the control valve.
Installation: Lightly lubricate the lock valve O-rings and

Locate the tilt circuit lock valve (Item 1) [Figure 20-40-
115].

Figure 20-40-118

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

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

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

178 of 928
HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-121
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-119
1
P-51707
File has expired.

2
P-68010 Remove the main relief valve (Item 1) [Figure 20-40-
121].
Remove the tubeline (Item 1) and fitting (Item 2) [Figure Figure 20-40-122
20-40-119] from the valve.

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

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

casting.

179 of 928
(CONT'D)
Check Valve Removal And Installation
Figure 20-40-123
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-
File has expired.

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

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

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

20 - 24 ft.-lb. (27 - 33 N•m) torque.

180 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) The auxiliary function is operated by pilot pressure.
There is one solenoid located by each side of the spool.
Description Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid
Figure 20-41-1 sends pilot pressure oil to one side of the spool and
forces the spool to shift.
The hydraulic control valve also contains a main relief

valve which is adjustable.
Figure 20-41-2

Publications.
P-85528
NOTE: The hydraulic control valve can be equipped

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

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

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

control valve are operated using electronic control
handle/levers or foot pedals that send an electronic
signal to the electronic actuators to move the lift and tilt
spools in the control valve.

181 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Raise the operator cab. (See Raising on Page 10-30-1.)
(CONT’D)
Clean the area around the control valve.

on Page 50-100-2.)
Figure 20-41-3
P-90328
AVOID DEATH
•
File has expired.
1


Remove the right rear tire.

P-34004
Publications.
WARNING Locate and remove the access covers (Item 1) [Figure
20-41-3] on the right side of the machine.
W-2059-0598 3
2
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all 1
tubelines and ports to keep dirt out. Dirt can quickly P-68204
damage the system.
I-2003-0888
Mark and disconnect the three electric solenoid
Lift and block the loader. (See Procedure on Page 10-10- connectors for correct installation (Item 1) [Figure 20-41-
1.) 4].
Raise the lift arms and install an approved lift arm Disconnect and cap the supply hose (Item 2). Remove
support device (See Installing on Page 10-20-1.) the supply hose clamp (Item 3) [Figure 20-41-4].

182 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-7
(CONT’D)
Figure 20-41-5
1
P-66965
2
Remove the two lift arm bypass valve bracket mounting
File has expired.

P-68206
bolts (Item 1) [Figure 20-41-7].
Remove the lift arm bypass valve and mounting bracket.
Disconnect and cap the tubelines (Item 1) [Figure 20-41- Figure 20-41-8
5] from the lift arm bypass valve to the hydraulic control

valve.

Disconnect and cap the hose (Item 2) [Figure 20-41-5]
from the lift arm bypass valve to the drive motor case 1
drain.
Figure 20-41-6
Publications.
P-66968
1 Remove tubeline clamp screw (Item 1) [Figure 20-41-8]

from the auxiliary tubelines in the left rear upright.

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

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

183 of 928
(CONT’D)
Figure 20-41-9
1
3 2
5
2
1 1 4
P-66973
Remove the supply tubeline clamp screw (Item 1)
File has expired.

P-68203
[Figure 20-41-11].

torque.
Remove and cap both tubelines (Item 1) [Figure 20-41-
9] from the auxiliary section of the control valve.

Remove supply tubeline (Item 2) [Figure 20-41-11] from
loader.
Disconnect and cap the drain hose (Item 2) [Figure 20-
Publications.
Remove and cap the outlet tubeline (Item 3) [Figure 20-
41-9] from the control valve to the hydraulic oil cooler.
Remove and cap the charge tubeline (Item 4) [Figure 20-

41-9] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-41-9] from

the engine, then pull the throttle rod out of the loader from
the rear.
Figure 20-41-10
P-66961
Disconnect and cap the supply tubeline (Item 1) [Figure

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

184 of 928
(CONT’D)
Figure 20-41-12
1
P-66962
3
Remove any tie-straps (Item 1) [Figure 20-41-14]

securing the fixed end main valve hose.
Figure 20-41-15
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-41-12] from the tilt section of the control

valve.

Disconnect and cap the tubeline (Item 3) [Figure 20-41-
12] from the lift section of the control valve.
Publications.
Figure 20-41-13
P-66960
Remove the fixed-end main valve hose (Item 1) [Figure

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

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

control valve installation.

185 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out of Loader)
(CONT’D)
Figure 20-41-18
Figure 20-41-16
1 1
File has expired.

P-68202
P-68028

Connect a hoist to the lifting brackets (Item 1) [Figure 20- from the lift actuator.
41-16] on the control valve.

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

186 of 928
(CONT’D)
Actuator Removal And Installation (Out of Loader) 1

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

from the tilt actuator.
Installation: Tighten the mounting bolts to 90 - 100 in.-lb.

(10 - 11,3 N•m) torque.
Using a drift pin and a hammer, remove the actuator

Figure 20-41-23
linkage pin (Item 1) [Figure 20-41-20] from the actuator

and the lift spool.
Remove the actuator and linkage pin from the valve.

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

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

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

replace as needed.

187 of 928
(CONT’D)
Actuator Removal And Installation (Out of Loader) 3

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

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

linkage pin (Item 1) [Figure 20-41-24] from the actuator Installation: Tighten the mounting bolts to 90 - 100 in.-lb.
and the tilt spool.
Remove the actuator and linkage pin from the valve.

(10 - 11,3 N•m) torque (Item 1) [Figure 20-41-26]

1
P-68031
Inspect the O-ring (Item 1) [Figure 20-41-25] on the nose

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

replace as needed.

188 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-27
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3
B2 D3
D4 C4 E2
A2
D1
File has expired.
D2
A1
E1

F1 H2 B1
H3
MR
Use updated files from Bobcat H1
C1
J1
J3
MS1972
ITEM
Publications.
S175/S185 LOADER ITEM S175/S185 LOADER
A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 LIft Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS Valve Solenoid
C3 Load Check Valve Auxiliary Function H2 BICS Lock Valve (Tilt)
C4 Check Valve
H3 BICS Lock Valve (Lift)
D1 Anti-Cavitation Valve
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm Bypass Orifice
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Base End) MR Main Relief Valve – 3300 PSI
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

189 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Figure 20-41-29
Mount Bracket Removal And Installation
Remove the control valve and mount bracket from the

loader.
Figure 20-41-28
1 1
P-68013
File has expired. Remove the tubeline (Item 1) [Figure 20-41-29] from the
control valve.
3
P-68011 Figure 20-41-30

and lift eyes (Item 2) from the hydraulic control valve.
control valve. Publications.

Remove the mount bracket (Item 3) from the hydraulic 1
P-68014

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

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

55 - 65 ft.-lb. (75 - 88 N•m) torque.

190 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-33

(Cont’d)
Figure 20-41-31
1
2
File has expired.

P-68007
P-51439 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-33].
Remove and install new O-rings (Item 1) and back-up

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

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

20-41-34].


34] on the plug and lightly lubricate with oil before
torque.

191 of 928
(CONT’D)
Anti-Cavitation Valve Removal And Installation (Lift,

Rod End) 4
Figure 20-41-35
1
3
2
1
P-51453
File has expired.

P-68037
20-41-37].

At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-41-35]. 37] on the plug and lightly lubricate with oil before
Use updated files from Bobcat installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.
IMPORTANTPublications.
damage the system.
I-2003-0888
Figure 20-41-36
P-51452
Always use new O-ring (Item 1) [Figure 20-41-36] on the

anti-cavitation valve plug.

192 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-40

Installation (Lift, Base End)
Figure 20-41-38
File has expired.

P-68037
P-68037 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-41-40] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item

Figure 20-41-41
1) [Figure 20-41-38].

Figure 20-41-39
Publications.
1
1
P-68039
P-68038 Replace the O-ring (Item 1) [Figure 20-41-41] before

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

45 ft.-lb. (52 - 61 N•m) torque.

193 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-44
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-41-42 1
P-68037
File has expired.

P-68037
Remove the port relief plug (Item 1) [Figure 20-41-44]
from the auxiliary circuit of the control valve.
Figure 20-41-45
Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-41-42] from the rod end of the tilt section.

Figure 20-41-43
Publications.
1
P-51801
1

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

installation.
Installation: Lightly lubricate with oil and tighten to 38 -

45 ft.-lb. (52 - 61 N•m) torque.

194 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Plug Removal And Installation
(CONT’D)
Figure 20-41-48
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-46
1
1
P-68016
File has expired. P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-48].
The control valve may be equipped with an optional Figure 20-41-49

auxiliary port relief valve (Item 1) [Figure 20-41-46].

Remove the auxiliary port relief valve.
Figure 20-41-47
Publications.
1
1
P-51460

P-51640

20-41-47]. Lightly lubricate with oil and tighten to 38 - 45

195 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) End Cap Block Removal And Installation
(CONT’D)
Remove the lift and tilt actuators from the control valve.
Plug Removal And Installation (Cont’d) (See Actuator Removal And Installation (Out of Loader)
on Page 20-41-6.)
Figure 20-41-50
Figure 20-41-52
File has expired.

1 P-51461
P-68040
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-50].

Disconnect the tube line (Item 1) [Figure 20-41-52] from
the end cap block.
Figure 20-41-51
Remove the two end cap block mount screws (Item 2)
[Figure 20-41-52].
Publications. Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Figure 20-41-53
1
P-51462 1

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

from the control valve.

196 of 928
(CONT’D)
1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-54 1
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-56] from
File has expired. the lift spool end cap.
Installation: Lubricate the screws and tighten to 90 - 100

in.-lb. (10 - 11,3 N•m) torque.

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

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

1 from the control valve.
P-68047

20-41-55] from the lift spool.

197 of 928
(CONT’D)

(Cont'd)
Figure 20-41-58
P-51772
1
Clamp the linkage end of the spool in a vise [Figure 20-
File has expired.

P-68045
41-60].
NOTE: Protect spool before clamping in vise.
Figure 20-41-61
Remove the lift spool assembly and seal (Item 1) [Figure

20-41-58] from the control valve.

Figure 20-41-59
Publications. 1
1
P-51773

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

from the linkage end of the valve.

198 of 928
(CONT’D)

(Cont'd)
Figure 20-41-62
1
1
N-18920
Removal of the plastic plug:

Make a center point in the plug using a 1/16 in. drill.
Drill a hole all the way through the plug using a 7/64 in.
tap drill

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

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

199 of 928
(CONT’D)

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

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

Install the plastic plug and O-ring in the spool [Figure 20-

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


200 of 928
(CONT’D)

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

control valve.
Figure 20-41-72
Install the spool seal (Item 1) [Figure 20-41-69] on the

actuator end of the valve.

Figure 20-41-70 3
Publications. 2
1 P-68040
Install the end cap block (Item 1) and the two mount bolts
2
(Item 2) [Figure 20-41-72].
P-68049 Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Install the O-ring (Item 1) and spacer (Item 2) [Figure 20- Connect the tube line (Item 3) [Figure 20-41-72] to the
41-70] on the lift spool. end cap block.
Install the lift and tilt actuators to the control valve.

201 of 928
(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-41-16.)
Figure 20-41-73 2
P-68051
1 File has expired.

2
Check and replace the O-ring (Item 2) [Figure 20-41-75]

before replacing the spool centering block.
P-68049

Figure 20-41-76

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

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


N•m) torque.

202 of 928
(CONT’D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-41-77
3
4
1
N-18944A

Figure 20-41-80
Put the linkage end of the spool in the vice [Figure 20-
41-77]. 2

1

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

N-19014

centering spring to the spool.

N•m) torque.
Remove spring tool from the spring assembly.

203 of 928
(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-81
1
1
2
P-68054
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure
File has expired.

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

the spool centering block.

N•m) torque. Publications.

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

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

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

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

retainer on the opposite end of the spool also.

204 of 928
(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-85


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

205 of 928
(CONT’D)

A3L534999 & Below)
Figure 20-41-87
1 1
P-68083
File has expired.

P-68082
Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19
N•m) torque.
Figure 20-41-90
Remove the nut (Item 1) [Figure 20-41-87] from both

solenoids.

Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)
torque.
1
2
2
P-51555
Remove the O-rings (Item 1) [Figure 20-41-90] from the

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

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

[Figure 20-41-88].

resistance.

206 of 928
(CONT’D)

A3L535001 & Above)
Figure 20-41-91
2
1
2 1
Remove the screws (Item 1) [Figure 20-41-91] from both

solenoids.

Remove the solenoids (Item 1) [Figure 20-41-91] from
the control valve.
Publications.
Installation: Tighten the nut to 21.6 - 26.4 in.-lb. (2,44 -
2,98 N•m) torque.
Figure 20-41-92
P-85556
Check and remove the O-rings (Item 1) [Figure 20-41-

92] from the solenoid stem.

resistance.

207 of 928
(CONT’D)
Solenoid Removal And Installation
Figure 20-41-93
P-68085
2
File has expired.

P-68084 Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Remove the nut (Item 1) [Figure 20-41-93] from the Figure 20-41-96
solenoid stem.

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-93]. 3
1
1
N-18694

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

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

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

208 of 928
(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-97 1
1
1
2
1
1
2
2
2
P-51564

[Figure 20-41-99] from the lift lock valve, and replace
with new.
Figure 20-41-100
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit, and (Item 2) [Figure 20-41-97] is for the lift circuit.

Figure 20-41-98
Publications.
1
1 P-68080
Remove the tilt lock valve (Item 1) [Figure 20-41-100]

P-68081 from the back of the control valve.
Installation: Lightly lubricate the lock valve o-rings and

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


209 of 928
(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-101
1
1
1
1
2
2
2
File has expired.
P-51564

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

with new.

Publications.

210 of 928
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-104
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-102
P-68088
File has expired.P-68087 Remove the main relief valve (Item 1) [Figure 20-41-
104].
Remove the fitting (Item 1) [Figure 20-41-102] from the Figure 20-41-105
valve.

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

casting.

211 of 928
(CONT’D)
Check Valve Removal And Installation
Figure 20-41-106
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-
File has expired.

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

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

107] from the hydraulic control valve.

212 of 928
LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Description
The lift arm bypass control valve is located on the right

DANGER
side of the machine close to the engine speed control.
The lift arm bypass control valve is manually operated by

pulling up on the valve knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise a 1/4 turn. The valve
releases the hydraulic fluid from the base end of the lift
cylinder(s) which allows the lift arm to slowly come down
to the transport position.
P-90328
Testing
AVOID DEATH
Figure 20-50-1 • Disconnecting or loosening any hydraulic
File has expired.

1
D-1009-0409

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

213 of 928
LIFT ARM BYPASS CONTROL VALVE (CONT'D) Remove the two mounting bolt/nuts (Item 4) [Figure 20-
50-3].
Installation: Tighten the mounting bolts to 180 - 200 in.-
Figure 20-50-2 lb. (21 - 23 N•m) torque.
Remove the lift arm bypass control valve.
1 Disassembly And Assembly
3 Figure 20-50-4
2
File has expired.

P-68160
Hold the Lift Arm Bypass Control knob (Item 1) and

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

shaft [Figure 20-50-2].

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

N•m) torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.
2
3
1
P-68160
Disconnect the base end lift tubeline (Item 1) [Figure 20-

50-3] from the Lift Arm Bypass valve.
Disconnect the drain tubeline (Item 2) [Figure 20-50-3]

from the Lift Arm Bypass valve.
Disconnect the motor case drain hose (Item 3) [Figure

20-50-3].

214 of 928
HYDRAULIC PUMP (STANDARD) Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
the front auxiliary quick couplers.
Description
This procedure will require a operator in the cab and one
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle RPM. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
The hydraulic gear pump has a dedicated charge pump. RPM*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
control clockwise on the tester so it reads about a 1000
A seal kit is available to service the hydraulic pump. If PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.
Pump Test At Quick Couplers File has expired. Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.

The GPM should drop off slightly until the pressure
MEL10003 - In-Line Hydraulic Tester
MEL10006 - Flow Meter Fitting Kit
Figure 20-60-1
reaches approximately 2800 PSI. At approximately 2800
PSI the flow should start decreasing rapidly until the
pressure reaches 3250 - 3300 PSI. At 3250 - 3300 PSI
the flow should be at 0 GPM. Turn the restrictor (Item 2)
Publications. 1
[Figure 20-60-1] counterclockwise to free flow. Shut the
front auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to Direct

Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full RPM.
P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 3/4 in. in diameter and
connected directly to the hydraulic tester
without using any type of “quick coupler” on
the connection to the tester. Also make sure
your hydraulic tester is capable of at least 50
GPM.

215 of 928
HYDRAULIC PUMP (STANDARD) (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following

procedure: 2
MEL1563 or 7003031 - Remote Start Tool

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
WARNING 1
P-68163
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
File has expired.

W-2017-0286
that comes from the gear pump, and connects to the
tubeline on the control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

Raise the lift arms and install an approved lift arm support

device. (See Installing on Page 10-20-1.)
Publications.
WARNING 2
1

P-48256A
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-1.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-3] from the tester to the tubeline (Item 2) [Figure
Connect the remote start tool. (See REMOTE START 20-60-2] on the control valve.
TOOL KIT-MEL1563 on Page 10-60-1.)
IMPORTANT
position before you start the engine.
I-2024-0284

216 of 928
HYDRAULIC PUMP (STANDARD) (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Figure 20-60-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
File has expired.

Hydraulic Control
Valve

Sample tester connection shown [Figure 20-60-4].
BH-196
Publications.
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor

control (Item 1) [Figure 20-60-4] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.
Push the maximum/variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X 100

FREE FLOW (GPM)
A low percentage may indicate a failed pump.


217 of 928
Direct Pump Test (Charge Section)

procedure:

MEL10003 - Hydraulic Tester 2
MEL10006 - Hydraulic Test Kit 1
WARNING
P-69182
Failure to use jackstands can allow the machine to Disconnect the proportioning valve electrical connector
File has expired.

W-2017-0286
(Item 1) [Figure 20-60-5].
Remove the tie-strap (Item 2) [Figure 20-60-5] from the

Lift and block the loader. (See Procedure on Page 10-10- electrical harness.
1.)

Figure 20-60-6

Publications.
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
P-69184
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1)[Figure 20-60-6].
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-1.) for system relief pressure and full RPM.
Connect the remote start tool. (See REMOTE START


218 of 928
HYDRAULIC PUMP (STANDARD) (CONT'D) Start the engine and run at low idle RPM. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-60-7 RPM*.
4 3 Warm the fluid to 140° F (60° C) by turning the restrictor

600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).
Open the restrictor control and record the free flow
(GPM) at full RPM*.
Turn the restrictor down to system operating pressure

approximately 1000 PSI (69 bar). DO NOT EXCEED
1200 PSI (82,7 bar). Refer to Hydraulic Schematics for
flow. The high pressure flow must be at least 80% of free
flow.
HIGH PRESSURE FLOW (GPM)
1 %= X 100
2 FREE FLOW (GPM)

Connect the filter inlet hose (Item 1) to the inlet side of *Refer to the Hydraulic Schematics for pump flow and
the tester (Item 2) [Figure 20-60-7]. RPM.

Connect the OUTLET hose (Item 3) from the hydraulic

tester to the inlet fitting (Item 4) of the charge filter
[Figure 20-60-7].
Figure 20-60-8
Publications.
P-48256A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-60-8].
IMPORTANT
I-2024-0284

219 of 928
DANGER
1
P-66880
P-90328
AVOID DEATH Disconnect and cap the outlet hoses (Item 1) [Figure 20-
•
File has expired.
60-9] from the back of the hydraulic pump.

WARNING

D-1009-0409
Use updated files from Bobcat Never work on a machine with the lift arms up unless
IMPORTANTPublications. to fall and cause injury or death.
W-2059-0598

Figure 20-60-10
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Installing on

Page 10-20-1.) 1
device. (See Procedure on Page 10-10-1.)
Drain the hydraulic fluid from the reservoir. (See P-66882

Checking And Adding Fluid on Page 10-120-1.)
Open the rear door of the loader. Disconnect and cap the inlet hoses (Item 1) [Figure 20-
60-10] from the front of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

220 of 928
Figure 20-60-11
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-13] on the
File has expired. P-66897 hydraulic pump.
Reverse the removal procedure to install the hydraulic

Figure 20-60-12 pump.

1
Publications.
P-66898

11] and [Figure 20-60-12] from the hydraulic pump.
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

221 of 928
Hydraulic Pump Start Up
NOTE: This procedure to prevent a dry start up of the

hydraulic pump.
Figure 20-60-14
Starter
Solenoid
P-59355
S Terminal
File has expired.

Inlet Hose
Battery Terminal
P-66897
P-59356

Disconnect the pump inlet hose connection at the front of
the hydrostatic pump. Fill the pump inlet and hose
completely with hydraulic fluid. Reconnect the hose
[Figure 20-60-14].
Connect the starter bypass tool to the starter solenoid
battery terminal and S terminal. Crank the engine for 15
seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
Figure 20-60-15
Publications. Momentary Switch
tool [Figure 20-60-16].
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
After operating the engine at low idle, Remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
Starter Bypass Tool Check for hydraulic leaks.
P-59354
To crank the engine without starting, the machine key

switch can be bypassed. Obtain a starter bypass tool
from a local source which can be used as a universal
connection to remotely crank the engine without starting.
The starter bypass tool consists of two wires, each with a

clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.

222 of 928
HYDRAULIC PUMP (STANDARD) (CONT'D)
15
14
7 5
13
8
5 6
4
12 3
File has expired.

7

7
8
Publications. 11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A

223 of 928
Disassembly And Assembly 1
Figure 20-60-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-60-
File has expired.

P-64508 18].
Mark the pump sections for correct assembly [Figure 20-

60-17].

Remove the eight pump housing bolts (Item 1) [Figure
20-60-17].
Installation: Tighten the bolts (Item 2) [Figure 20-60-17]
Publications.
to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888

224 of 928
Figure 20-60-19 1
P-64511
2
Figure 20-60-22
File has expired.

P-64509
1
Figure 20-60-20

3
4
Publications.
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 60-21] and [Figure 20-60-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-60-19] and [Figure 20-60-20] from the pump 60-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-20]

inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-60-20] and bushings (Item 4) [Figure 20-60-
20]. If excessive wear or damage is visible, the
pump must be replaced.

225 of 928
Figure 20-60-23
P-64515
Figure 20-60-26
File has expired.

P-64513
Figure 20-60-24

1
Publications.
P-64516
Remove the idler gear (Item 1) [Figure 20-60-25] and

P-64514 [Figure 20-60-26] from the pump center section.
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

Remove the drive gear (Item 1) [Figure 20-60-23] and 26]. If excessive wear or damage is visible, the
[Figure 20-60-24]. pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-


226 of 928
Figure 20-60-27
1
P-64519
1
2 Figure 20-60-30
File has expired.P-64517
2
Figure 20-60-28

2
Publications.
1
1
P-64520
Remove the load seal (Item 1) [Figure 20-60-29] and

P-64518 [Figure 20-60-30]. Inspect for damage and replace as
needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-60-30].
[Figure 20-60-27] and [Figure 20-60-28] from the pump
center section. Inspect for damage and replace as
needed.

toward gears.

227 of 928
Figure 20-60-31
2
1
1
P-64526
Figure 20-60-34
File has expired.

P-64521
3
Inspect the pre-load seal (Item 1) [Figure 20-60-31] for

damage and replace as needed. 4

NOTE: Inspect the pump center section (Item 2) and

bushings (Item 3) [Figure 20-60-31]. If
excessive wear or damage is visible, the
pump must be replaced. 1

2
1
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2)

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-60- pump must be replaced.
32].

228 of 928
Figure 20-60-35
1
P-64530
1
Remove the drive gear (Item 1) [Figure 20-60-37] from
File has expired.P-64528 the pump flange section.
Figure 20-60-38
Figure 20-60-36

Publications.
1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
60-35] and [Figure 20-60-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

60-36]. If excessive wear or damage is visible,
the pump must be replaced.

229 of 928
Figure 20-60-39
2
P-64535
Figure 20-60-42
File has expired.

P-64532
Remove the spline shaft (Item 1) [Figure 20-60-39] from

the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-60-39].

Figure 20-60-40
Publications. 1
2
P-64536

1 [Figure 20-60-41] and [Figure 20-60-42] from the pump
flange section. Inspect for damage and replace as
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


230 of 928
Figure 20-60-43
3
2
1
P-64540
File has expired.P-64537 damage and replace as needed.
NOTE: Inspect the pump flange section (Item 2) and

Figure 20-60-44 bushings (Item 3) [Figure 20-60-45]. If

Use updated files from Bobcat Figure 20-60-46
Publications. 1
2
2
1 P-30188A
P-64538

[Figure 20-60-44]. Inspect for damage and replace as
P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-60-44]. Remove the shaft seal (Item 1) [Figure 20-60-46] from
the pump flange section.
Installation: The shaft seal flush surface (Item 2)

[Figure 20-60-46] must be facing out away from the
pump.

231 of 928
File has expired.

Publications.

232 of 928
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
Description
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle RPM. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
The hydraulic gear pump has a dedicated charge pump. RPM*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
The high flow hydraulic pump has an additional pump PSI (69 bar).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 3300 PSI.
File has expired.

from a button on the panel in the cab.
A seal kit is available to service the hydraulic pump. If

Turn the restrictor control (Item 2) [Figure 20-61-1] on
any of the main components of the pump are damaged, should be approximately 16 - 17 GPM. Start turning the
the entire pump must be replaced. restrictor clockwise, causing more restriction on the flow.

Pump Test At Quick Couplers
procedure:
Publications.

Figure 20-61-1 Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-61-2.)

1
P-16903 P-66894

GPM.

233 of 928
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Figure 20-61-2
(CONT'D)
The tools listed will be needed to do the following 2

procedure:

1
WARNING
P-68163

Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
File has expired.
W-2017-0286
Figure 20-61-3
Lift and block the loader. (See Procedure on Page 10-10-

1.)

Publications.
WARNING
2
1

to fall and cause injury or death. P-48256A
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-61-3] from

Raise the operator cab. (See Raising on Page 10-30-1.) the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Open the rear door of the loader. 20-61-3] from the tester to the tubeline (Item 2) [Figure
20-61-2] on the control valve.

234 of 928
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
(CONT'D)
Figure 20-61-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
File has expired.
Hydraulic Control
Valve

Use updated files from Bobcat BH-196
Publications.
RPM*.


80% of free flow.
HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)


235 of 928
(CONT'D)

procedure:
MEL1563 or 7003031 - Remote Start Tool 2

WARNING
P-69182

Disconnect the proportioning valve electrical connector
File has expired.
W-2017-0286
(Item 1) [Figure 20-61-5].

electrical harness.

1.) Figure 20-61-6

Publications.
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-69184

filtered after it passes through the Hydraulic Disconnect the filter inlet hose (Item 1) [Figure 20-61-6].
Tester, to prevent any contamination to the
Hydrostatic Pumps.


236 of 928
(CONT'D)
Direct Pump Test (Charge Section) (Cont’d) IMPORTANT

Figure 20-61-7
4 3 I-2024-0284
RPM*.

600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).
2
File has expired.
1
P-69185
(GPM) at full RPM*.
Turn the restrictor down to system operating pressure

Connect the filter inlet hose (Item 1) to the inlet side of approximately 1000 PSI (69 bar). DO NOT EXCEED
the tester (Item 2) [Figure 20-61-7].

flow. The high pressure flow must be at least 80% of free

Connect the OUTLET hose (Item 3) from the hydraulic
[Figure 20-61-7].
flow.
%= HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X 100
Figure 20-61-8Publications. A low percentage may indicate a failed pump.
*Refer to the Hydraulic Schematics for pump flow and

RPM.
P-48256A
[Figure 20-61-8].

237 of 928
(CONT'D)
Direct Pump Test (High Flow Section)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-61-9] onto the
File has expired.

front auxiliary quick couplers.
support device. Failure to use an approved lift arm device. (See Installing on Page 10-20-1.)

to fall and cause injury or death. Figure 20-61-10
Use updated files from Bobcat W-2059-0598
position before you start the engine. 1
I-2024-0284
The tools listed will be needed to do the following 2

procedure:
P-48235

Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow valve INLET fitting (Item 2) [Figure 20-
61-10].
1.)


238 of 928
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Warm the fluid to 140° F (60° C) by turning the restrictor
(CONT'D) control (Item 1) [Figure 20-61-12] on the tester to about
1000 PSI (6895 kPa).
Direct Pump Test (High Flow Section) (Cont'd)
NOTE: DO NOT EXCEED 3300 PSI.
Figure 20-61-11
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
2 1 Relief Valve Adjustment on Page 20-150-2.)
Record the highest pressure (PSI) and flow (GPM). The

high pressure flow must be at least 80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X100

FREE FLOW (GPM)
File has expired. P-48256A
Connect the INLET hose (Item 1) [Figure 20-61-11] from *Refer to Hydraulic Schematics Legend for system relief
the tester, to the high flow pump OUTLET hose (Item 1) pressure and full RPM.

[Figure 20-61-10]. Connect the OUTLET hose (Item 2)

[Figure 20-61-11] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-61-10] on the High Flow
valve.
Lower the cab. Publications.

Figure 20-61-12
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
High Flow Valve
1
B-16277
Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.

239 of 928
(CONT'D)
DANGER
1
P-64545
P-90328
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
AVOID DEATH
•
File has expired.

WARNING

Use updated files from Bobcat D-1009-0409 Never work on a machine with the lift arms up unless
W-2059-0598

parts clean. Always use caps and plugs on hoses, Figure 20-61-14
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
1
Drain the hydraulic fluid from the reservoir. (See

Removing And Replacing Hydraulic Fluid on Page 10-
P-66882
120-2.)
Open the rear door of the loader. Disconnect and cap the inlet hoses (Item 1) [Figure 20-
Remove the Power Bob-Tach block if equipped. (See

240 of 928
(CONT'D)
Figure 20-61-15
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-61-17] on the

hydraulic pump.

pump.
Figure 20-61-16

1
Publications.
P-66898

15] and [Figure 20-61-16] from the hydraulic pump.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

241 of 928
(CONT'D)

hydraulic pump.
Figure 20-61-18 Starter

Solenoid
P-59355
S Terminal
File has expired.

Inlet Hose
Battery Terminal
P-66897
P-59356


[Figure 20-61-18].
Figure 20-61-19 Publications. tool [Figure 20-61-20].
Momentary Switch Start the loader from the operators cab and run the
hydraulics.
of cylinder stroke.

Check for hydraulic leaks.
Starter Bypass Tool
P-59354
[Figure 20-61-19] To crank the engine without starting,

the machine key switch can be bypassed. Obtain a
starter bypass tool from a local source which can be used
as a universal connection to remotely crank the engine
without starting.


242 of 928
(CONT'D)
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
File has expired. 6

9
7

12
7
8
9
7
5
6
3 4
Publications. 5 11
6
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

243 of 928
(CONT'D)
1
Figure 20-61-21
1
P-64553
P-64554
1
1 Remove the high flow end section (Item 1) [Figure 20-
File has expired.

P-64552
61-22].

61-21].

20-61-21].
Publications.
IMPORTANT
damage the system.
I-2003-0888

244 of 928
(CONT'D)

1
Figure 20-61-23
P-64556
2 Figure 20-61-26

1
Figure 20-61-24

3

4
Publications.
1 P-64557
2 Remove the high flow pump section (Item 1) [Figure 20-

61-25] and [Figure 20-61-26] from the charge center
P-64555 section.
NOTE: Inspect the high flow pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-26]. If excessive wear or
[Figure 20-61-23] and [Figure 20-61-24] from the high damage is visible, the pump must be
flow end section. replaced.

toward gears.
NOTE: Inspect the high flow end section (Item 3) and


245 of 928
(CONT'D)
Figure 20-61-27
P-64560
Figure 20-61-30
File has expired.

P-64558
Figure 20-61-28

1
Publications.
P-64561

[Figure 20-61-30] from the charge center section.
P-64559
Remove the drive gear (Item 1) [Figure 20-61-27] and pump must be replaced.
[Figure 20-61-28].


246 of 928
(CONT'D)
Figure 20-61-31
1
P-64564
2 Figure 20-61-34

2
Figure 20-61-32

Publications.
1
2 1
P-64565

P-64563 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-34].

[Figure 20-61-31] and [Figure 20-61-32] from the
charge center section. Inspect for damage and replace
as needed.

toward gears.

247 of 928
(CONT'D)

2
Figure 20-61-35
3
1
1 P-64569
Figure 20-61-38
File has expired.

P-64567 3

4
damage and replace as needed.

NOTE: Inspect the charge center section (Item 2) and
1
Publications.
Figure 20-61-36
2
P-64571
1

as needed.

toward gears.

P-64568 bushings (Item 4) [Figure 20-61-38]. If
Remove the charge center section (Item 1) [Figure 20-
61-36].

248 of 928
(CONT'D)
Figure 20-61-39
1
1
P-64574
File has expired.

P-64572
the auxiliary center section.
Figure 20-61-42
Figure 20-61-40

1
Publications. 1
P-64575
P-64573
Remove the charge pump section (Item 1) [Figure 20- pump must be replaced.
61-39] and [Figure 20-61-40] from the auxiliary pump
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-61-40]. If excessive wear or
damage is visible, the pump must be
replaced.

249 of 928
(CONT'D)
Figure 20-61-43
1
2
1
2
P-64578
Figure 20-61-46
File has expired.

P-64576

the end of the drive gear. Inspect for damage and replace

as needed.

2
1
Figure 20-61-44
Publications.
P-64579
1 Remove the wear plate (Item 1) and O-ring (Item 2)

auxiliary center section. Inspect for damage and replace
as needed.

toward gears.
P-64577


250 of 928
(CONT'D)
2
Figure 20-61-47
1 1
P-64521

NOTE: Inspect the auxiliary center section (Item 2)

and bushings (Item 3) [Figure 20-61-49]. If
Figure 20-61-48 excessive wear or damage is visible, the


2 Figure 20-61-50
Publications.
1
P-64520

P-64525
needed.
Remove the auxiliary center section (Item 1) [Figure 20-
Remove the pre-load seal (Item 2) [Figure 20-61-48]. 61-50].

251 of 928
(CONT'D)
Figure 20-61-51
P-64528
1
Figure 20-61-54
File has expired.

P-64526
Figure 20-61-52

3

4 1
Publications.
1 P-64529
Remove the auxiliary pump section (Item 1) [Figure 20-

2
61-53] and [Figure 20-61-54] from the pump flange
P-64527 section.
NOTE: Inspect the auxiliary pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-54]. If excessive wear or
[Figure 20-61-51] and [Figure 20-61-52] from the damage is visible, the pump must be
auxiliary center section. Inspect for damage and replace replaced.
as needed.

toward gears.


252 of 928
(CONT'D)
Figure 20-61-55
1
2
P-64532

Remove the drive gear (Item 1) [Figure 20-61-55] from Figure 20-61-58

Figure 20-61-56
1
Publications. 1
P-64534
P-64531 Remove the idler gear (Item 1) [Figure 20-61-58] from

NOTE: Inspect the drive gear (Item 1) [Figure 20-61- NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
56]. If excessive wear or damage is visible, the 58]. If excessive wear or damage is visible, the
pump must be replaced. pump must be replaced.

253 of 928
(CONT'D)
Figure 20-61-59
P-64537
Figure 20-61-62
File has expired.

P-64535
Figure 20-61-60

Publications. 1
P-64538
1

2 [Figure 20-61-62]. Inspect for damage and replace as
P-64536 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-62].

Remove the wear plate (Item 1) and section seal (Item 2)
needed.

toward gears.

254 of 928
(CONT'D)
Figure 20-61-63
3
2
File has expired.

1
P-64540


Publications.
Figure 20-61-64
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-61-64] from


pump.

255 of 928
File has expired.

Publications.

256 of 928
HYDRAULIC PUMP (SJC) This procedure will require a operator in the cab and one
operator running the tester.
Description
Start the engine and run at low idle RPM. Press the Front
The hydraulic gear pump is attached to the end of the Auxiliary button. Engage the front auxiliary with the
hydrostatic pumps and is located on the right side of the trigger on the right handle. Make sure the tester is
loader between the hydraulic control valve and the connected correctly. If no flow is indicated on the tester,
engine. the hoses are connected wrong. With the hoses
The hydraulic gear pump is a combination of gear pumps RPM*.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about a 1000
This supplies flow to the hydraulic fan motor and charge PSI (69 bar).
pressure to the hydrostatic pump.
any of the main components of the pump are damaged, Turn the restrictor control (Item 2) [Figure 20-70-1] on
the entire pump must be replaced. the tester counterclockwise to obtain free flow, the flow
Pump Test At Quick Couplers File has expired. should be approximately 16 - 17 GPM. Start turning the
restrictor clockwise, causing more restriction on the flow.
The tools listed will be needed to do the following reaches approximately 2800 PSI. At approximately 2800
procedure: PSI the flow should start decreasing rapidly until the

Figure 20-70-1
Publications. If flow and pressure specs are not obtained, go to Direct

on Page 20-70-2.)
1 *Refer to (See Hydraulic System on Page SPEC-10-3.)

P-16903 P-66894
Install a hydraulic tester (Item 1) [Figure 20-70-1] onto


GPM.

257 of 928
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-70-2

procedure: 2

WARNING 1
P-68163
File has expired.

W-2017-0286
1.)


Publications.
WARNING 2 1

P-48256A
W-2059-0598

258 of 928
HYDRAULIC PUMP (SJC) (CONT'D)
Figure 20-70-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
File has expired.

Hydraulic Control
Valve

BH-196
Publications.
RPM*.


80% of free flow.

FREE FLOW (GPM)


259 of 928
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-70-5

procedure:

WARNING
P-69182
File has expired.

W-2017-0286
(Item 1) [Figure 20-70-5].

1.)

Figure 20-70-6

Publications.
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-1.) for system relief pressure and full RPM.


260 of 928
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-70-7
IMPORTANT
4 3 position before you start the engine.
I-2024-0284
RPM*.

2 1 600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).

(GPM) at full RPM*.
Connect the filter inlet hose (Item 1) to the inlet side of Turn the restrictor down to system operating pressure
the tester (Item 2) [Figure 20-70-7]. approximately 1000 PSI (69 bar). DO NOT EXCEED

Connect the OUTLET hose (Item 3) from the hydraulic flow. The high pressure flow must be at least 80% of free

[Figure 20-70-7].
flow.
FREE FLOW (GPM)
X 100
Figure 20-70-8
Publications. A low percentage may indicate a failed pump.

RPM.
P-48256A
[Figure 20-70-8].

261 of 928
Removal And Installation WARNING

DANGER the lift arms are secured by an approved lift arm
W-2059-0598
Figure 20-70-9
P-90328
AVOID DEATH
•
File has expired.
2
1


D-1009-0409
IMPORTANTPublications. Open the rear door of the loader.
Disconnect and cap the outlet hose (Item 1) [Figure 20-

Remove the Power Bob-Tach block (Item 2) [Figure 20-
70-9] if equipped. (See Removal And Installation on
damage the system.
I-2003-0888
Page 20-130-1.)
Figure 20-70-10
Page 10-10-1.)
Raise the operator cab. (See Raising on Page 10-30-1.) 1
Drain the hydraulic fluid from the reservoir. (See

Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
1
P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 20-


262 of 928
HYDRAULIC PUMP (SJC) (CONT'D) Remove the hydraulic pump (Item 3) [Figure 20-70-12]
from the hydrostatic pump.
Figure 20-70-13
Figure 20-70-11
File has expired.

P-64446
P-64549
Replace the O-ring (Item 1) [Figure 20-70-13] in the

hydrostatic pump.
11] from the hydraulic pump.

pump.
(75 - 85 N•m) torque.
Figure 20-70-12
Publications.
3
1
P-64343
Remove the bracket mounting bolt (Item 1) from the

pump mounting bracket (Item 2) [Figure 20-70-12].
Note: The mounting bolt is a special purpose bolt.

Only replace with original Bobcat Parts.
Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-70-

12].

263 of 928
HYDRAULIC PUMP (SJC) (CONT’D) Figure 20-70-16

hydraulic pump.
Figure 20-70-14
Starter
Solenoid
P-59355
S Terminal
File has expired.

Inlet Hose
Battery Terminal
P-66897
P-59356

[Figure 20-70-14].
Figure 20-70-15
hydraulics.
of cylinder stroke.

P-59354

without starting.


264 of 928
HYDRAULIC PUMP (SJC) (CONT’D)
15
14
7 5
13
8
5 6
4
12 3
File has expired.

7

7
8
Publications. 11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
11. Spline Shaft
12. Pump Center Section
14. Pump End Section
15. Bolt (8)
B-21259A

265 of 928
Figure 20-70-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-70-
File has expired.

P-64508 18].

70-17].

20-70-17].
Publications.
IMPORTANT
damage the system.
I-2003-0888

266 of 928
Figure 20-70-19 1
P-64511
2
Figure 20-70-22
File has expired.

P-64509
1
Figure 20-70-20

3
4
Publications.
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 70-21] and [Figure 20-70-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-70-19] and [Figure 20-70-20] from the pump 70-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.

toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-70-20] and bushings (Item 4) [Figure 20-70-

267 of 928
Figure 20-70-23
P-64515
Figure 20-70-26
File has expired.

P-64513
Figure 20-70-24

1
Publications.
P-64516

P-64514 [Figure 20-70-26] from the pump center section.



268 of 928
Figure 20-70-27
1
P-64519
1
2 Figure 20-70-30
2
Figure 20-70-28

2
Publications.
1
1
P-64520

needed.
needed.

toward gears.

269 of 928
Figure 20-70-31
2
1
1
P-64526
Figure 20-70-34
File has expired.

P-64521
3


NOTE: Inspect the pump center section (Item 2) and

pump must be replaced. 1

2
1
P-64527

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-70- pump must be replaced.
32].

270 of 928
Figure 20-70-35
1
P-64530
1
File has expired.P-64528 the pump flange section.
Figure 20-70-38
Figure 20-70-36

Publications.
1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
70-35] and [Figure 20-70-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

70-36]. If excessive wear or damage is visible,
the pump must be replaced.

271 of 928
Figure 20-70-39
2
P-64535
Figure 20-70-42
File has expired.

P-64532



Figure 20-70-40
Publications. 1
2
P-64536

1 [Figure 20-70-41] and [Figure 20-70-42] from the pump
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


272 of 928
Figure 20-70-43
3
2
1
P-64540

Figure 20-70-44 bushings (Item 3) [Figure 20-70-45]. If

Publications. 1
2
2
1 P-30188A
P-64538

P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-70-44]. Remove the shaft seal (Item 1) [Figure 20-70-46] from
Installation: The shaft seal flush surface (Item 2) [Figure

20-70-46] must be facing out away from the pump.

273 of 928
File has expired.

Publications.

274 of 928
HYDRAULIC PUMP (SJC) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description connected directly to the hydraulic tester
The hydraulic gear pump is attached to the end of the the connection to the tester. Also make sure
hydrostatic pumps and is located on the right side of the your hydraulic tester is capable of at least 50
loader between the hydraulic control valve and the GPM.
engine.
The hydraulic gear pump is a combination of gear pumps operator running the tester.
that provide hydraulic flow to several hydraulic systems.
Start the engine and run at low idle RPM. Press the Front
The hydraulic gear pump has a dedicated charge pump. Auxiliary button. Engage the front auxiliary with the
This supplies flow to the hydraulic fan motor and charge trigger on the right handle. Make sure the tester is
pressure to the hydrostatic pump. connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
The high flow hydraulic pump has an additional pump connected correctly, increase the engine speed to full
section that provides an additional amount of flow that is RPM*.
controlled by an external valve. The valve is switched
File has expired.

from a button on the panel in the cab.

PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.

Pump Test At Quick Couplers
procedure:
Turn the restrictor control (Item 2) [Figure 20-71-1] on
should be approximately 16 - 17 GPM. Start turning the
restrictor clockwise, causing more restriction on the flow.
Publications.
Figure 20-71-1 the flow should be at 0 GPM. Turn the restrictor (Item 2)
2 front auxiliary hydraulics off.

on Page 20-71-2.)

P-16903 P-66894
Install a hydraulic tester (Item 1) [Figure 20-71-1] onto


275 of 928
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D) Figure 20-71-2

procedure: 2

WARNING 1
P-68163
File has expired.

W-2017-0286
1.)


Publications.
WARNING 2 1

P-48256A
W-2059-0598

276 of 928
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D)
Figure 20-71-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
File has expired.

Hydraulic Control
Valve

BH-196
Publications.
RPM*.


80% of free flow.

FREE FLOW (GPM)


277 of 928

procedure:

WARNING
P-69182
File has expired.

W-2017-0286
(Item 1) [Figure 20-71-5].

1.)

Figure 20-71-6

Publications.
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.


278 of 928
HYDRAULIC PUMP (SJC) (HIGH FLOW)(CONT'D)
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-71-7
IMPORTANT
4 3 position before you start the engine.
I-2024-0284
RPM*.

2 1 600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).

(GPM) at full RPM*.
Connect the filter inlet hose (Item 1) to the inlet side of Turn the restrictor down to system operating pressure
the tester (Item 2) [Figure 20-71-7]. approximately 1000 PSI (69 bar). DO NOT EXCEED

Connect the OUTLET hose (Item 3) from the hydraulic flow. The high pressure flow must be at least 80% of free

[Figure 20-71-7].
flow.
FREE FLOW (GPM)
X 100
Figure 20-71-8
Publications. A low percentage may indicate a failed pump.

RPM.
P-48256A
[Figure 20-71-8].

279 of 928
Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-71-9] onto the
File has expired.

front auxiliary quick couplers.

W-2059-0598

I-2024-0284

procedure:


1.)


280 of 928
Direct Pump Test (High Flow Section) (Cont'd) EXAMPLE: TESTER

CONNECTION
Reservoir
Figure 20-71-10
Hydraulic Pump
Out In
High Flow Valve
1 1
B-16277
2 Sample tester connection shown [Figure 20-71-12].

Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
Disconnect the high flow pump OUTLET hose (Item 1) button (on the right control lever) for fluid flow to the quick
from the high flow valve INLET fitting (Item 2) [Figure 20- coupler. Make sure the tester is connected correctly. If no

71-10]. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-71-11 engine speed to full RPM*.
Publications. control (Item 1) [Figure 20-71-12] on the tester to about

1000 PSI (6895 kPa).

2 1
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-2.)
P-48256A
Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-71-11] from
the tester, to the high flow pump OUTLET hose (Item 1)
%= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-71-10]. Connect the OUTLET hose (Item 2)
[Figure 20-71-11] from the tester, to the high flow valve FREE FLOW (GPM)
INLET fitting (Item 2) [Figure 20-71-10] on the High Flow
valve. A low percentage may indicate a failed pump.
Lower the cab. *Refer to Hydraulic Schematics Legend for system relief
pressure and full RPM.

281 of 928
DANGER
P-64545
P-90328
AVOID DEATH Figure 20-71-14

•
File has expired.

D-1009-0409

1
Publications.
Page 10-10-1.)
2
P-64546
Drain the hydraulic fluid from the reservoir. (See Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Removing And Replacing Hydraulic Fluid on Page 10- 71-13] and [Figure 20-71-14] from the back of the
120-2.) hydraulic pump.
Open the rear door of the loader. Remove the Power Bob-Tach block (Item 2) [Figure 20-
71-14] if equipped. (See Removal And Installation on
Page 20-130-1.)
WARNING
W-2059-0598

282 of 928
Figure 20-71-15
3
1
1
2
1 P-64343
Remove the bracket mounting bolt (Item 1) from the
File has expired. P-64544 pump mounting bracket (Item 2) [Figure 20-71-17].
NOTE: The mounting bolt is a special purpose bolt.

Disconnect and cap the inlet hoses (Item 1) [Figure 20- Only replace with original Bobcat Parts.

Installation: Apply a medium strength threadlocker to
Figure 20-71-16 mounting bolt and tighten to 90 - 100 ft.-lb. (122-136
Use updated files from Bobcat N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-71-
Publications. 17].
Remove the hydraulic pump (Item 3) [Figure 20-71-17]

from the hydrostatic pump.
1
Figure 20-71-18
P-64549

16] from the hydraulic pump.

(75 - 85 N•m) torque.
P-64446
Replace the O-ring (Item 1) [Figure 20-71-18] in the

hydrostatic pump.

pump.

283 of 928

hydraulic pump.
Figure 20-71-19
Starter
Solenoid
P-59355
S Terminal
File has expired.

Inlet Hose
Battery Terminal
P-66897
P-59356

[Figure 20-71-19].
Figure 20-71-20
hydraulics.
of cylinder stroke.

P-59354

without starting.


284 of 928
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
File has expired. 7

6
9
12

7
8

9
7
3 4
5
6
Publications. 6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

285 of 928
Figure 20-71-22
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
File has expired.

P-64552 71-23].

71-22].

20-71-22].
Publications.
IMPORTANT
damage the system.
I-2003-0888

286 of 928
Figure 20-71-24 1
P-64556
2
Figure 20-71-27
1
Figure 20-71-25

3
4

Publications.
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 71-26] and [Figure 20-71-27] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-71-24] and [Figure 20-71-25] from the high [Figure 20-71-27]. If excessive wear or
flow end section. damage is visible, the pump must be
replaced.
toward gears.
NOTE: Inspect the high flow end section (Item 3) and


287 of 928
Figure 20-71-28
P-64560
Figure 20-71-31
File has expired.

P-64558
Figure 20-71-29

1
Publications.
P-64561

P-64559 [Figure 20-71-31] from the charge center section.



288 of 928
Figure 20-71-32
P-64564
2
Figure 20-71-35
2
Figure 20-71-33

2
Publications.
1
1
P-64565

needed.
as needed.

toward gears.

289 of 928
Figure 20-71-36 2
3
1
1
P-64569
Figure 20-71-39
File has expired.

P-64567
3



1
2
1 P-64571

as needed.

toward gears.
P-64568 NOTE: Inspect the charge center section (Item 3) and

Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
71-37].

290 of 928
Figure 20-71-40
1 1
P-64574
File has expired.

P-64572 the auxiliary center section.
Figure 20-71-43
Figure 20-71-41

1

Publications. 1
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 43]. If excessive wear or damage is visible, the
71-40] and [Figure 20-71-41] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-71-41]. If excessive wear or
damage is visible, the pump must be
replaced.

291 of 928
Figure 20-71-44
1 2
2
P-64578
Figure 20-71-47
File has expired.

P-64576

the end of the drive gear. Inspect for damage and replace

as needed.

Figure 20-71-45 2
1
Publications.
P-64579
1
auxiliary center section. Inspect for damage and replace
as needed.

P-64577 toward gears.


292 of 928
Disassembly And Assembly (Cont'd) 2
Figure 20-71-48
1
1
P-64521

Figure 20-71-49 and bushings (Item 3) [Figure 20-71-50]. If


2
Figure 20-71-51
Publications.
1
P-64520

P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-71-49]. Remove the auxiliary center section (Item 1) [Figure 20-
71-51].

293 of 928
Figure 20-71-52
P-64528
1
Figure 20-71-55
File has expired.

P-64526
Figure 20-71-53

3

4
1
Publications.
1
P-64529
2 Remove the auxiliary pump section (Item 1) [Figure 20-

P-64527 71-54] and [Figure 20-71-55] from the pump flange
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-71-52] and [Figure 20-71-53] from the [Figure 20-71-55]. If excessive wear or
auxiliary center section. Inspect for damage and replace damage is visible, the pump must be
as needed. replaced.

toward gears.


294 of 928
Figure 20-71-56
1
1
P-64532
File has expired.P-64530 the end of the drive gear.

the pump flange section. Figure 20-71-59

Figure 20-71-57

1 Publications. 1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-71-59] from
57]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-71-
pump must be replaced. 59]. If excessive wear or damage is visible, the

295 of 928
Figure 20-71-60
P-64537
Figure 20-71-63
File has expired.

P-64535
Figure 20-71-61

Publications. 1
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-71-63].
needed.

toward gears.

296 of 928
Figure 20-71-64
3
2
File has expired.

1
P-64540



Publications.
Figure 20-71-65
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-71-65] from


pump.

297 of 928
File has expired.

Publications.

298 of 928
HYDRAULIC / HYDROSTATIC FILTERS Disconnect the tubeline (Item 3) [Figure 20-80-1] from
the filter housing.
Description
Figure 20-80-2
The hydraulic/hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic/
hydrostatic systems are operating.
The hydraulic/hydrostatic filter system consists of one

gear pump filter and one fan/charge pressure filter.
The gear pump hydraulic/hydrostatic filter removes 1

contaminants after the oil cooler.
2
The charge pressure filter removes contaminants before
the oil enters the hydrostatic pump.
File has expired.

P-68220
IMPORTANT
Disconnect the temperature sender connector (Item 1)
When repairing hydrostatic and hydraulic systems, [Figure 20-80-2] from the filter housing.

parts clean. Always use caps and plugs on hoses, Disconnect the wire connector (Item 2) [Figure 20-80-2]
tubelines and ports to keep dirt out. Dirt can quickly from the differential pressure switch on the filter housing.
damage the system.
I-2003-0888
Publications.
Housing Removal And Installation
Figure 20-80-1
2
P-68234
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)
Remove the mounting bolt (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-80-1].

299 of 928
HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-80-3
File has expired.

P-48257
Using MEL 1558 tool disconnect the oil cooler tubeline

(Item 1) [Figure 20-80-3] from the filter housing.

Figure 20-80-4

1
Publications.
P-48258
Remove the two mounting screws (Item 1) [Figure 20-

80-4] from the filter housing mounting bracket.

Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)

300 of 928
HYDRAULIC / HYDROSTATIC FILTERS (CONT’D) Figure 20-80-7
Charge Filter Housing Removal And Installation
Figure 20-80-5 2
2 1
2
1 P-68127
Remove filter inlet hose (Item 1) [Figure 20-80-7].

Remove the four mounting screws (Item 2) [Figure 20-
80-7].
Remove filter outlet hose (Item 1) [Figure 20-80-5].
Installation: Tighten the mount screws to 15 - 20 ft.-lb.

Disconnect the electrical connector (Item 2) [Figure 20- (20 - 27 N•m) torque.
80-5] from the charge pressure sender.

Figure 20-80-6
Remove filter assembly from the loader.
Figure 20-80-8
Publications.
2
1
P-66884
P-66609
Disconnect the charge pressure tubeline (Item 1) [Figure

20-80-6] that connects to the control valve. Remove the four mounting bolts (Item 1) [Figure 20-80-
8].
Disconnect the electrical connector from the filter sensor
(Item 2) [Figure 20-80-6]. Installation: Tighten the mount bolts to 25 ft.-lb. (34
N•m) torque.

301 of 928
File has expired.

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302 of 928
HYDRAULIC FLUID RESERVOIR
Description
IMPORTANT
The hydraulic fluid reservoir is a storage container for the
loaders hydraulic/hydrostatic fluid. The reservoir contains When repairing hydrostatic and hydraulic systems,
a vented fill cap with a fluid screen to prevent clean the work area before disassembly and keep all
contaminants from entering the reservoir while adding parts clean. Always use caps and plugs on hoses,
fluid. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The hydraulic fluid reservoir is located below the I-2003-0888
operators cab on the left side of the loader.
Stop the engine.
1.) Remove the fluid from the hydraulic reservoir.
Start the engine. Raise the lift arms and install an Remove the control panel. (See Removal And Installation
10-20-1.) File has expired.

approved lift arm support device. (See Installing on Page on Page 50-100-2.)
Remove Bucket position valve if so equipped. (See

DANGER

Remove the crossbar linkage, if so equipped. (See
Use updated files from Bobcat Linkage Removal And Installation on Page 50-90-2.)
Figure 20-90-1
Publications.
2
P-90328
AVOID DEATH
1
P-34113
D-1009-0409
Remove the left rear tire assembly (Item 1) [Figure 20-

90-1].
WARNING Remove the two access panels (Item 2) [Figure 20-90-
1].
W-2059-0598

303 of 928
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-4
Figure 20-90-2
1 3
1 2
2 P-68132
Remove the drive motor drain hose (Item 1) [Figure 20-
File has expired.

P-68130 90-4] at the drain filter
Remove the auxiliary pressure relief drain hose (Item 2)

Remove the two mounting screws (Item 1) and remove [Figure 20-90-4] at the drain filter.
the plate (Item 2) [Figure 20-90-2] from the loader.

Remove the drive motor supply hose (Item 3) [Figure 20-
Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27 90-4] from the drive motor and the hydrostatic pump.
N•m) torque.
Figure 20-90-3
Figure 20-90-5
Publications.
2
2
1
1
P-68131
P-66831
Remove the control valve drain hose (Item 1) [Figure 20-

Remove the hose clamp (Item 1) [Figure 20-90-3] from 90-5].
the fill hose.
Remove the hydraulic fill hose (Item 2) [Figure 20-90-3] reservoir.
from the hydraulic reservoir.

304 of 928
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-8
Figure 20-90-6
2
P-34044
Remove the hose clamp (Item 1) [Figure 20-90-8] from
File has expired.P-34042 the fitting.
Remove the breather hose (Item 2) [Figure 20-90-8]

Remove the hose clamp (Item 1) [Figure 20-90-6] from from the hydraulic reservoir.
the tank outlet.

Figure 20-90-9
Remove the hydrostatic supply hose (Item 2) [Figure 20-

90-6] from the bottom of the reservoir.
Figure 20-90-7
Publications.
1
1
2
P-34052
Remove the hydraulic reservoir (Item 1) [Figure 20-90-9]

P-34043 from the loader.
Remove the bolt and nut (Item 1) [Figure 20-90-7].
Loosen the bolt and nut (Item 2) [Figure 20-90-7] to

allow the hydraulic reservoir mount to drop down.

305 of 928
HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Figure 20-90-10
File has expired.

P-68128

Remove the hose clamp (Item 1) and remove the
hydraulic fill hose (Item 2) [Figure 20-90-10] from the

hydraulic reservoir.
Figure 20-90-11
Publications.
1
P-68129
Remove the hydraulic fluid screen (Item 1) [Figure 20-

90-11] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

306 of 928
OIL COOLER Figure 20-100-2
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
The oil cooler is located underneath the rear grille

between the A/C condenser (if so equipped) and the
radiator.
N-19346
IMPORTANT Figure 20-100-3
File has expired.


damage the system.
I-2003-0888

Remove the rear grille from the loader. (See Removal
And Installation on Page 50-60-1.)
Publications.
Figure 20-100-1
P-45242
1
2 Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 20-100-2] and [Figure 20-
100-3].
N-19345
Install tool MEL 1558 (Item 1) to outside of rubber sleeve

(Item 2) [Figure 20-100-1].

307 of 928
OIL COOLER (CONT’D)
Figure 20-100-4
1
2
1
File has expired.

P-45101
Disconnect the inlet and outlet hoses (Item 1) from the oil
cooler (Item 2) [Figure 20-100-4].

NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed
together.
Publications.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.

308 of 928
BUCKET POSITION VALVE Figure 20-110-2
Description
The Bucket Position Valve is an option that allows the

loader to meter the lift and tilt circuits. The metering of the
lift and tilt circuits allows the operator to hold the
attachment at the same angle from the ground to 2
maximum lift height without using the tilt function.
The bucket position valve is located below the operators

cab on the right side of the hydraulic fluid reservoir.
See Hydraulic Schematic for more circuit information. 1
Solenoid Removal And Installation P-26311A
Figure 20-110-1
Remove the solenoid nut (Item 1) [Figure 20-110-2].
File has expired. Installation: Tighten the solenoid nut to 4 - 6 ft.-lb. max.
(5 - 8 N•m max.) torque. Overtightening may cause valve
failure.

Remove the solenoid coil (Item 2) [Figure 20-110-2].
2

1
Figure 20-110-3
Publications.
P-68162
Disconnect the wire harness connector (Item 1) [Figure

20-110-1] from the bucket position shut-off solenoid.
NOTE: Loosening the two mounting screws (Item 2)

[Figure 20-110-1] on the Bucket Positioning
Valve Bracket may aid in the solenoid 1
removal. P-26312A
Remove the solenoid stem (Item 1) [Figure 20-110-3]

from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

309 of 928
BUCKET POSITION VALVE (CONT'D) Solenoid Testing
Solenoid Removal And Installation (Cont’d) Figure 20-110-5
Figure 20-110-4
1
2
P9175
File has expired.

N-18191
Use a test meter to measure coil resistance [Figure 20-
110-5]. Coil wires do not have polarity. Correct resistance
Inspect the solenoid stem and replace the O-rings (Item for the coil is 9.8 ohm.
1) and the back-up washer (Item 2) [Figure 20-110-4].

Replace the test meter with 12 volt power. You can see
and hear the spool shift.
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310 of 928
BUCKET POSITION VALVE (CONT'D) Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
Removal And Installation 10-20-1.)
Stop the engine.
DANGER Raise the operator cab. (See Raising on Page 10-30-1.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-110-6].
Figure 20-110-7
P-90328
AVOID DEATH
2
•
File has expired.

1
D-1009-0409
Use updated files from Bobcat P-26311A
WARNING

W-2059-0598
1
Figure 20-110-6
P-26312A

1
Installation: Tighten the nut to 4 - 6 ft.-lb. max. (5 - 8
N•m max.) torque. Overtightening may cause valve
failure.
Remove the solenoid (Item 2) [Figure 20-110-7] and the

solenoid stem (Item 1) [Figure 20-110-8].
P-68162
Installation: Put oil on the O-rings and back-up washers

and tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

311 of 928
BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 20-110-11
Figure 20-110-9
N-19069
File has expired.

P-68158
Disconnect the tubeline (Item 1) [Figure 20-110-9] from Installation: Tighten the solenoid nut to maximum 6 ft.-
the fitting under the solenoid on the bucket position valve. lb. max. (8 N•m max.) torque.

Figure 20-110-10 Figure 20-110-12
Publications.
1 4 2
3 P-68157 N-19070
Remove the tubeline (Item 1) [Figure 20-110-10] from Remove the solenoid (Item 1) and the solenoid stem
the B port to the control valve. (Item 2) [Figure 20-110-12].
Disconnect the tubeline (Item 2) [Figure 20-110-10] from
Installation: Put oil on O-rings and back-up washers and
the C port (tilt rod end) on the BPV.
tighten the solenoid stem to 30 - 40 ft.-lb. (40,7 - 50,2
Disconnect the tubeline (Item 3) [Figure 20-110-10] from N•m) torque.
the D port (tilt base end) on the BPV.
Remove the mounting screws (Item 4) [Figure 20-110-

10].

Remove the bucket position valve and bracket from the

loader.

312 of 928
BUCKET POSITION VALVE (CONT'D) Figure 20-110-15
Figure 20-110-13
N-18339
1 Remove the plug (Item 1), and flow control spool (Item 2)
File has expired. N-19072 [Figure 20-110-15].
Assembly: Tighten the plug to 56 - 64 ft.-lb. (75,9 - 86,8

Remove the flow adjustment valve and O-ring (Item 1) N•m) torque.
[Figure 20-110-13].

Inspect the flow control spool for wear, inspect the O-ring
Installation: Tighten the flow adjustment valve to 15 - 30 on the plug and replace as needed.
ft.-lb. (20,3 - 40,7 N•m) torque.
NOTE: Always install new O-rings before any parts

Figure 20-110-16
Publications.
are installed into the valve. Inspect the parts
for wear or damage and replace as needed.
Figure 20-110-14
3
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

1 2) and plug (Item 3) [Figure 20-110-16]. Inspect for wear,
N-19041 inspect the O-ring and replace as needed.

Remove the plug (Item 1) [Figure 20-110-14]. N•m) torque.

N•m) torque.

313 of 928
BUCKET POSITION VALVE (CONT'D)
Figure 20-110-17
File has expired.

N-19045
Remove the plug [Figure 20-110-17].

N•m) torque.

Figure 20-110-18
Publications.
3
N-19046
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-110-18].
Inspect all parts and replace as needed. Install a new O-

ring on the plug before installing.

N•m) torque.

314 of 928
REAR AUXILIARY DIVERTER VALVE
Description
The rear auxiliary diverter valve is an optional valve that

diverts oil from the front auxiliary circuit to two sets of rear
auxiliary couplers or the right side auxiliaries. The
couplers are used for rear mounted attachments.The
right side auxiliaries are used for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
The right side auxiliaries are located on the inside of the

right side lift arm at the front of the machine.
The rear auxiliary valve is located on the right side of the

machine behind the blower housing. The valve is
accessed by remove a panel on the right side of the
machine.
File has expired.
See Hydraulic Schematic for more circuit information.
Solenoid Testing

Figure 20-120-1
Publications.
P9137

is 8.6 - 9.5 ohm @ 68° F.

315 of 928
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disconnect the negative battery cable. (See Removal
Remove the speed control lever. (See Lever Removal

on Page 50-100-2.)
Remove the right rear tire. (See TIRE MAINTENANCE

on Page 10-160-1.)
Figure 20-120-2
P-90328
AVOID DEATH
•
File has expired.
1

D-1009-0409
WARNING
Publications. The rear auxiliary valve (Item 1) [Figure 20-120-2] is
located between the control valve and the gear pump on
Never work on a machine with the lift arms up unless the right side of the loader.
W-2059-0598 IMPORTANT
WARNING parts clean. Always use caps and plugs on hoses,
damage the system.
AVOID INJURY OR DEATH I-2003-0888
explosion or fire.
W-2103-0508

1.)

316 of 928
REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-120-5
Figure 20-120-3
1
1
P-48300
2 Disconnect the four solenoid connectors (Item 1) [Figure
File has expired. P-48302 20-120-5] from the rear auxiliary valve.
Figure 20-120-6
Disconnect the base and rod end tubelines (Item 1)
[Figure 20-120-3].

Remove the fittings (Item 2) [Figure 20-120-3] from the
valve.
Figure 20-120-4
Publications. 1
P-48304
Disconnect the drain tubeline (Item 1) [Figure 20-120-6]

from the lift arm by pass valve.
P-48872
Remove the three access covers (Item 1) [Figure 20-

120-4] on the right side of the machine.

317 of 928
Figure 20-120-7
1
P-48869
Loosen and remove the two bolts and nuts (Item 1)
File has expired.

P-48303 [Figure 20-120-9] that hold the rear auxiliary valve.
Figure 20-120-10
Disconnect and remove the drain tubeline (Item 1)
[Figure 20-120-7] from the rear auxiliary valve.

Figure 20-120-8

Publications. 1
2
P-48870
1
Remove the rear auxiliary valve (Item 1) [Figure 20-120-
P-48305 10] by moving the valve to the rear access hole which
allows enough room for the valve to be removed from the
loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-
120-8] from the rear auxiliary valve. The valve needs to be tilted as shown in [Figure 20-120-
10] for it to be removed through the hole.
Disconnect the tubeline (Item 2) [Figure 20-120-8] from
the bottom of the control valve and the rear auxiliary
valve.

318 of 928
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888 1
P-76791
Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
assembly. There are 11 #4 SAE hex head plugs (Item 1) [Figure 20-
Figure 20-120-11 File has expired. 120-12] located on all sides of the diverter valve and can
be removed for clean out purposes.
Assembly: Put oil on O-rings. Tighten to 10 ft.-lb. (13,6

N•m) torque.

2
Figure 20-120-13
Publications. 1
1
P-76747
Remove the two mount bolts (Item 1) from the diverter

valve mount plate (Item 2) [Figure 20-120-11] and
remove the mount plate. P-48752
Inspect O-ring (Item 1) [Figure 20-120-13].
Assembly: Put oil on O-ring.

319 of 928
Figure 20-120-14
1
1
P-76789A
Remove the differential sensing valve (Item 1) [Figure
File has expired.

P-76789A 20-120-16].
Assembly: Put oil on O-rings and back-up washers.

Remove the shuttle valve (Item 1) [Figure 20-120-14]. Tighten to 85 ft.-lb. (115,25 N•m) torque.

Assembly: Put oil on the O-rings and back-up washers. Figure 20-120-17
Tighten to 8 ft.-lb. (10,8 N•m) torque.

Figure 20-120-15
Publications. 2
1
1 1
2 P-48757
P-48756 Inspect the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-120-17] for damage.
Inspect the O-rings (Item 1) and back-up washers (Item


320 of 928

1
Figure 20-120-18
1 P-76794
NOTE: Before removing the solenoid coils, mark the
File has expired. P-48753 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-120-20] from the

Remove the relief valve (Item 1) [Figure 20-120-18]. solenoid valve stem.

Assembly: Put oil on O-rings and back-up washers. Assembly: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
Tighten to 25 ft.-lb. (34 N•m) torque. torque.
Figure 20-120-19 Figure 20-120-21
Publications.
1
2
2
1
P-48754 P-76796
Inspect the O-rings (Item 1) and back-up washer (Item 2) Remove the metal shields (Item 1) and solenoid valve
[Figure 20-120-19] for damage. coils (Item 2) [Figure 20-120-21].

321 of 928
Figure 20-120-22
1
P-48761
NOTE: Before removing the solenoid coils, mark the
File has expired.

P-48763A coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-120-24] from the

Remove the solenoid valve stem (Item 1) [Figure 20- solenoid valve stems.
120-22]

Assembly: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
Assembly: Put oil on the O-rings and back-up washers. torque.
Tighten to 25 ft.-lb. (34 N•m) torque.
Figure 20-120-23
Figure 20-120-25
Publications.
1
1
P-48762
2 P-48764
Remove the solenoid valve stems (Item 1) [Figure 20-

Inspect the O-rings (Item 1) and back-up washers (Item 120-25].
Assembly: Put oil on the O-rings and back-up washers.
Tighten to 25 ft.-lb. (34 N•m) torque.

322 of 928
Figure 20-120-26
1 1
P-48752
2

Assembly: Put oil on O-ring.
Inspect the O-rings (Item 1) and back-up washer (Item 2) Figure 20-120-29
[Figure 20-120-26].

Figure 20-120-27

Publications. 1
1
P-48766
P-48765 Remove and inspect the orifice (Item 1) [Figure 20-120-

29] for dirt and debris.
Remove the #8 SAE hex head plug (Item 1) [Figure 20- Assembly: Tighten the orifice to 22 ft.-lb. (29,8 N•m)
120-27]. torque.
Assembly: Tighten the plug to 38 ft.-lb. (51,5 N•m)

torque.

323 of 928

1
Figure 20-120-30
1
2
P-76798
Remove the #4 SAE hex head plug (Item 1) and the #6
File has expired.

P-48765 SAE hex head plugs (Item 2) [Figure 20-120-32].
Assembly: Tighten the #4 SAE hex head plug to 10 ft.-

Remove the #4 SAE hex head plug (Item 1) [Figure 20- lb. (13,6 N•m) torque.
120-30].

Assembly: Tighten the #6 SAE hex head plugs to 14 ft.-
Assembly: Tighten the plug to 10 ft.-lb. (13,6 N•m) lb. (19 N•m) torque.
torque.
Figure 20-120-31
Figure 20-120-33
Publications.
1
P-48752
P-48786

Remove the orifice (Item 1) [Figure 20-120-31] and
inspect for dirt and debris. Assembly: Put oil on O-ring.
Assembly: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)

torque.

324 of 928
BOB-TACH (POWER) BLOCK
Description
The power Bob-Tach block is an option that allows the

IMPORTANT
operator to hydraulically control the Bob-Tach levers for
mounting and dismounting the attachments. When repairing hydrostatic and hydraulic systems,
The power Bob-Tach is operated by a switch on the front parts clean. Always use caps and plugs on hoses,
console. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The power Bob-Tach block is mounted on the right side
of the machine in front of the engine on the backside of
the hydraulic gear pump. Figure 20-130-1

3
File has
WARNING expired. 1


support device. Failure to use an approved lift arm 3

W-2059-0598
2
P-66869
Publications. Lift and block the loader. (See Procedure Page 10-10-1.)
DANGER Raise the lift arms and install an approved lift arm
support device. (See Installing Page 10-20-1.)
Raise the operator cab. (See Raising Page 10-30-1.)
Open the rear door.

Replacing Hydraulic Fluid Page 10-120-2.)
P-90328
Remove the nut from the speed control linkage (Item 1)
AVOID DEATH and unplug the rear lights electrical connector (Item 2)
• Disconnecting or loosening any hydraulic [Figure 20-130-1].
can cause lift arms to drop. Remove the fuel fill bracket mounting bolts (Item 3)
• Keep out of this area when lift arms are raised [Figure 20-130-1].
D-1009-0409

325 of 928
BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-130-4
Figure 20-130-2
P-48227
Remove the four mounting bolts (Item 1) [Figure 20-130-
File has expired.

P-48230 4].

Installation: The harness connectors are marked with (34 - 38 N•m) torque.
Red or Black tie straps. Be sure the connectors with the

same color are connected. Remove the power Bob-Tach block.

Disconnect the power Bob-Tach harness from the
solenoid connectors (Item 1) [Figure 20-130-2] by the
hydraulic pump.
NOTE: There is an O-ring in-between the power Bob-
Tach block and the hydraulic pump. Inspect
and replace as needed.

4
P-48226

“DR” port fitting on the block.

power Bob-Tach cylinder rod end fitting on the block.

power Bob-Tach cylinder base end fitting on the block.
Disconnect the outlet hose (Item 4) [Figure 20-130-3]

from the fitting on top of the block.

326 of 928
Figure 20-130-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
File has expired. P-48115 spool (Item 3) [Figure 20-130-6].
Inspect the O-ring (Item 4) [Figure 20-130-6] on the plug

Clean the block (Item 1) [Figure 20-130-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-130-7

Remove the plug (Item 2) [Figure 20-130-5].
Assembly: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6

N•m) torque.
Publications.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-7].
Assembly: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.

327 of 928
Figure 20-130-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-130-10].
File has expired.

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-130-8]. will be altered.

Assembly: Oil the check valve and O-rings and tighten Figure 20-130-11
the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.

Figure 20-130-9
Publications.
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-130-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Assembly: Tighten the plug (Item 1) [Figure 20-130-11]
(Item 2) [Figure 20-130-9]. to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Inspect the O-rings and back up washers (Item 3)

[Figure 20-130-9] on the check valve and piston
assembly and replace as needed.

328 of 928
Figure 20-130-12 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second
File has expired. P-48664 solenoid coil (Item 2) [Figure 20-130-14].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-130-11] and [Figure 20-130-

12]. Figure 20-130-15

Assembly: Tighten the orifice screw (Item 2) [Figure 20-
130-12] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Publications.
Figure 20-130-13
1
2 P-48386
P-48127 Assembly: Tighten the solenoid stem to 20 - 25 ft.-lb.

(27,1 - 34 N•m) torque.
NOTE: This plug is a zero leak plug and should not be

removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-13].
Assembly: Tighten the solenoid valve stem nut to 15 -

45 in.-lb. (1,7 - 5,1 N•m) torque.

329 of 928
Figure 20-130-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-
File has expired.

P-48175 130-18].
Assembly: Tighten the screened orifice plug to 11 - 12

Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9 - 16,3 N•m) torque.
130-16].

Figure 20-130-19
Figure 20-130-17

Publications.
3
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 130-19] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
130-17].
Inspect the O-ring (Item 2) [Figure 20-130-19] and
NOTE: If the solenoid stem is damaged (Item 1) replace as needed.
inspect the armature assembly (Item 2) for
damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-130-
17].

330 of 928
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Description Figure 20-140-2
The front auxiliary hydraulic coupler block is the

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers 1
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm. 2
Removal And Installation 4

3
IMPORTANT P-34661
File has expired.

Figure 20-140-3

damage the system.
1

I-2003-0888

Figure 20-140-1
6 2
Publications.2
4
5 3
1
3 P-34760
Remove the male coupler (Item 1) [Figure 20-140-2] and

[Figure 20-140-3].
Assembly: Tighten the male coupler (Item 1) [Figure 20-
P-48464
140-2] and [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
Remove the drain coupler (Item 2) [Figure 20-140-2] and
[Figure 20-140-3].
Disconnect the auxiliary tubelines (Item 1) and drain
tubeline (Item 2) from the coupler block [Figure 20-140- Assembly: Tighten the drain coupler (Item 2) [Figure
1]. 20-140-2] and [Figure 20-140-3] to 37 ft.-lb. (50 N•m)
Remove the female coupler (Item 3) [Figure 20-140-2]
and [Figure 20-140-3].
1].
Assembly: Tighten the female coupler (Item 3) [Figure
20-140-2] and [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
Remove the fittings (Item 4) [Figure 20-140-2] and
[Figure 20-140-3] check the O-rings (Item 5) [Figure 20-
140-3] and replace as needed.
Remove the springs (Item 6) [Figure 20-140-3].

331 of 928
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-140-6
(CONT’D)

1
Figure 20-140-4
1
2
P-34665
Inspect the O-rings (Item 1) back-up O-rings (Item 2) for
File has expired.

P-34663
damage and replace as needed [Figure 20-140-6].
Figure 20-140-7
Inspect the O-ring (Item 1) [Figure 20-140-4] for damage


1

Figure 20-140-5
Publications. 1
P-34664
Inspect the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-140-7].
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-140-5] for damage and replace as
needed.

332 of 928
HIGH FLOW VALVE
Description WARNING
The high flow valve is an optional valve with a 12 volt
solenoid that diverts flow from a dedicated high flow Put jackstands under the front axles and rear corners
section on the gear pump. of the frame before running the engine for service.
The valve is in plumbed in series with the female coupler fall or move and cause injury or death.
side on the front auxiliary circuit. W-2017-0286
High Flow Relief Valve Testing Figure 20-150-2
Figure 20-150-1
1
2
File has expired.

2
1 P-76460C
Use updated files from Bobcat Start the engine and run at low idle RPM.
P-34480
Publications.
Press the HIGH FLOW button (Item 1) [Figure 20-150-
2].
procedure: The light (Item 2) [Figure 20-150-2] will be ON.


1.)
NOTE: Check the Main Relief Valve See MAIN RELIEF

VALVE on Page 20-30-1 for proper flow and
pressure before checking the High Flow Relief
Valve.
Connect the IN port of the hydraulic tester to the female

quick coupler (Item 1) [Figure 20-150-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-150-1] on the loader.
IMPORTANT
I-2024-0284

333 of 928
HIGH FLOW VALVE (CONT'D) High Flow Relief Valve Adjustment
High Flow Relief Valve Testing (Cont’d) NOTE: The high flow relief valve is located between
the control valve and the hydraulic reservoir.
Figure 20-150-3
Figure 20-150-4
Right
Steering
Lever
Control
1
File has expired.
P-31833
P-48231
• Push the front switch (Item 1) [Figure 20-150-3] to

give the front quick couplers a constant flow of fluid. If the relief pressure is not correct, stop the engine and

raise the operator cab. (See Raising on Page 10-30-1.)
• To release from continuous operation, press the front

switch (Item 1) [Figure 20-150-3] a second time.
Watch the flow meter on the hydraulic tester to make

Remove the high flow relief valve adjustment plug (Item
1) [Figure 20-150-4].
Publications.
sure the flow is correct. Increase the engine speed to full
RPM.

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 27 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 3100 PSI. At
approximately 3100 PSI the flow should start decreasing
rapidly until the pressure reaches 3250 - 3350 PSI. At
3250 - 3350 PSI the flow should be at 0 GPM. Turn the
restrictor control counter clockwise to free flow. Shut the
If the specs from above are reached, the high flow relief
valve is OK.
If the high flow relief pressure is not correct, stop the

engine and adjust the high flow relief valve. (See High
Flow Relief Valve Adjustment on Page 20-150-2.)

334 of 928
HIGH FLOW VALVE (CONT'D) Solenoid Testing
High Flow Relief Valve Adjustment (Cont’d) Figure 20-150-6
Figure 20-150-5
P9175

150-6]. Coil terminals do not have polarity. Correct
To increase the high flow relief valve PSI turn the screw resistance for the pressure relief coil is 7.5 ohm.
(Item 1) [Figure 20-150-5] clockwise a 1/4 turn and

recheck the high flow relief valve. (1/4 turn equals Replace the test meter with 12 volt power. You can see
approximately 200 PSI.) and hear the spool shift.
To decrease the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-150-5] counterclockwise a 1/4 turn
Publications.
and recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
NOTE: If the relief screw (Item 1) [Figure 20-150-5]

has been turned in 1/4 turn and the pressure
remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.

335 of 928
HIGH FLOW VALVE (CONT'D) Figure 20-150-8
Figure 20-150-7
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
File has expired.

P-48235 150-8] from the solenoid.
Figure 20-150-9


[Figure 20-150-7].
2
Publications.
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 25 -
28 ft.-lb. (34 - 38 N•m) torque.
The high flow valve is located between the control valve

1
and the hydraulic reservoir.
P-48238
IMPORTANT Mark all tubelines and hoses for correct installation.
When repairing hydrostatic and hydraulic systems, Disconnect and cap the hose (Item 1) [Figure 20-150-9]
clean the work area before disassembly and keep all from the pump outlet to the high flow valve.
tubelines and ports to keep dirt out. Dirt can quickly Disconnect and cap the hose (Item 2) [Figure 20-150-9]
damage the system. from the high flow valve to the pump inlet.
I-2003-0888

336 of 928
HIGH FLOW VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-150-11
Figure 20-150-10
2 1
1
2
P-48108

Remove the solenoid nut (Item 1) and solenoid (Item 2)
[Figure 20-150-11] from the solenoid valve.
Disconnect and cap the tubelines (Item 1) [Figure 20-
150-10] to the tilt cylinders. Assembly: Tighten to 4 - 6 ft.-lb. (5 - 8 N•m) torque.

Remove the two mounting bolts (Item 2) [Figure 20-150- Figure 20-150-12
10].
Publications.
(34 - 38 N•m) torque.
P-48109
Remove the solenoid valve (Item 1) [Figure 20-150-12]

from the valve.
Assembly: Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

337 of 928
HIGH FLOW VALVE (CONT'D) Figure 20-150-15
Figure 20-150-13
2 2
P-48112
1 Inspect the relief valve and replace the two O-rings (Item
File has expired.

P-48110 1) and washer (Item 2) [Figure 20-150-15].
Figure 20-150-16
Inspect O-rings (Item 1) and back-up washer (Item 2) on
the solenoid stem [Figure 20-150-13].

Assembly: Put oil on O-rings and back-up washer.

Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
Figure 20-150-14
Publications. 1
1
P-45469
Inspect the O-ring (Item 1) [Figure 20-150-16] on the

relief valve adjustment plug for damage and replace as
needed.
P-48111 Assembly: Tighten to 20 ft.-lb. (27,1 N•m) torque.
Remove the relief valve (Item 1) [Figure 20-150-14].
Assembly: Apply to oil to the O-rings and back-up

washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

338 of 928
HIGH FLOW VALVE (CONT'D)
Figure 20-150-17
Remove the check valve (Item 1) [Figure 20-150-17]

from the high flow valve.

Figure 20-150-18

Publications.
1
P-48114
Inspect the check valve, O-rings and back-up washers

for wear and replace as needed [Figure 20-150-18].
Assembly: Apply oil to the O-rings (Item 1) and back-up

washers (Item 2) [Figure 20-150-18]. Tighten to 30 - 35

339 of 928
File has expired.

Publications.

340 of 928
HYDROSTATIC SYSTEM
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 SAFETY &
MAINTENANCE
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 HYDROSTATIC
Sender Removal And Installation (S/N A3L529999 & Below) . . 30-40-3 SYSTEM
Sender Removal And Installation (S/N A3L530001 & Above) . . 30-40-5
Testing (S/N A3L529999 & Below). . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Testing (S/N A3L530001 & Above) . . . . . . . . . . . . . . . . . . . . . . 30-40-4 DRIVE
SYSTEM
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
File has expired.

Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .
30-60-3
30-60-1
30-60-1
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-7
Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-6

ELECTRICAL
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . . . . . 30-60-5 SYSTEM &
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . 30-60-4 ANALYSIS
HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Publications.
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-20-1
30-20-5
ENGINE
SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . 30-21-1 SPECIFICATIONS

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Removal And Installation (Left Side) . . . . . . . . . . . . . . . . . . . . . 30-21-2
Removal And Installation (Right Side) . . . . . . . . . . . . . . . . . . . . 30-21-5
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH

MANUAL CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-7
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-30-2

341 of 928
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC

CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-4
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-2
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Hydrostatic Pump Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
File has expired.

Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Replenishing / High Pressure Relief Valve Removal And Installation . . . 30-50-1
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-10
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Publications.
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-51-29
Hydraulic Controller Removal And Installation. . . . . . . . . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-7
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
TWO-SPEED VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD

ITEMS MAY VARY.

342 of 928
HYDROSTATIC SYSTEM INFORMATION
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
File has expired.

No drive on one side in both directions.
The loader does not move in a straight line.
2, 3, 4, 5
2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9

KEY TO CORRECT THE CAUSE
1.
2.
The hydrostatic pump relief / replenishing valves not seating.
The steering linkage needs adjustment.
3.
4.
5.
Publications.
The hydrostatic pump has damage.
The final drive chains are broken.
The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and/or incorrect steering drift compensation setting.

343 of 928
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.
File has expired.

Publications.

344 of 928
HYDROSTATIC DRIVE MOTOR Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

DANGER
the hydrostatic pumps.
In this system there is a case drain filter for each motor to

filter the excess low pressure oil before the oil enters the
hydraulic reservoir.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission tub which houses the drive chains. P-90328
The hydrostatic motors do not have an internal brake. AVOID DEATH

Inside the endcap of the hydrostatic motor, there is a tubeline, hose, fitting, component or a part failure
shuttle valve. The shuttle valve helps to keep the motor can cause lift arms to drop.
File has expired.

cool by mixing case drain oil with cooled low pressure oil
from the charge circuit. The shuttle valve is shifted by the
high pressure oil coming from the hydrostatic pumps. If
the shuttle valve sticks, a delay or lack of drive may or D-1009-0409
may not be felt in the controls and/or an overheated

hydrostatic motor will result.

Figure 30-20-1
Bobcat
Publications. Never work on a machine with the lift arms up unless
W-2059-0598
WARNING
P-68211 AVOID INJURY OR DEATH
explosion or fire.
W-2103-0508
Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-1.)

1.)
Remove the front and rear wheel/tire assemblies. (See

TIRE MAINTENANCE on Page 10-160-1.)

345 of 928
HYDROSTATIC DRIVE MOTOR (CONT’D) Mark the two hoses (Item 1) [Figure 30-20-3] before
disconnecting them from the hydrostatic motor for correct
Removal And Installation (Cont’d) installation.
Figure 30-20-2 Remove the two hoses (Item 1) [Figure 30-20-3] from
the hydrostatic motor.
Remove the drain hose and case drain filter (Item 2)

[Figure 30-20-3] from the hydrostatic motor.
NOTE: The hydraulic fitting (Item 3) [Figure 30-20-3]

on the hydrostatic motor must be tightened to
115 - 125 ft.-lb. (156 - 170 N•m) torque.
Figure 30-20-4
1
File has expired.

P-34004
Remove the four motor cover mounting screws (Item 1)

[Figure 30-20-2].

Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
P-68208
Remove the four hydrostatic motor mounting bolts (Item

When repairing hydrostatic and hydraulic systems, 1) [Figure 30-20-4] that fasten the hydrostatic motor to
clean the work area before disassembly and keep all the hydrostatic motor carrier.
tubelines and ports to keep dirt out. Dirt can quickly Installation: Tighten the hydrostatic motor mounting
damage the system. bolts to 90 - 100 ft.-lb. (122 - 136 N•m) torque.
I-2003-0888
Figure 30-20-3
2
1
P-68208

346 of 928
HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-5
1
2
Remove the hydrostatic motor from the access hole in

the loader frame [Figure 30-20-5].

Inspect hydrostatic motor O-ring (Item 1) and carrier

shaft seal (Item 2) [Figure 30-20-5].
Reverse the removal procedure to install the hydrostatic

motor.
Publications.

347 of 928
HYDROSTATIC DRIVE MOTOR (CONT’D)
16
14
20 3
15
14
19 14
16 18
3 13
18
19
17 3 5
12
File has expired. 11
10
5
9

8
Use updated files from Bobcat7 10
Publications. 6 3
3
5
4
2
1
PE2620T
Ref.Description Ref.Description
1.SHAFT, drive 11.GEROLER®
2.SEAL, face 12.PLATE, valve
3.O-RING 13.END CAP
4.FLANGE, mounting 14.POPPET
5.SEAL, square cut 15.SPRING
6.RING, back-up 16.PLUG
7.SPRING, belleville 17.BOLT
8.PLATE, outer balance 18.SLEEVE
9.PLATE, inner balance 19.SPRING
10.BALL 20.VALVE, shuttle

348 of 928
HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-7

1
IMPORTANT
damage the system.
I-2003-0888
P-68211
Figure 30-20-6
Remove the nine tie bolts (Item 1) [Figure 30-20-7] from
File has expired. the motor.
Figure 30-20-8
3
8

6
2
1
7
Drain the oil from the motor. 4
Seal all open ports and clean the motor with solvent.
P-68211
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-6]. Assembly:
1. Tighten the bolts to 45 - 55 ft.-lb. (61 - 75 N•m) torque

in the order shown in figure [Figure 30-20-8].
2. Re-tighten the bolts to 55 - 65 ft.-lb. (75 - 88 N•m)

torque in the order shown in figure [Figure 30-20-8].
NOTE: To prevent damage to the balance plate, never

lift or support the motor by the drive shaft.

349 of 928
Figure 30-20-9
3
1
2
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet
File has expired.

P-64267 (Item 3) [Figure 30-20-11] that make up the relief valve
assembly. Inspect for scoring on poppet. Ensure it can
operate freely in the bore. Inspect O-ring on plug.
Once the tie bolts have been removed and the motor
begins to separate, the drive shaft (Item 1) [Figure 30- Installation: Lubricate relief valve assembly with

20-9] can be removed. hydraulic oil and tighten plug to 260 in.-lb. (41 N•m)
torque.
Assembly: Install drive shaft before tightening tie bolts.
Figure 30-20-10
Figure 30-20-12
Publications. 1
2
1
P-68213
P-68212
Remove the plug (Item 1) and shuttle valve assembly

Lift and remove the end cap (Item 1) [Figure 30-20-10] (Item 2) [Figure 30-20-12]. Inspect for scoring on shuttle
from the motor. valve. Ensure it can operate freely in the bore. Inspect O-
ring on plug.
NOTE: Do not scratch or damage the surfaces of the
motor sections. Always put them on a soft Installation: Lubricate shuttle valve assembly with
surface. hydraulic oil and tighten plug to 260 in.-lb. (41 N•m)
torque.

350 of 928

3
Figure 30-20-13
2
P-64274
Remove and inspect/replace seal (Item 1) [Figure 30-20-
File has expired.P-39897 15].
Remove the Geroler® section as an assembly (Item 2)

Remove the remaining pieces to the shuttle valve [Figure 30-20-15].
assembly (Item 1) [Figure 30-20-13] from the inside of

the end cap. Inspect for broken or damaged parts. Parts NOTE: There are two check balls on the backside of
should move freely in bore. the Geroler® section. Be careful not to lose
Assembly: Apply grease to shuttle valve parts to help
hold in place during assembly.
these check balls. See [Figure 30-20-16]. Note
location of case drain hole (Item 3) [Figure 30-
20-15]. Align hole with other sections on
Publications.
Figure 30-20-14
hydrostatic motor.
2 3
P-39898
Remove and inspect/replace seals (Item 1) [Figure 30-

20-14].
Remove the valve plate (Item 2) [Figure 30-20-14].
Assembly: Apply grease to seals. Note location of case

drain hole (Item 3) [Figure 30-20-14]. Align hole with
other sections on hydrostatic motor.

351 of 928
HYDROSTATIC DRIVE MOTOR (CONT’D) Remove the balance plate (Item 3) [Figure 30-20-17].
Disassembly And Assembly (Cont’d) Assembly: Apply grease to seals. Note location of case
drain hole (Item 4) [Figure 30-20-17]. Align hole with
Figure 30-20-16 other sections on hydrostatic motor.
File has expired.

P-39901
Remove the two check balls (Item 1) [Figure 30-20-16]

from the Geroler®.

Assembly: Check for scoring and wear on the Geroler®

assembly. Apply grease to check balls to keep them from
falling out of there seats when assembling.
Publications.
NOTE: Care should be taken to keep the Geroler®
assembly together.
NOTE: If rollers are removed, put them back in their

original bore.
Figure 30-20-17
1
4
2
3
P-64268
Remove the center piece of the balance plate (Item 1)

[Figure 30-20-17].
Remove and inspect/replace the seal (Item 2) [Figure

30-20-17].

352 of 928

1
Figure 30-20-18
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-20].

Assembly: If the belleville spring is no longer cone
shaped, replace with new.
Remove the back up ring (Item 1) [Figure 30-20-18].
Figure 30-20-21

Assembly: Apply grease to back up ring. One side of the
back up ring is grooved to fit against the o-ring

underneath.
Figure 30-20-19
Publications.
1
1
P-64273
1
Carefully turn the mounting flange over and remove the

1 seal (Item 1) [Figure 30-20-21].
P-64271
Assembly: Replace the seal.
Remove and inspect/replace the seals (Item 1) [Figure

30-20-19] from the Geroler®.
Assembly: Apply grease to seals.

353 of 928
File has expired.

Publications.

354 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
In this system there is a case drain filter for filtering the

excess low pressure oil before the oil enters the hydraulic
reservoir.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing drive
loop return oil with cooled low pressure oil from the
charge circuit. The shuttle valve is shifted by the high
pressure oil coming from the hydrostatic pumps. If the
shuttle valve sticks, a delay or lack of drive may or may
not be felt in the controls and/or an overheated
hydrostatic motor will result.
File has expired.

There are two hydrostatic motors mounted to motor
carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

Publications.

355 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Remove the front and rear wheel/tire assemblies. (See
(CONT'D) TIRE MAINTENANCE on Page 10-160-1.)
Removal And Installation (Left Side) Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.)
DANGER Remove the linkage on foot control loaders. (See
Linkage Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-21-1
P-90328
AVOID DEATH
•
File has expired.
Keep out of this area when lift arms are raised 1 1

D-1009-0409

WARNING
Publications.
P-45492
Remove the motor cover mount bolts (Item 1) [Figure

Never work on a machine with the lift arms up unless 30-21-1].
support device. Failure to use an approved lift arm Remove the motor cover from the loader.
W-2059-0598
IMPORTANT
damage the system. 1
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P-73665
1.)
Raise the lift arms and install an approved lift arm Loosen the bolts (Item 1) [Figure 30-21-2] holding the
support device. (See Installing on Page 10-20-1.) lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
Raise the operator cab. (See Raising on Page 10-30-1.) below the motor.

356 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-5
(CONT'D)
Removal And Installation (Left Side) (Cont'd)

1
Figure 30-21-3
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

5] from the motor.
Installation: Tighten the mounting bolt to 210 ft.-lb. (285

N•m) torque.
Mark the hoses and tubeline for correct installation.

Figure 30-21-6
Disconnect both high pressure hydraulic tubelines (Item

1) [Figure 30-21-3] from the motor.
Disconnect the pre-warming tubeline (Item 2) [Figure 30- 1
Publications.
21-3] from the motor.
Figure 30-21-4
P-76146
1 Remove two mounting bolts (Item 1) [Figure 30-21-6]

from the motor.
3 Installation: Tighten the mounting bolts to 210 ft.-lb.

P-76159 (285 N•m) torque.
Remove the motor from the access hole in the loader

Mark the hose and tubelines for correct installation. frame.
Disconnect the case drain tubeline (Item 1) [Figure 30-

Disconnect the shift pressure tubeline (Item 2) [Figure

30-21-4] from the motor.

motor.

357 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
1
2
File has expired.

P-82716
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-7].

Inspect the hydrostatic motor carrier shaft seal (Item 2)
[Figure 30-21-7].
Figure 30-21-8
Publications.
1
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

shaft seal (Item 1) [Figure 30-21-8] in the mounting
flange cavity with the convex surface facing outward.
Reverse the removal procedure to install the two speed

hydrostatic motor.

358 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Raise the operator cab. (See Raising on Page 10-30-1.)
(CONT'D)
Remove the front and rear wheel/tire assemblies.
Removal And Installation (Right Side)
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.)
DANGER Remove the linkage on foot control loaders. (See
Linkage Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-21-1
P-90328
AVOID DEATH
•
File has expired.
• Keep out of this area when lift arms are raised 1 1

Publications.
WARNING P-45492
Remove the motor cover mount bolts (Item 1) [Figure

Never work on a machine with the lift arms up unless 30-21-1].
support device. Failure to use an approved lift arm Remove the motor cover from the loader.
W-2059-0598
IMPORTANT
damage the system. 1
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P-73665
1.)
Raise the lift arms and install an approved lift arm Loosen the bolts (Item 1) [Figure 30-21-2] holding the
support device. (See Installing on Page 10-20-1.) lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
below the motor.

359 of 928
(CONT'D)
Removal And Installation (Right Side) (Cont'd)

2
Figure 30-21-3
P-76127
2
Mark the hose and tubelines for correct installation.
File has expired.

P-76153 Disconnect the case drain tubeline (Item 1) [Figure 30-
Mark the hoses and tubeline for correct installation. Disconnect the shift pressure tubeline (Item 2) [Figure

30-21-5] from the motor.
Disconnect both high pressure hydraulic tubelines (Item

1) [Figure 30-21-3] from the motor.
Disconnect the pre-warming tubeline (Item 2) [Figure 30-

Figure 30-21-6
Figure 30-21-4
Publications. 1
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

6] from the motor.
P-76152
N•m) torque.
Mark the hose and tubelines for correct installation.
Disconnect the hoses (Item 1) [Figure 30-21-4] from the

motor.

360 of 928
(CONT'D)
Removal And Installation (Right Side) (Cont'd)

1
Figure 30-21-7
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

shaft seal (Item 1) [Figure 30-21-9] in the mounting
flange cavity with the convex surface facing outward.
Reverse the removal procedure to install the two speed

Remove two mounting bolts (Item 1) [Figure 30-21-7] hydrostatic motor.
from the motor.

Installation: Tighten the mounting bolts to 210 ft.-lb.
(285 N•m) torque.
Publications.
Remove the motor from the access hole in the loader
frame.
Figure 30-21-8
1
2
P-82716
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-8].
Inspect the hydrostatic motor carrier shaft seal (Item 2)

[Figure 30-21-8].

361 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
1. Shaft Seal 10
2. Mounting Flange 11
12 15
3. O-ring 13 14
4. Main Drive
5. Geroler® 16
6. O-ring
7. Valve Drive
8. Selector Plate
9. Gasket 17
9 18
10. Plug
11. Compression Spring
12. Compression Spring 8
13. Control Spool
14. Plug
15.
16.
17.
Cap Screw
Spool Housing
Plug
File has expired. 6
7
18. O-ring
19. Valve 5
20. Outer Balance Ring

21. Back-up Ring
22. O-ring
23.
24.
25.
Back-up Ring
Inner Balance Ring
Back-up Ring
3 4
26. O-ring 2
27.
28.
29.
Dowel Pin
Plug Publications.
Compression Spring
30. Plug
31. Valve Housing 33
32. Shuttle Valve Assembly
33. 12 Point Screw 28
34. Plug 32
35. Plug 31
36. Ball Seat
37. Ball
1
32
28
34
35
27
25 37 36
24 29
23
20 21 26 30
19
22
MS2315SA

362 of 928
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Drain the oil from the motor casing.
(CONT'D)
Place the mounting flange (Item 1) [Figure 30-21-11] on
Disassembly a protective material built up two and one-fourth inches to
allow room for main drive.
Figure 30-21-10
Figure 30-21-12
1
2
File has expired.

1
P-76142
P-73524
Remove the tubeline (Item 1) and relief valve (Item 2)

[Figure 30-21-10] from the motor.

Remove the nine mounting bolts (Item 1) [Figure 30-21-
12] from the valve housing.
Remove the fittings [Figure 30-21-10] from the motor.
Figure 30-21-11
Figure 30-21-13
Publications.
1
1
P-73529
P-73525
Remove the valve housing from the motor assembly and

NOTE: The motor is connected to the carrier for place on a clean work surface.
photo purposes [Figure 30-21-11]. Install a
mark on the valve housing, selector plate, Remove and discard the O-ring (Item 1) [Figure 30-21-
Geroler®, and mounting flange for correct 13].
assembly.
NOTE: Always protect any sealing surfaces. Any

scratches or marks will cause premature
failure.
NOTE: It is not recommended to remove any plugs

unless they are leaking.

363 of 928
(CONT'D)
Disassembly (Cont'd)
1
Figure 30-21-14
P-73532
Remove four compression springs (Item 1) [Figure 30-
File has expired.

P-73530
21-16] and inspect for damage.
Figure 30-21-17
Remove the dowel pin (Item 1) [Figure 30-21-14] and

inspect for wear. 1

Figure 30-21-15
Publications.
1
P-73534
Remove the outer balance ring (Item 1) [Figure 30-21-

17] from the valve housing. Tap the ring lightly with a
P-73531 wooden dowel or hammer handle if binding. Inspect the
face of the outer balance ring for wear.
Remove the inner balance ring (Item 1) [Figure 30-21-

15] from the valve housing and inspect face for wear.

364 of 928
(CONT'D)
Figure 30-21-18
P-73539
Remove and discard the back-up ring (Item 1) [Figure
File has expired.

1
P-73535
30-21-20] from the valve housing.
Figure 30-21-21
Remove and discard the O-ring and two back-up rings

(Item 1) [Figure 30-21-18] from the outer balance ring.

Figure 30-21-19
Publications. 1
P-73538
Remove and discard the O-ring (Item 1) [Figure 30-21-

21] from the valve housing.
P-73536
Remove the six compression springs (Item 1) [Figure

30-21-19] and inspect for damage.

365 of 928
(CONT'D)
Figure 30-21-22
1
1
P-76390
Remove the plug (Item 1) [Figure 30-21-24] from the
File has expired.

P-76387
valve housing.
Figure 30-21-25

valve housing.

Figure 30-21-23
Publications.
1
P-76389
1
Remove O-ring (Item 1) [Figure 30-21-25] on plug.
P-76389

366 of 928
(CONT'D)
Figure 30-21-26
1
2
1 P-76395

valve housing.
Figure 30-21-29
Remove the ball seat (Item 1) and ball (Item 2) [Figure

30-21-26] from the valve housing.

NOTE: To remove the ball seat, use a long allen
wrench to reach down into the valve housing.
Publications.
Figure 30-21-27
P-76389
P-76394A

367 of 928
(CONT'D)
Figure 30-21-30
1
1
1
1
1
1
1
1 P-76400
Remove the shuttle valve assembly (Item 1) [Figure 30-

1
File has expired.
P-76397
21-32] from the valve housing.
Figure 30-21-33
Remove the plugs (Item 1) [Figure 30-21-30] from both

sides of the valve housing.

Figure 30-21-31
Publications. 1
P-73526
1
Remove the valve (Item 1) [Figure 30-21-33] and inspect
for wear.
P-76389
Remove O-ring (Item 1) [Figure 30-21-31] on plugs.

368 of 928
(CONT'D)
Figure 30-21-34
2
1
P-73528
Remove and discard the O-ring (Item 1) [Figure 30-21-

36].
Remove the Geroler® assembly (Item 2) [Figure 30-21-

36] and inspect for wear.
Remove the selector plate (Item 1) [Figure 30-21-34]
and inspect for wear.

Figure 30-21-37

Figure 30-21-35
1
1
2
Publications.
P-73540
P-73543
Remove the main drive (Item 1) [Figure 30-21-37] and
inspect for wear.
Remove the valve drive (Item 1) [Figure 30-21-35] and
inspect for wear. Remove and discard the O-ring (Item 2) [Figure 30-21-
37].

369 of 928
(CONT'D)
Figure 30-21-38
1
1
P-73549
Mount the spool housing in a vise taking care to protect it
File has expired.

P-73546
from damage. Remove the spool retaining plug (Item 1)
[Figure 30-21-40].
NOTE: The plug is under slight spring pressure.

Remove the ten screws (Item 1) [Figure 30-21-38] from Remove the plug carefully.
the selector spool housing.

Figure 30-21-41
Figure 30-21-39
Publications.
2 1
1
P-73550
P-73547
Remove the two nested springs (Item 1) [Figure 30-21-

Remove and discard the gasket (Item 1) [Figure 30-21- 41] from the spool housing.
39].
Inspect the selector plate (Item 2) [Figure 30-21-39] for

wear.
NOTE: Clean any old thread sealer from the threaded

holes before assembly.

370 of 928
(CONT'D)
Figure 30-21-42
P-73552
Inspect the spool for wear or damage [Figure 30-21-44].
File has expired.

P-73523 Clean the spool and spool housing.
Figure 30-21-45
Inspect springs for wear and deformation [Figure 30-21-
42].

Figure 30-21-43
Publications. 1
P-73550A
1 Remove the plug (Item 1) [Figure 30-21-45] from the

P-73551 spool housing.
Remove the spool (Item 1) [Figure 30-21-43] from the

spool housing.

371 of 928
(CONT'D)
Figure 30-21-46
P-76389
1
Remove O-ring (Item 1) 23 on plug.
File has expired.

P-76389

Figure 30-21-47

Publications.
1
P-76438

spool housing.

372 of 928
(CONT'D)
Assembly
NOTE: Always use new O-rings and back up washers

during assembly and lubricate them with
clean petroleum jelly.
Figure 30-21-49
P-76389
Install new O-ring (Item 1) [Figure 30-21-51] on plug.
1

P-76389

Publications.
Figure 30-21-50 1
1
P-73550A
Install the plug (Item 1) [Figure 30-21-52] in the spool

housing with a light coat of oil.
Tighten the plug to 14 - 18 ft.-lb. (19 - 24 N•m) torque.
P-76438
Install the plug (Item 1) [Figure 30-21-50] in the spool

housing with a light coat of oil.

373 of 928
(CONT'D)
Assembly (Cont’d)
Figure 30-21-53
P-73549
1
Install the plug (Item 1) [Figure 30-21-55] with a light
File has expired.

P-73551
coat of oil.
Lubricate with hydraulic oil and insert the spool (Item 1)

[Figure 30-21-53] into the spool housing.

Figure 30-21-54
Publications.
P-73550
Install two nested springs (Item 1) [Figure 30-21-54] on

the spool shaft.

374 of 928
(CONT'D)
Assembly (Cont'd)
Figure 30-21-56
Apply Loctite® 262 Here
P-73774
Install the new gasket (Item 1) [Figure 30-21-57] onto

the selector plate.
Figure 30-21-58
NOTE: Before assembling the new gasket, the spool

housing, or the screws, remove any old

thread sealer from the threaded holes.

Put a VERY SMALL amount of Loctite® 262 into each of
the ten threaded holes of the selector plate. DO NOT put
Publications.
Loctite® on the screw threads [Figure 30-21-56].
Remove any trapped air from below the Loctite®. Wipe

any excess Loctite® from the selector plate surface.
NOTE: If too much Loctite® is applied and any

trapped air is not removed, it can pool in the
bottom of the threaded holes. This can
P-73776
prevent the screws from reaching full thread
contact and the correct torque may not be
reached. Install the ten screws [Figure 30-21-58] through the
spool housing and into the selector plate.
NOTE: Installing the screws can force some of the
Loctite® out of the holes and onto the selector
plate surface. If any Loctite® gets between the
new gasket and the selector plate it will create
a poor seal. Be sure to wipe excess Loctite®
from the surface.

375 of 928
(CONT'D)
Assembly (Cont'd)
2 1
Figure 30-21-59
10 4 1 6 7
3
P-73528
9 5 2 3 8 Install the Geroler® assembly (Item 1) with the groove in
File has expired.

MS2316S
the ring facing up. The star groove (Item 2) must be
facing up. Take care to line up the shuttle flow hole (Item
3) [Figure 30-21-61].
Tighten the ten screws to 70 - 80 in.-lb. (8 - 9 N•m) torque
using the sequence shown [Figure 30-21-59]. Lubricate and install the new O-ring (Item 4) [Figure 30-

21-61].
Repeat the tightening sequence to insure the correct
torque.
Put the selector plate assembly aside until needed for
Motor Timing
Figure 30-21-62
assembly. Publications.
installation. Let the Loctite® cure for six hours after
4
Figure 30-21-60
2
1
2
3
1
P-73544
Locate a tooth (Item 1) [Figure 30-21-62] that lines up

P-73540 with a star tip.
Install the main drive (Item 1) [Figure 30-21-60]. Ensure Install the valve drive (Item 2) [Figure 30-21-62] in the
it is supported from beneath until assembly is complete. Geroler®.
Lubricate and install the new O-ring (Item 2) [Figure 30- Mark the spline (Item 3) in the Geroler® star that is 11.25
21-60]. degrees counter-clockwise. Mark the corresponding
tooth (Item 4) on the small end of the valve drive that
NOTE: Two eight inch long steel rods installed in the aligns with the spline mark (Item 3) [Figure 30-21-62].
mounting bolt holes will help align the bolt
holes in each section of the motor during
assembly.

376 of 928
(CONT'D)
Assembly (Cont’d)
Motor Timing (Cont’d)
Figure 30-21-63
1
1
P-76389
2 Install new O-rings (Item 1) [Figure 30-21-65] on both
File has expired. plugs.
Figure 30-21-66
P-73527

Install the selector plate (Item 1) with the slotted holes

facing up. Be sure to line up the shuttle flow hole (Item 2)
[Figure 30-21-63].
1
1
Figure 30-21-64
Publications. 1
1
1
1
1
1 P-76400
3
Assemble the shuttle valve assembly (Item 1) [Figure
2 30-21-66] and insert into the valve housing.
P-73545
Install the valve (Item 1) [Figure 30-21-64] on the valve

drive. The round holes and four grooves must be facing
up.
Align any one of the four grooves (Item 2) in the valve

with the marked tooth on the valve drive (Item 3) [Figure
30-21-64].

377 of 928
(CONT'D)
Assembly (Cont’d)
Figure 30-21-67
2
1
P-76392
Install the ball (Item 1) and ball seat (Item 2) [Figure 30-
1
File has expired.
P-76397
21-69] into the valve housing.
Tighten the ball seat to 18 - 22 in.-lb. (2 - 3 N•m) torque.
Install the plugs (Item 1) [Figure 30-21-67] with a light NOTE: To install the ball seat, use a long allen
coat of oil on both sides of the valve housing.

wrench to reach down into the valve housing.

Figure 30-21-68
Figure 30-21-70
Publications.
1
P-76389
P-76394A

378 of 928
(CONT'D)
Assembly (Cont’d)
Figure 30-21-71
1
P-76395

1
coat of oil.
Install the plug (Item 1) [Figure 30-21-71] with a light Figure 30-21-74
coat of oil.

Figure 30-21-72
Publications.
1
P-76389
1
P-76389

379 of 928
(CONT'D)
Assembly (Cont’d)
Figure 30-21-75
1
1
P-73539
Lubricate and install the back-up ring (Item 1) [Figure 30-
File has expired.

P-76387
21-77] on the valve housing.
Figure 30-21-78

coat of oil.

Figure 30-21-76
1
Publications.
P-73536
Install the six compression springs (Item 1) [Figure 30-

21-78].
1
P-73538
Lubricate and install new O-ring (Item 1) [Figure 30-21-

76] on the valve housing.

380 of 928
(CONT'D)
Assembly (Cont’d)
1
Figure 30-21-79
P-73532
Install four compression springs (Item 1) [Figure 30-21-
File has expired.

1
P-73535
81].
Figure 30-21-82
Lubricate and install the O-ring and two back-up rings

(Item 1) [Figure 30-21-79] on the outer balance ring.

Figure 30-21-80
1
1
Publications.
P-73531
Install the inner balance ring (Item 1) [Figure 30-21-82]

in the valve housing.
P-73534
Install the outer balance ring (Item 1) [Figure 30-21-80]

in the valve housing.

381 of 928
(CONT'D)
Assembly (Cont’d)
1
Figure 30-21-83
P-73773
Install the valve housing (Item 1) [Figure 30-21-85] on
File has expired.

P-73529
the assembly taking care to maintain correct alignment.
NOTE: Be careful when installing the valve housing

so the balance rings and springs remain in
Install the dowel pin (Item 1) [Figure 30-21-83]. position.

Figure 30-21-84 Figure 30-21-86
1
Publications.
P-73529
P-73525
Lubricate and install new O-ring (Item 1) [Figure 30-21- Verify correct assembly with the marks that were made
84]. prior to disassembly [Figure 30-21-86].

382 of 928
(CONT'D)
Assembly (Cont'd)
Figure 30-21-87
2
P-76142
Install the relief valve (Item 1) and tubeline (Item 2) and

[Figure 30-21-89] on the motor.
Install the fittings [Figure 30-21-89] on the motor.
Lubricate the nine bolts (Item 1) [Figure 30-21-87] with

hydraulic oil and install them into the assembly. Hand

tighten the bolts.

Figure 30-21-88
Publications. 5 8
2 3
7 6
4 9
1 MS2317S
Tighten the nine bolts to 50 - 70 ft.-lb. (68 - 95 N•m)

torque using the sequence shown in [Figure 30-21-88].
Perform a final tightening of the nine bolts to 110 ft.-lb.

(149 N•m) torque using the same sequence shown in
[Figure 30-21-88].

383 of 928
File has expired.

Publications.

384 of 928
HYDROSTATIC MOTOR CARRIER (SINGLE AND Figure 30-30-2
TWO-SPEED WITH MANUAL CONTROLS)
Single / Two-Speed
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission case.
2
The hydrostatic motor carrier contains a shaft that rotates
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
1
P-82710
A brake disk is installed on each hydrostatic motor
carrier. The brake disk is mounted to the shaft in the
motor carrier. The motor carrier hydrostatic motor mounting holes (Item
File has expired.

The hydrostatic motor carriers are made to fit on both the
right or left hand side of the loader. There are two sets of
1) [Figure 30-30-1] and [Figure 30-30-2] are the only
difference between the single, two-speed and single /
two-speed motor carriers with manual controls. The
mounting holes on each hydrostatic motor carrier to disassembly and assembly procedures are the same.
fasten the hydrostatic motors. One set for the left hand

side and another set for the right hand side of the loader. The single / two speed motor carrier has a notch (Item 2)
[Figure 30-30-2] removed from one side of the carrier.
Figure 30-30-1
Publications.
Single Speed Two-Speed
1 1
P-73920
P-68214

385 of 928
TWO-SPEED WITH MANUAL CONTROLS) (CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

DRIVE MOTOR on Page 30-20-1.) or (See
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) on Page
30-21-1.)
WARNING P-82711
Drill a 0.125 in. (3 mm) hole in the motor carrier seal

File has expired.
[Figure 30-30-4].
Figure 30-30-5
• Flying debris or loose material is present.


Figure 30-30-3
W-2019-0907
Publications.
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-30-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-30-3] is

located on the outside of the motor carrier shaft.

386 of 928
Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-6
1 2
P-82716
Photo [Figure 30-30-8] shows the motor carrier seal

correctly installed.
Inspect the O-ring (Item 1) [Figure 30-30-8] and replace

if needed.
Installation: Install a new seal over the motor carrier

NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 2) [Figure 30-30-8]
Figure 30-30-7 located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
Publications. motor can leak into the chaincase.
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-30-7].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-30-7].

387 of 928

2
WARNING 1

W-2059-0598
P-54227
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-30-
File has expired.

1.)
9]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or
(See BRAKE (TWO-SPEED) on Page 40-11-1.)
Remove the six motor carrier mounting bolts (Item 2)

Raise the loader operator cab. (See Raising on Page 10- [Figure 30-30-9] from the inside of the chaincase.

30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing And
Replacing Oil on Page 10-130-1.)
125 - 140 ft.-lb. (170 - 190 N•m) torque.
Figure 30-30-10
Publications.
Remove the engine speed control. (See Removal And
1
Remove the control panel. (See Removal And Installation
on Page 50-100-2.) or (See Removal And Installation on
Page 50-101-1.)
2
Remove the lift arm bypass control valve. (See Removal
Remove the traction lock assembly. (See Removal And

Remove the center chaincase cover. (See Center Cover

Removal And Installation on Page 40-30-2.) P-54226
Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-1.) For ease of removal, fasten the front drive chain
(previously removed) to the chaincase as shown (Item 1)
Remove the front axle and sprocket. (See Axle Sprocket [Figure 30-30-10].
And Bearings Removal And Installation on Page 40-20-
4.) Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-30-
Remove the hydrostatic motor. (See HYDROSTATIC 10] from the sprocket.
30-21-1.)

388 of 928
HYDROSTATIC MOTOR CARRIER (SINGLE AND
Figure 30-30-11
File has expired.

P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

30-11].

Installation: Ensure both motor carrier sealing surface
and transmission sealing face is clean and apply
polyurethane sealant to both surfaces.
Publications.
Figure 30-30-12
P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-30-12] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

389 of 928
SINGLE SPEED
1
5
2
6
3
7
8
4
File has expired.

TWO SPEED
&
SINGLE / TWO SPEED
TWO-SPEED
Publications. 6
5
1
2
7
8 3
4
P-76446
P-76445
1.SHAFT 5.RACE
2.BEARING 6. BEARING
3.RACE 7. SNAP RING
4.HOUSING 8. SEAL

390 of 928
Figure 30-30-13
3.000 in. O.D. Diameter

(76,2 mm)
2.530 in. I.D. Diameter

(64,26 mm)
7.000 in.
Length P-39816
(177,8 mm)
Put the motor carrier in the hydraulic press as shown
File has expired. MC-2102

[Figure 30-30-15].
Use 2-1/4 in. driver tool and press the sprocket shaft out
of the motor carrier housing [Figure 30-30-15].
It is necessary to locate or fabricate a press tool for this

procedure. Refer to [Figure 30-30-13] for the correct NOTE: The outer bearing will now be free from the
dimensions of the tool needed. sprocket shaft.
Figure 30-30-14 Figure 30-30-16
Publications.
2
1
P-82709 P-4365
A hydraulic press, slide hammer with puller end and snap Remove the housing from the press and install a bearing
ring pliers are also recommended for this procedure. puller (Item 1) [Figure 30-30-16] on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal Put the assembly in the hydraulic press. Use the same
Removal And Installation on Page 30-20-2.) tool driver and remove the bearing (Item 2) [Figure 30-
30-16] from the shaft.
Remove the snap ring (Item 1) [Figure 30-30-14] from
the motor carrier shaft using the snap ring pliers.

391 of 928
Figure 30-30-17
P-39820
Put the motor carrier housing in the press as shown
File has expired.

P-39817
[Figure 30-30-19].
Use 4-5/16 in. driver tool and press the new inner bearing
race into the motor carrier housing [Figure 30-30-19].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30-

Press the bearing race in until it is fully seated in the
30-17] facing up. carrier housing.
Install the slide hammer with puller end (Item 2) [Figure
30-30-17] on the bottom side of the bearing race.
Figure 30-30-20
Publications.
Remove the bearing race from the carrier housing
[Figure 30-30-17].
Figure 30-30-18
P-39819
Turn the motor carrier housing over as shown [Figure

30-30-20].
P-39818 Use 4-5/16 in. driver tool and press the new outer
bearing race into the motor carrier housing [Figure 30-
30-20].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-30-18]. Press the bearing race in until it is fully seated in the
carrier housing.
Use a 3-7/8 in. driver tool and press the outer bearing
race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

392 of 928
Figure 30-30-21
File has expired.

Put the motor carrier housing (Item 1) [Figure 30-30-22]
Publications.
P-4366
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 in. driver Put the outer bearing over the end of the sprocket shaft
tool, install the new inner bearing (Item 2) [Figure 30-30- and press the bearing on with the press tool and driver
21] on the sprocket shaft as shown. tool [Figure 30-30-22].
Remove the press and drive tools from the sprocket Remove the press and driver tools from the sprocket
shaft. shaft.

393 of 928
Figure 30-30-23
File has expired.

P-82708
Put the snap ring (Item 1) [Figure 30-30-23] over the end P-4375
of the sprocket shaft.

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-30-
NOTE: Use the snap ring pliers to spread the snap
ring so it will fit over the sprocket shaft.
25] and install the shaft seal.
Publications.
Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-30-23] over the sprocket.
Figure 30-30-26
Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-30-24
P-39821
1
Use a rubber mallet [Figure 30-30-26], tap down on the

P-82707 cluster shaft.
Put a new shaft seal (Item 1) [Figure 30-30-24] on the

sprocket shaft.

394 of 928
Figure 30-30-27
File has expired.

Use updated files from Bobcat N-15087
Publications.
Install a dial indicator as shown in Photo [Figure 30-30-
27].
Use a pry bar (Item 1) [Figure 30-30-27] to lift the carrier

shaft and read the end play on the dial indicator.
The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).

395 of 928
File has expired.

Publications.

396 of 928
TWO-SPEED WITH SJC CONTROLS)
Description
Single Speed Two-Speed
The hydrostatic motor carrier is the mating connection
from the hydrostatic drive motor to the transmission 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 1 1

the chain case oil from the hydrostatic motor case drain P-73920
P-68214
oil.
Loaders equipped with Selectable Joystick Controls Figure 30-31-2
File has expired.

(SJC) use a speed sensor installed in the motor carrier
housing. The speed sensor senses a disk that is fixed to
the shaft in the motor carrier. If the loader does not have
Single / Two-Speed
(SJC), a plate covers the hole where the sensor would

be.

A brake disk is installed on each hydrostatic motor 2

carrier. The brake disk is mounted to the shaft in the
motor carrier.
Publications.
The hydrostatic motor carriers are made to fit on both the
right or left hand side of the loader. There are two sets of
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
1
side and another set for the right hand side of the loader. P-82710
The motor carrier hydrostatic motor mounting holes (Item

1) [Figure 30-31-1] and [Figure 30-31-2] are the only
difference between the single, two-speed and single /
two-speed motor carriers with SJC controls. The
disassembly and assembly procedures are the same.
The single / two speed motor carrier has a notch (Item 2)

[Figure 30-31-2] removed from one side of the carrier.

397 of 928
TWO-SPEED WITH SJC CONTROLS) (CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

30-21-1.)
WARNING P-82711
Drill a 0.125 in. (3 mm) hole in the motor carrier seal

File has expired.
[Figure 30-31-4].
Figure 30-31-5


Figure 30-31-3
W-2019-0907
Publications.
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-31-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-31-3] is

located on the outside of the motor carrier shaft.

398 of 928
Shaft Seal Removal And Installation (Cont’d)
Figure 30-31-6
2 1
P-82716
Photo [Figure 30-31-8] shows the motor carrier seal

correctly installed.
Inspect the O-ring (Item 1) [Figure 30-31-8] and replace

if needed.
Installation: Install a new seal over the motor carrier

NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 2) [Figure 30-31-8]
Figure 30-31-7 located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
Publications. motor can leak into the chaincase.
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-31-7].

399 of 928
WARNING 2

support device can allow the lift arms or attachment 1
W-2059-0598
P-39781
support device. (See Installing on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-31-
File has expired.

1.)
9]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or
(See BRAKE (TWO-SPEED) on Page 40-11-1.)
Remove the six motor carrier mounting bolts (Item 2)

Raise the loader operator cab. (See Raising on Page 10- [Figure 30-31-9] from the inside of the chaincase.

30-1.)
125 - 140 ft.-lb. (170 - 190 N•m) torque.
Figure 30-31-10
Publications.
1
on Page 50-100-2.)
Remove the lift arm bypass control valve. (See Removal 2



P-54226
Remove the front chaincase cover. (See Front Cover
For ease of removal, fasten the front drive chain
Remove the front axle and sprocket. (See Axle Sprocket (previously removed) to the chaincase as shown (Item 1)
And Bearings Removal And Installation on Page 40-20- [Figure 30-31-10].
4.)
Tip the end of the sprocket toward the rear of the loader
Remove the hydrostatic motor. (See HYDROSTATIC and remove the rear drive chain (Item 2) [Figure 30-31-
DRIVE MOTOR on Page 30-20-1.) or (See 10] from the sprocket.
30-21-1.)

400 of 928
Figure 30-31-11
File has expired.

P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

31-11].

Installation: Ensure both motor carrier sealing surface
and transmission sealing face is clean and apply
polyurethane sealant to both surfaces.
Publications.
Figure 30-31-12
P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-31-12] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

401 of 928
SINGLE SPEED
1
6
2
7 3
4
8
9
5
File has expired.

TWO SPEED

&
TWO-SPEED
SINGLE / TWO SPEED
Publications.
7
6
1
2
8 4 3
9
5
P-76448
P-76447
1.SHAFT 6.RACE
2.SENSOR DISC 7.BEARING
3.BEARING 8.SNAP RING
4.RACE 9.SEAL
5.HOUSING

402 of 928
Figure 30-31-13
3.000” O.D. Diameter

(76,2 mm)
2.530” I.D. Diameter

(64,26 mm)
7.000”
Length
P-39816
(177,8 mm)
Put the motor carrier in the hydraulic press as shown

[Figure 30-31-15].
Use 2-1/4 in. driver tool and press the sprocket shaft out
of the motor carrier housing [Figure 30-31-15].
It is necessary to locate or fabricate a press tool for this
procedure. Refer to [Figure 30-31-13] for the correct

NOTE: The outer bearing will now be free from the
dimensions of the tool needed. sprocket shaft.
Figure 30-31-14 Figure 30-31-16
Publications.
1
P-82709
P-76462
A hydraulic press, slide hammer with puller end and snap Remove the housing from the press and install a bearing
ring pliers are also recommended for this procedure. puller on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal Put the assembly in the hydraulic press. Use the same
Removal And Installation on Page 30-21-2). tool driver and remove the bearing (Item 1) [Figure 30-
31-16] from the shaft.
the motor carrier shaft using the snap ring pliers.

403 of 928
Figure 30-31-17
P-39820
Put the motor carrier housing in the press as shown
File has expired.

P-39817
[Figure 30-31-19].
Use 4-5/16 in. driver tool and press the new inner bearing
race into the motor carrier housing [Figure 30-31-19].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30-

Press the bearing race in until it is fully seated in the
31-17] facing up. carrier housing.
Install the slide hammer with puller end (Item 2) [Figure
30-31-17] on the bottom side of the bearing race.
Figure 30-31-20
Publications.
Remove the bearing race from the carrier housing
[Figure 30-31-17].
Figure 30-31-18
P-39819
Turn the motor carrier housing over as shown [Figure

30-31-20].
P-39818 Use 4-5/16 in. driver tool and press the new outer
bearing race into the motor carrier housing [Figure 30-
31-20].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-31-18]. Press the bearing race in until it is fully seated in the
carrier housing.
Use a 3-7/8 in. driver tool and press the outer bearing
race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

404 of 928
Figure 30-31-21
2 1
P-76462
Use the fabricated press tool and 3.0 in. driver tool, install

the new inner bearing (Item 1) [Figure 30-31-23] on the
sprocket shaft as shown.
Remove the press and drive tools from the sprocket

Figure 30-31-22 shaft.

1
Publications.
P-76466
Install the sensor disc (Item 1) on the shaft (Item 2)

[Figure 30-31-21] and [Figure 30-31-22].
NOTE: Protrusion on disc to be aligned with pin area

on sprocket.

405 of 928
Figure 30-31-24
1 P-82708
Put the snap ring (Item 1) [Figure 30-31-25] over the end
File has expired. of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap

ring so it will fit over the sprocket shaft.

Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-25] over the sprocket.
Use updated files from Bobcat Press the snap ring on until it snaps into the groove on
the shaft.
Publications. P-4371 Figure 30-31-26
Put the motor carrier housing (Item 1) [Figure 30-31-24]

over the sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft
and press the bearing on with the press tool and driver
Remove the press and driver tools from the sprocket

shaft. 1
P-82707
Put a new shaft seal (Item 1) [Figure 30-31-26] on the

sprocket shaft.

406 of 928
Figure 30-31-27
P-76467
1 Install a dial indicator as shown in Photo [Figure 30-31-
File has expired. 29].
Use a pry bar (Item 1) [Figure 30-31-29] to lift the carrier

shaft and read the end play on the dial indicator.

The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).
Publications.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-31-
27] and install the shaft seal.
Figure 30-31-28
P-76463
Use a rubber mallet [Figure 30-31-28], tap down on the

cluster shaft.

407 of 928
File has expired.

Publications.

408 of 928
CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender can be located on the

charge filter housing mounted next to the blower housing
or on the hydraulic fan motor depending on the style of
File has expired.

fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

Publications.

409 of 928
CHARGE PRESSURE (CONT’D)
Testing (S/N A3L529999 & Below)

WARNING
Figure 30-40-1
W-2059-0598
2 4
1 3 Place the loader on jackstands. (See Procedure on Page
10-10-1.)
File has expired.

P-43196
Figure 30-40-3
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic

gauge (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5)
(Item 4) [Figure 30-40-1].

Figure 30-40-2
Publications. 1
1
P-66884
3
2
Remove the hydraulic tubeline (Item 1) [Figure 30-40-8]
from the charge pressure sender adapter fitting and the
hydraulic control valve.
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-40-2].
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to

the adapter fitting. Tighten all connections.

410 of 928
CHARGE PRESSURE (CONT’D) Sender Removal And Installation (S/N A3L529999 &
Below)
Testing (S/N A3L529999 & Below) (Cont’d)
Figure 30-40-5
Figure 30-40-4
1
3 2
File has expired.

P-66884
P-68256
Disconnect the charge pressure sender connector (Item

Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4]. 1) [Figure 30-40-5] from the sender.

Install a hose (Item 2) [Figure 30-40-4], to replace the Remove the sender (Item 2) [Figure 30-40-5] from the
tubeline that was there. adapter fitting.
Install the hose (Item 3) [Figure 30-40-4], that is
attached to the pressure gauge, to the T fitting.
Installation: Tighten the charge pressure sender to 7.4 -
8.1 ft.-lb. (10 - 11 N•m) torque.
Publications.
Tighten the hydraulic fittings.
NOTE: Inspect the O-ring on the sender and replace
if necessary before installation.
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 140° F.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 140° F is 335 - 385
PSI (23,1 - 26,5 bar) with the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 335 - 395
PSI (23,1 - 27,2 bar) at 140° F (60° C) fluid @
High idle.

411 of 928
CHARGE PRESSURE (CONT’D)
Testing (S/N A3L530001 & Above)

WARNING
Figure 30-40-6
W-2059-0598
2 4
1 3 Place the loader on jackstands. (See Procedure on Page
10-10-1.)
File has expired.

P-43196
Figure 30-40-8
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic

gauge (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5)
(Item 4) [Figure 30-40-6].

Figure 30-40-7
1
Publications. 1
P-76947
3
2
Disconnect the hydraulic hose (Item 1) [Figure 30-40-8].
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-40-7].
Connect the hydraulic hose (Item 3) [Figure 30-40-7] to

the adapter fitting. Tighten all connections.

412 of 928
CHARGE PRESSURE (CONT’D) Sender Removal And Installation (S/N A3L530001 &
Above)
Testing (S/N A3L530001 & Above) (Cont’d)
Figure 30-40-10
Figure 30-40-9
2
2
File has expired.

P-76947
P-76948
Disconnect the wire (Item 1) [Figure 30-40-10] from the

Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-9]. sender.

Install the hose (Item 2) [Figure 30-40-9], that was Remove the sender (Item 2) [Figure 30-40-10] from the
disconnected from the motor, to the T fitting. motor.
Install the hose (Item 3) [Figure 30-40-9], that is
attached to the pressure gauge, to the T fitting.
Installation: Tighten the charge pressure sender to 7.4 -
8.1 ft.-lb. (10 - 10,9 N•m) torque.
Publications.
Tighten the hydraulic fittings. NOTE: Inspect the O-ring on the sender and replace
if necessary before installation.
Connect the remote start tool. (See Remote Start Tool -
MEL1563 on Page 10-60-1.)
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 140° F.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 140° F is 335 - 385
PSI (23,1 - 26,5 bar) with the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 335 - 385
PSI (23,1 - 26,5 bar) at 140° F (60° C) fluid @
High idle.

413 of 928
CHARGE PRESSURE (CONT’D) Figure 30-40-12
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-40-11 Remove the plug, spring and poppet [Figure 30-40-12].
1 File has expired. Check the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.

Figure 30-40-13
Publications.
N-19567
If the charge pressure is not correct loosen the charge 1

relief valve plug (Item 1) [Figure 30-40-11].
Assembly: Always use a new O-ring. Tighten the plug to

30 - 50 ft.-lb. (41 - 68 N•m) torque. N-19568
There are several different thickness of the shims (Item

1) [Figure 30-40-13] and are used to adjust the charge
pressure.
NOTE: 0.010 in. (0,254 mm) is 8 PSI (0,55 bar)

increase in pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).

414 of 928
CHARGE PRESSURE (CONT'D) Figure 30-40-15
Adjusting (Cont’d)
SJC Machines
IMPORTANT
damage the system.
P-64435
I-2003-0888
Figure 30-40-14 Check the poppet and spring for wear or damage.
File has expired. Inspect the seat inside the hydrostatic pump case for
wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-15] used to adjust the charge pressure.

1 NOTE: 1.0 mm shim (Item 1) [Figure 30-40-15] = 43.5
PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
Publications. decreases charge pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-14].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

30 - 50 ft.-lb. (41 - 68 N•m) torque.

415 of 928
File has expired.

Publications.

416 of 928
HYDROSTATIC PUMP Figure 30-50-2
Description
1
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic drive motors.
The pump flow and direction are controlled by two hand
levers, one for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement 2
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure P-66670
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump contains the charge pressure Remove the replenishing/high pressure relief valve (Item
File has expired.

relief. The charge pressure relief is adjustable with
shims.
1) [Figure 30-50-2] from the pump.
Assembly: Tighten the plug to 30 - 50 ft.-lb. (41 - 68

The hydrostatic pump is located in the center of the N•m) torque.
mainframe mounted to the engine flywheel housing.

Check for damage and replace as needed.
Replenishing / High Pressure Relief Valve Removal
And Installation
Figure 30-50-1
Check the O-ring (Item 2) [Figure 30-50-2] for damage
Publications. 1
If the replenishing/high pressure relief valve must be
replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing/high

pressure relief valve is 5000 PSI (345 bar).
N-19565
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-50-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

417 of 928
HYDROSTATIC PUMP (CONT’D) Figure 30-50-4

1
IMPORTANT
2
damage the system.
I-2003-0888
P-34567B
Remove the engine/hydrostatic pump assembly from the
loader. (See Engine Removal And Installation on Page
70-10-9.) Loosen the drive belt tensioner (Item 1) [Figure 30-50-4]
File has expired.

Remove the control handle linkage from the hydrostatic
pump. (See Linkage Removal And Installation on Page
and remove the drive belt.
Remove the hydrostatic pump drive pulley mounting nut

50-100-7.) (Item 2) [Figure 30-50-4] and washer.

Remove the hydraulic pump from the hydrostatic pump. Installation: Tighten the pump pulley mounting nut to
(See HYDRAULIC PUMP (STANDARD) on Page 20-60- 175 - 200 ft.-lb. (237 - 271 N•m) torque.
1.)
Figure 30-50-3
Publications.
1 P-34567A
P-34568
Install a puller on the hydrostatic pump drive pulley and

Remove the hydrostatic pump mounting bolt (Item 1) remove the pulley from the pump shaft [Figure 30-50-5].
[Figure 30-50-3] and washer(s).
Installation: Tighten the mounting bolt to 90 - 100 ft.-lb.

(125 - 135 N•m) torque.
NOTE: Mounting bolt (Item 1) [Figure 30-50-3] is a

special purpose bolt, replace with genuine
Bobcat parts only.

418 of 928
HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Start Up
Removal And Installation (Cont’d) Follow the hydraulic pump start up procedure. (See
Hydraulic Pump Start Up on Page 20-60-8.)
Figure 30-50-6
WARNING
1
explosion or fire.
W-2103-0508
File has expired.

P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-50-6] before installing the pump drive

pulley.

Figure 30-50-7
Publications.
1
P-28850
Hold the nut (Item 1) [Figure 30-50-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-50-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65 - 70

Reverse the removal procedure to install the hydrostatic

pump assembly.

419 of 928
HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9
8
14.
15.
16.
Wear Plate
Piston Assembly
Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16
13
21.
22.
23.
Gasket
Poppet
Shim
Publications. 2
17
12
17
15 24.
25.
Replenishing/High
Pressure Relief Valve
Coupler
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

420 of 928
Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13.
14.
15.
Retainer
Piston Assembly
Wear Plate
File has expired. 7 4
3 9
16. Swash Plate
17. Housing 10

18. Seal
10 8
19. Cover
20.
21.
22.
Shaft
Snap Ring
Dust Seal
13 11
13
10
23.
Publications.
Piston Retainer
23
8
12
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

421 of 928
HYDROSTATIC PUMP (CONT'D) Figure 30-50-10
Disassembly
1
Figure 30-50-8
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-50-10].
File has expired.

N-19550
Check the valve plate for wear. (Both Sides.)
Remove the four bolts (Item 1) [Figure 30-50-8] from the

pump housing end cap.

Figure 30-50-9

Publications.
1
N-19551
Remove the pump housing end cap (Item 1) [Figure 30-

50-9].
Remove the gasket (Item 2) [Figure 30-50-9].

422 of 928
1
Figure 30-50-11
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure
File has expired.N-17194 30-50-13] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-50-13] for wear

Check the valve plate locating pin (Item 1) [Figure 30-50- and replace the rotating group as needed.
11] for wear and replace if needed.

Figure 30-50-14
Check the needle bearing (Item 2) [Figure 30-50-11] for

wear and replace if needed.
Figure 30-50-12
1
Publications.
1
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-50-

N-17197 14] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-50-12]

from the pump.

423 of 928
Figure 30-50-15
1
3 3
2
3 3 2 1
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)
File has expired.

N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-50-17].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-50-18
2) for wear and replace as needed [Figure 30-50-15].

Remove the four pins (Item 3) [Figure 30-50-15] from the
cylinder block.
Check the cylinder block for wear and replace as needed.
1
Publications.
Check pins (Item 3) [Figure 30-50-15] to see if they are
all the same length.
Figure 30-50-16
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-50-18] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-50-16] from

the pump housing.

424 of 928
Figure 30-50-19 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-50-21] for
File has expired. N-17240 wear and replace if needed.
Figure 30-50-22
the pump housing and remove the driveshaft and bearing

from the housing.

Figure 30-50-20
Publications.
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-50-22]
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

425 of 928
Figure 30-50-23
2
2
1 1
1 N-17246
Remove the four mount bolts (Item 1) from the pump
File has expired.

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-50-25].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-50-26
from the pump housing [Figure 30-50-23].

Figure 30-50-24

Publications. 1
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-50-

26].
Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-24] for wear and replace as needed.

426 of 928
Figure 30-50-27
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)
File has expired. N-17250 [Figure 30-50-29] and replace as needed.
Figure 30-50-30
Inspect the seal (Item 1) [Figure 30-50-27] in the upper
trunnion cover and replace if needed.

Figure 30-50-28

Publications. 1
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-50-30] from
the swash plate shaft.
Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-28] from the pump housing.

427 of 928
Assembly
Figure 30-50-31
N-17252
Install the swash plate and bearing into the pump
File has expired.

N-17252 housing [Figure 30-50-33].
Tilt the swash plate (Item 1) [Figure 30-50-31] and

remove the swash plate and lower bearing from the

pump housing.

Figure 30-50-32
Publications. 1
N-17253
Install the lower bearing (Item 1) [Figure 30-50-32] on

the swash plate.

428 of 928
Assembly (Cont'd)
Figure 30-50-34
1 1
2
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-50-36]
File has expired. N-17249 and cover.
Figure 30-50-37
Install the tapered bearing (Item 1) [Figure 30-50-34] on
the swash plate shaft.

Figure 30-50-35

Publications. 1
2
N-17246
3
Install the linkage bracket (Item 1) [Figure 30-50-37] and
N-17248 the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 -
30 N•m) torque.
Install the bearing race (Item 2) and O-ring (Item 3) as

shown in [Figure 30-50-34] and [Figure 30-50-35].

429 of 928
Assembly (Cont'd)
Figure 30-50-38
2
N-17243
Align the marks on the lower trunnion cover and pump
File has expired.

N-17245 housing as shown in [Figure 30-50-40].
Install the four mounting bolts and tighten to 18 - 22 ft.-lb.

Figure 30-50-39 (24 - 30 N•m) torque.

Figure 30-50-41

1
Publications.
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-50-38] and O-
ring (Item 2) [Figure 30-50-38] at the lower trunnion as
shown in [Figure 30-50-39]. Install the snap ring (Item 1) [Figure 30-50-41] on the
pump shaft.

430 of 928
Assembly (Cont'd) 1 1
Figure 30-50-42
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-50-44]
File has expired. N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the bearing and snap ring (Item 1) [Figure 30-50- and install into the ball guide retainer (Item 3) [Figure 30-
42] on the pump shaft. 50-44].

Figure 30-50-43 Figure 30-50-45
Publications.
1
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
50-43]. 30-50-45] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-50-43].

431 of 928
Assembly (Cont'd)
1
2
Figure 30-50-46
N-17194
Replace the needle bearing (Item 1) and valve plate
File has expired.

N-17198 locating pin (Item 2) [Figure 30-50-48] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-49
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
50-46].

Figure 30-50-47
2 1
Publications.
N-17196
The bearing cage (Item 1) [Figure 30-50-49] will

protrude from 0.08 - 0.10 in. (2,0-2,5 mm) from the
N-17197 surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

Lay the pump housing on its side and install the cylinder 50-49] will protrude from 1.65 - 0.185 in. (4,19-4,70 mm)
block, piston assembly into the housing. from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-50-47].

432 of 928
Assembly (Cont'd)
1 1
Figure 30-50-50
N-19550
Install the valve plate and end cap on the pump housing.
File has expired. N-17193 Tighten the bolts (Item 1) [Figure 30-50-52] to 35 - 45 ft.-
Coat the backside of the valve plate with petroleum jelly Figure 30-50-53
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-50-50].

The notch (Item 1) [Figure 30-50-50] on the valve plate
must engage the locating pin.
Publications.
Figure 30-50-51 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-50-53].
Install the large new O-ring (Item 2) [Figure 30-50-53].
N-19551 Install the pump coupler (Item 3) [Figure 30-50-53].
Coat a new end cap gasket (Item 1) [Figure 30-50-51]

with petroleum jelly and install onto the end cap.

433 of 928
Assembly (Cont'd)
Figure 30-50-54
File has expired.

N-19570
Install the two pumps together [Figure 30-50-54].

Figure 30-50-55
1 Use updated files from Bobcat

Publications.
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-50-55] to 35 -

45 ft.-lb. (47 - 61 N•m) torque.

434 of 928
HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The endcaps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from
an external charge pump. 12 volt electrical solenoids shift Ports are labeled on the hydrostatic pump casting.
a spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1
File has expired.

Publications.
P-64943
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

435 of 928
HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be
removed when the hydrostatic pump is separated from
the engine/hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the 1

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install and approved lift arm P-64460
Place the loader on jack stands. (See Procedure on Page Disconnect all of the electrical harness connectors (Item
10-10-1.)
File has expired. 1) [Figure 30-51-3] from the loader harness.
Removal:
WARNING

IMPORTANT
Failure to use jackstands can allow the machine to When repairing hydrostatic and hydraulic systems,
Publications.
W-2017-0286
Raise the operator cab. (See Raising on Page 10-30-1.) damage the system.
I-2003-0888
Figure 30-51-2
Figure 30-51-4
1
P-64425
P-64426
Locate the two hydraulic controllers (Item 1) [Figure 30-

51-2] on the hydrostatic pumps. Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.

436 of 928
Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-51-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 7.7

ft.-lb. (10,4 N•m) torque. Ensure bolts are tight to
specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-51-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-41-29.)
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump. Figure 30-51-8
Installation:
Figure 30-51-6
Publications.
1
P-64978
With the engine running and the loader on jack stands:

P-64444 Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in out of the set screw. Tighten set screw to 18 in.-lb. (2
the center of the servo piston groove (Item 1) [Figure 30- N•m) torque.
51-6].
Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].
Be sure the pump surface is clean.

437 of 928
Remove the hydrostatic pump/engine assembly from the

70-10-9.)
IMPORTANT 1

P-64345
damage the system.
I-2003-0888 Loosen the washer and nut (Item 1) [Figure 30-51-10] on
Figure 30-51-9 File has expired. the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271

N•m) torque

1 Figure 30-51-11

Publications. 2
P-64344
1
Loosen the tensioner mount bolt (Item 1) [Figure 30-51-

9]. P-64346
Remove the drive belt (Item 2) [Figure 30-51-9].

Use a puller (Item 1) [Figure 30-51-11] to loosen the
Installation: (See Belt Removal And Installation on Page pulley from the pump drive shaft.
30-60-3.)
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.

438 of 928
Figure 30-51-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-51-14] at
File has expired.

P-64348 the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 90 - 100 ft.-lb. (125

Figure 30-51-13 - 135 N•m)

NOTE: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
1 1 Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
Publications. BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Start Up on Page 30-41-6.)
P-64337 P-64338

12] and nuts (Item 1) [Figure 30-51-13].
Installation: Tighten the mounting bolts and nuts to 65 -

70 ft.-lb. (88 - 95 N•m) torque.
Make sure the key (Item 2) [Figure 30-51-12] is installed.

439 of 928
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydrostatic Pump Start Up
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.
Figure 30-51-15
File has expired.

Publications.
1
P-64458
Remove the air bleed plugs (Item 1) [Figure 30-51-15].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.

440 of 928
3 1
1. O-ring 5 4
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt
15
16
19 17
21
24 23 22 26

20
25
26
18
Publications.
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010

441 of 928
High Pressure Relief And Bypass Valve
Figure 30-51-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-51-18]
File has expired.

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-16].

Assembly: Tighten cap to 111 - 125 ft.-lb. (150 - 170
N•m) torque.
Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.
Figure 30-51-17 Publications. Factory setting on the relief valve is 5075 PSI (350 bar).
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-51-17] to

ensure it is not broken or flattened.

442 of 928
Charge Relief Valve
Figure 30-51-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)
File has expired. P-64431 [Figure 30-51-21] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-51-19] is Inspect the sealing ring (Item 3) [Figure 30-51-21] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

foreign material.
Remove the charge relief valve.

Assembly: Tighten charge relief valve to 52 ft.-lb. (70
N•m) torque.
Inspect the spring (Item 4) and the charge relief valve
shims (Item 5) [Figure 30-51-21].
Publications.
Figure 30-51-20
NOTE: 1.0 mm shim (Item 5) [Figure 30-51-21] = 43.5
PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-51-20].

443 of 928
Remove the hydrostatic pump/engine assembly from the

2
70-10-9.)
Figure 30-51-22
1
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers
Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque.
P-64458 Figure 30-51-25

Remove the hydraulic controllers (Item 1) [Figure 30-51-
22]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.)
1

2 2
1 1
1
P-64440
Remove the mounting bolts and washers for the swash

plate angle sensor (Item 1) [Figure 30-51-25].
Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque.

P-64438
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-23].
Note the connectors facing each other.
Note the steel covers facing direction.

444 of 928
Figure 30-51-26
P-64442
Both swash plate angle sensors and associated
File has expired.P-64441 hardware removed from the hydrostatic pump. [Figure
30-51-28].
Assembly: Note the slotted portion (Item 1) of the

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-51-
26].

Note the machined section of the swash plate angle
sensor shaft faces the center of the hydrostatic pump.
Publications.
Figure 30-51-27
P-64453
NOTE: Improperly installing the swash plate angle

sensor, with the shaft facing toward the
outside of the hydrostatic pump, will make it
hard to install the sensor mounting bolts and
also destroy the seal (Item 1) [Figure 30-51-
27].

445 of 928
Right End Housing
Figure 30-51-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
1
File has expired.
P-64445
51-31].

Left End Housing
Figure 30-51-30
3
1
Publications.
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-29] and [Figure 30-51-30].
Assembly: Alternately, tighten mount bolts to 96 ft.-lb.

(130 N•m) torque.

446 of 928
Figure 30-51-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole
File has expired.

P-64465 in case housing (Item 2) [Figure 30-51-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-32].

Figure 30-51-33

Publications.
1
P-64466
Ensure servo follower (Item 2) [Figure 30-51-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-33].

447 of 928
Figure 30-51-35
RIGHT SIDE
File has expired.

P-64454
Figure 30-51-36

LEFT SIDE
Publications.
2
P-64501
Remove valve plate (Item 1) [Figure 30-51-35] and

[Figure 30-51-36] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-35] and [Figure 30-51-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

448 of 928

LEFT SIDE
Figure 30-51-37 1
2
RIGHT SIDE
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
File has expired.

P-64455 37] and [Figure 30-51-38] in the case housing with the
notch (Item 1) [Figure 30-51-39] and [Figure 30-51-40]
that does not go through the valve plate.
Figure 30-51-38
Align the shoulder of the roller bearing (Item 2) [Figure

LEFT SIDE 30-51-37] and [Figure 30-51-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-39] and [Figure
Use updated files from Bobcat 30-51-40].
NOTE: Valve plate should sit FLUSH with the case
Publications. housing when properly installed.
1
2
P-64502
Figure 30-51-39
RIGHT SIDE
1
2
P-64456

449 of 928
Figure 30-51-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-43].
File has expired.

B25012
Figure 30-51-44
Right Side Rotating Group [Figure 30-51-41].

Figure 30-51-42
1

Publications.
P-64475
Remove the pistons (Item 1) [Figure 30-51-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-42].

450 of 928

1
Figure 30-51-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-
File has expired.P-64476 47].
Figure 30-51-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-45] in the
1

slippers, are not plugged.

Figure 30-51-46
1
Publications.
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-48]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-46].

451 of 928

3
Figure 30-51-49
1
1
P-64479
Inspect mating surface for the slippers on the swash
File has expired.

P-64474 plate (Item 1) [Figure 30-51-51].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-51].
1) [Figure 30-51-49].

Remove the slide ring (Item 3) [Figure 30-51-51], ensure
Figure 30-51-50 it pivots freely.
1
2
Publications.
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-50] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-52].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-50] are not bent or damaged.

452 of 928
Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-
File has expired. P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-55] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-53]. the outside of the endcap housing

Figure 30-51-54 Inspect bearing surfaces for scratches or scoring.
2
Publications.
1
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-51-54] on swash plate.

453 of 928
Disassembly And Assembly (Cont'd) LEFT SIDE

Figure 30-51-56
1
2
1
P-64486
Figure 30-51-59
File has expired.

P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-51-56].

Figure 30-51-57

Publications.
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-51-58] and

[Figure 30-51-59] from the end housing.
Figure 30-51-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-51-57].
Inspect wear surfaces (Item 2) [Figure 30-51-57] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
1
P-64524
The pump seal (Item 1) [Figure 30-51-60] is removed by

inserting a screw into the seal and prying out.

454 of 928
HYDROSTATIC PUMP (SJC) (CONT'D) The Servo Piston Assembly [Figure 30-51-62] cannot be
removed unless the hydraulic controller and rotating
Disassembly And Assembly (Cont'd) group is removed first.
Figure 30-51-61 Figure 30-51-63
1 1 1
File has expired. P-64488 P-64489
The drive shaft can be tapped out of the end housing with Remove servo piston mounting bolts (Item 1) [Figure 30-
a rubber mallet. 51-63].

Inspect wear surfaces for scratches, and inspect splines Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,
Publications.
remove snap ring (Item 2) [Figure 30-51-61] and remove
bearing.
Figure 30-51-62
B25013
Servo Piston Assembly [Figure 30-51-62].

455 of 928
Figure 30-51-64
P-64492
Slide the servo piston assembly out of the bore. [Figure
File has expired.

P-64490 30-51-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-64].

Figure 30-51-65

Publications.
1
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-65].

456 of 928
Figure 30-51-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item
File has expired. P-64467 2) [Figure 30-51-69] from the pump housing.
Figure 30-51-70
Figure 30-51-68

1
Publications. 1
3
P-64494
P-64466
Each servo has a pair of bushings (Item 1), O-rings (Item

Assembly: Align the servo piston so the guide slot 2) and square-cut seals (Item 3) [Figure 30-51-70].
(Item 1) [Figure 30-51-68] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-51-
67].

457 of 928
Figure 30-51-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-73] from the
File has expired.

P-64495 servo piston.
Figure 30-51-74
Remove the lock nut (Item 1) [Figure 30-51-71] from the
servo piston.
1

Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. 2
Figure 30-51-72Use updated files from Bobcat

1
Publications.
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-51-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-51-74]

Remove the servo cover (Item 1) [Figure 30-51-72] from
the servo piston.

458 of 928
Figure 30-51-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure
File has expired. P-64461 30-51-77] at the top of the case housing to gain access to
the four orifices (Item 1) [Figure 30-51-78].
Remove the plug (Item 1) from the top center of the case Replace O-rings on plugs.
housing. Replace O-ring (Item 2) [Figure 30-51-75].

Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque.

Remove internal screen (Item 3) [Figure 30-51-75].
Figure 30-51-78
torque. Publications.
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m)
1
Figure 30-51-76
P-64500
Ensure the four orifices (Item 1) [Figure 30-51-78] in

case housing are clean and not plugged.
P-64462
Ensure screen is clean [Figure 30-51-76].

459 of 928
HYDROSTATIC PUMP (SJC) (CONT'D) Disconnect the swash plate angle sensors in the
electrical harness. This prevents unwanted swash plate
Disassembly And Assembly (Cont'd) movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
Figure 30-51-79 be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
2
1
WARNING
File has expired.
P-64502
Bearings (Item 1) [Figure 30-51-79] in case housing are physician familiar with this injury is not received
replaced by using a press and bearing driver. immediately.
W-2145-0290

Inspect center coupler (Item 2) [Figure 30-51-79].

Mechanical Neutral Adjustment
Publications.
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.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
WARNING
W-2017-0286
Raise the lift arms, and install an approved lift arm



460 of 928
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-80
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-82] from the
File has expired. P-64973 MA ports on the bottom of the pump, and install 7500 PSI
pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-80] Figure 30-51-83

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.

Figure 30-51-81
1
Publications. 1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-83]. Plug the ports with metal caps. The
P-64425 caps must be able to handle at least 7500 PSI. Plugging
the A and B ports eliminates leakage at the drive motors
from causing errors in the pump mechanical neutral
Remove the plugs (Item 1) [Figure 30-51-81] from the setting.
MB ports on the front side of the pump, and install 7500
PSI (241 bar) pressure gauges.

461 of 928
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-84
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-51-86]
File has expired.

P-64457 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-84]. Figure 30-51-87

Start the loader using the remote start tool and run at an
idle.
Publications.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-85
P-64457

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-64457

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

462 of 928
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-88 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic

2
controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
1 pressure gauges in the X1 and X2 ports on the
right side of the pump.

Place the loader on jack stands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-51-88] to 22 ft.-lb.

(30 N•m) torque.
WARNING
Shut loader OFF.
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
N•m) torque. Publications.

the pump. Install the plugs and tighten to 18 ft.-lb. (25 of the frame before running the engine for service.
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 18 ft.-lb. (25
N•m) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Connect the remote start tool. (See REMOTE START
29.) TOOL KIT-MEL1563 on Page 10-60-1.)
WARNING
physician familiar with this injury is not received
immediately.
W-2145-0290

463 of 928
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-89
2
1
P-64975
1
Install 500 PSI pressure gauges in the X1 and X2 ports
File has expired.

P-64460 pertaining to the side of the hydrostatic pump you are
adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-51-92

[Figure 30-51-89] from the loader wiring harness for the

hydraulic controller you are adjusting.

Figure 30-51-90
Publications.
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-51-92].

P-64458
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-90] pertaining to the side of the hydrostatic
pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

464 of 928
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-93
P-64459
File has expired. P-64459 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-96

in system pressure. Mark the position of the adjustment
screw.

Figure 30-51-94
2
Publications. 1
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-51-96] to
4.5 ft.-lb. (6,1 N•m) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-94] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 18 ft.-lb. (25
N•m) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See Lift And

Tilt Calibration (ACS) on Page 60-160-11.)

465 of 928
File has expired.

Publications.

466 of 928
DRIVE BELT Adjusting
Description To adjust the drive belt, between the flywheel and the
hydrostatic pump pulley, use the following procedure:
The drive belt makes the mechanical connection from the
engine flywheel to the hydrostatic pump pulley. Stop the engine. Open the rear door.
The belt is a cord-reinforced rubber design. Disconnect the negative (-) battery cable.
Constant tension is applied to the drive belt by the use of Remove the belt shield. (See Shield Removal And
a spring-loaded belt tensioner. Installation Page 30-50-1.)
The drive belt is protected by a plastic shield fastened to The belt tensioner is located between the flywheel and
the flywheel housing by metal clips. The shield is also in pump pulley.
place to protect the operator.
Figure 30-60-3
Shield Removal And Installation
Figure 30-60-1
File has expired. 1

1
P-66811 Loosen the bolt (Item 1) [Figure 30-60-3] on the spring

loaded belt tensioner.
Remove the three drive belt shield mounting clips NOTE: The pointer (Item 2) [Figure 30-60-3] will be at
(Item 1) [Figure 30-60-1]. the 1 o'clock position when the belt tensioner
is not under spring tension.
Figure 30-60-2
P-66812
Remove the belt shield (Item 1) [Figure 30-60-2].

467 of 928
DRIVE BELT (CONT’D) NOTE: Do not set the belt tensioner against the travel
stop in the 3 o'clock position.
Adjusting (Cont’d)
Run the engine for a few minutes.
Figure 30-60-4
Stop the engine and recheck the pointer position.
Readjust if necessary.
After the belt tensioner has been in service, readjust

when the pointer reaches the 1 o'clock position.
Install the belt shield using the fasteners.
Reconnect the negative (-) battery cable.

1
File has expired.

P-66814
Using the Belt Tensioner Bar (MEL1405) or a pry bar

push the belt tensioner against the belt, the pointer (Item

1) [Figure 30-60-4] will be at the 3 o'clock position when
the belt tensioner stop is bottomed out. Do not pry

directly on the pulley, pry on the belt tensioner bracket
the pulley is mounted on.
Note:
Publications.
If the pointer does not move when prying on
the belt tensioner mounting bracket, manually
move the arrow towards the 3 o’clock position
with a screwdriver while putting tension on
the bracket to help get it started.
Figure 30-60-5
P-66814
Raise the belt tensioner slightly so that the pulley is

operating on spring tension and not against the stop.
Tighten the mounting bolt (Item 1) [Figure 30-60-5] to 25

- 28 ft.-lb. (34 - 38 N•m) torque.

468 of 928
DRIVE BELT (CONT’D) Figure 30-60-8
Belt Removal And Installation
Figure 30-60-6
P-48481
Remove the drive belt from the pump pulley and flywheel.
File has expired. P-48000 Remove the drive belt from the loader [Figure 30-60-8].
Install the new drive belt. Install the belt tensioner

Stop the engine. Open the rear door. assembly.

Raise the operator cab. (See Raising Page 10-30-1.) Adjust the drive belt. (See Adjusting Page 30-50-1.)

Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance.
(See Removal And Installation Page 60-20-1.)
Reinstall belt shield and connect the negative (-) cable to
the battery.
Publications.
Remove the belt shield [Figure 30-60-6]. (See Shield
Removal And Installation Page 30-50-1.)
Figure 30-60-7
P-66813
Remove the air conditioner belt if so equipped.
The belt tensioner is located between the flywheel and

pump pulley. Loosen and remove the bolt (Item 1)
[Figure 30-60-7] from the belt tensioner.
Remove the belt tensioner assembly.

469 of 928
DRIVE BELT (CONT’D)
Tensioner Pulley Removal And Installation
Figure 30-60-9
File has expired.

P-48000
Stop the engine. Open rear door.

Remove the negative (-) cable from the battery. the
battery may be removed for additional working clearance.

(See Removal And Installation Page 60-20-1.)
Remove the belt shield [Figure 30-60-9]. (See Shield
Publications.
Removal And Installation Page 30-50-1.)
Figure 30-60-10
P-66813
Loosen and remove the belt tensioner mounting bolt

(Item 1) [Figure 30-60-10].
Installation: Apply Loctite® 242 to the mounting bolt and

Remove the belt tensioner from the flywheel housing.
Reverse the removal procedure to install the belt

tensioner.

470 of 928
DRIVE BELT (CONT’D)
Tensioner Pulley Parts Identification
1. Cover
2. Bolt with preapplied threadlocker 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate
File has expired. 5
17. Locating Pin
18. Spring

19. Shaft 6 13
20. Bracket

NOTE: Tensioner pulley parts are not all 5
14
Publications.
available individually. Consult
parts catalog for available
sub-assemblies. 7
15
8 16
17
9
18
10
19
20
E-2296

471 of 928
Tensioner Pulley Disassembly
Figure 30-60-11
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly
File has expired.

P-8858 (Item 2) [Figure 30-60-13] only if they have been
damaged.
Remove the grease cover (Item 1) [Figure 30-60-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-60-13] with a plastic hammer.

Figure 30-60-12
Figure 30-60-14
2 Publications.
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-60-14].
assembly (Item 5) [Figure 30-60-12].

472 of 928
Tensioner Pulley Assembly
Figure 30-60-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
File has expired. P-8871 (Item 1) [Figure 30-60-17] into the hub.
Figure 30-60-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-60-15] as shown.

Figure 30-60-16

Publications.
1
2
3
P-8874
Install a punch as shown and turn clockwise while

P-8872 applying down pressure on the pulley.
Turn until the pulley snaps down into place; this

Install the shaft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of the
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-60-18].
[Figure 30-60-16] over the alignment pin on the bracket.

473 of 928
Tensioner Pulley Assembly (Cont'd)
Figure 30-60-19
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly
File has expired.

P-8875 (Item 2) [Figure 30-60-21]. Press on the outer formed
edge of the grease cap.
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-60-19] over the roll pins. assembly, do not press down on the arrow

indicator plate. Support the hub assembly so
Figure 30-60-20 that it contacts only the hub and not the arrow
Use updated files from Bobcat indicator plate.
Publications.
2
1
P-8876
Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-60-20].
Tighten the bolt to 28 - 32 ft.-lb. (38 - 45 N•m) torque.
Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of
grease.
Installation: Clean and dry bolt threads. Apply Loctite®

242 to the bolt (Item 3) and tighten to 28 - 32 ft.-lb. (38 -
45 N•m) torque.

474 of 928
TWO-SPEED VALVE
Description
Figure 30-70-1
The two-speed valve (Item 1) [Figure 30-70-1] is located

on top of the chaincase in front of the hydrostatic pump.

The high range is selected by a switch located on the
right handle for manual loaders and on the left joystick for

SJC loaders.
When the high range is selected, the two-speed solenoid
Publications.
is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.
The two-speed valve also contains a two-speed pre-

warming solenoid, which provides warm hydraulic oil to
preheat the drive motors preventing damage in cold
conditions. When the hydraulic oil reaches a pre-
determined temperature, the pre-warming solenoid is
turned off and the two-speed is engaged.
The case drain filter for the drive motors is mounted to

the top of the two-speed valve.

475 of 928
TWO-SPEED VALVE (CONT'D) Mark all hydraulic hoses and tubelines for proper
installation.
Valve Removal And Installation
Figure 30-70-2
DANGER
2 2
1 1
P-90328
AVOID DEATH
File has expired.

• Disconnecting or loosening any hydraulic P-76174

can cause lift arms to drop. Scribe a mark across the top of the steering linkage bars
• Keep out of this area when lift arms are raised (Item 1) [Figure 30-70-2] which are connected to the
unless supported by an approved lift arm steering shaft on the control panel.

D-1009-0409 Remove the four steering linkage mounting bolts (Item 2)
Use updated files from Bobcat [Figure 30-70-2].

WARNING
Publications. bars. Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 N•m) torque. Verify linkage neutral
adjustment. (See Linkage Neutral (Adjusting) on Page
Never work on a machine with the lift arms up unless 50-100-13.)
support device. Failure to use an approved lift arm Figure 30-70-3
W-2059-0598
2
WARNING 1

W-2017-0286
P-76161
1.)
Raise the lift arms and install an approved lift arm 30-70-3] from the two-speed pre-warming solenoid.
Raise the operator cab. (See Raising on Page 10-30-1.) 30-70-3] from the two-speed solenoid.

476 of 928
TWO-SPEED VALVE (CONT'D) Figure 30-70-6
Valve Removal And Installation (Cont'd)
Figure 30-70-4
1
1
2
1
P-76148

1
File has expired. P-76160 6] from the valve bracket.
Remove the two-speed valve assembly from the loader.

Disconnect the three hydraulic tubelines (Item 1) [Figure
30-70-4] from the two-speed valve.

Disconnect the hydraulic hose (Item 2) [Figure 30-70-4]

from the two-speed valve.
Figure 30-70-5
Publications.
2
2
2
P-76155
Disconnect the hydraulic hose (Item 1) and the three

tubelines (Item 2) [Figure 30-70-5] from the two-speed
valve.

477 of 928
TWO-SPEED VALVE (CONT'D) Figure 30-70-8
Valve Disassembly And Assembly
Figure 30-70-7
1 6 1
3
4
2
7
5
P-76185
Check the O-rings (Item 1) [Figure 30-70-8] on the two-
File has expired.

P-76134 speed solenoid stem for wear and replace as needed.
Figure 30-70-9
Mark all hydraulic tubelines and fittings for proper
installation.

Remove the two-speed solenoid nut (Item 1), two-speed

solenoid (Item 2), and two-speed solenoid stem (Item 3)
[Figure 30-70-7] from the valve block.
Publications.
Assembly: Tighten the two-speed solenoid nut to 5 ft.-lb.
(6,8 N•m) torque.
1
Assembly: Tighten the two-speed solenoid stem to 20

ft.-lb. (27,1 N•m) torque.
Remove the pre-warming solenoid nut (Item 4), pre-

warming solenoid (Item 5), and pre-warming solenoid 2 P-76188
stem (Item 6) [Figure 30-70-7] from the valve block.
Assembly: Tighten the pre-warming solenoid nut to 5 ft.- Check the O-rings (Item 1) and back-up washers (Item 2)
lb. (6,8 N•m) torque. [Figure 30-70-9] on the pre-warming solenoid stem for
wear and replace as needed.
Assembly: Tighten the pre-warming solenoid stem to 20
ft.-lb. (27,1 N•m) torque.
Remove the tubeline (Item 7) [Figure 30-70-7] from the

valve fittings.

478 of 928
TWO-SPEED VALVE (CONT'D)
Valve Disassembly And Assembly (Cont’d)
Figure 30-70-10
Remove the two bolts and nuts (Item 1) [Figure 30-70-

10] fastening the two-speed valve and case drain filter

clamp to the valve mounting bracket.

Remove the two-speed valve (Item 1) and case drain
filter clamp (Item 2) [Figure 30-70-10] from the valve
mounting bracket.
Publications.
Assembly: Tighten the two mounting bolts to 80 - 90 in.-

479 of 928
File has expired.

Publications.

480 of 928
CASE DRAIN FILTER Remove the packing (Item 1) and O-ring (Item 2) [Figure
30-80-2] from the filter housing nut.
Description
Figure 30-80-3
The case drain filter is an external filter assembly in the
case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See 2

Removing And Replacing Hydraulic Case Drain Filters
(Single Speed Loaders) on Page 10-120-3.) or (See
Removing And Replacing Hydraulic Case Drain Filters
(Two-Speed Loaders) on Page 10-120-4.) 1
File has expired.

P-76218
Figure 30-80-1
Remove the filter element and spring assembly (Item 1)

[Figure 30-80-3]

NOTE: Remember the orientation of the filter element
and spring assembly for correct assembly.
Publications.
2
1
P-76212
Remove the filter housing nut (Item 1) from the filter 2

housing (Item 2) [Figure 30-80-1].
Figure 30-80-2
1
P-76216
2 The larger taper spring (Item 1) slides over the end of the
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-80-4] slides into the filter element.
P-76214

481 of 928
File has expired.

Publications.

482 of 928
DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1 SAFETY &
MAINTENANCE
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Disc Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . 40-11-2
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-11-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . 40-30-2 DRIVE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 SYSTEM
Front Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-1
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-3
File has expired.

DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . .
40-20-1
40-20-2
Axle Sprocket And Bearings Removal And Installation . . . 40-20-4
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-20-9

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM &
ANALYSIS
Publications.
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC
SECTION) UNLESS OTHERWISE SPECIFIED.
ENGINE
SERVICE

STANDARD ITEMS MAY VARY. SPECIFICATIONS

483 of 928
File has expired.

Publications.

484 of 928
BRAKE (SINGLE SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-1.)
Description
Disconnect and remove the engine speed control. (See
The brake is used to hold the machine in place. The Removal And Installation on Page 70-20-1.)
brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the front accessory panel. Remove the control panel from the loader. (See Removal
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the center chaincase cover. (See Center Cover
shafts. An electric solenoid is sent power from a relay to Removal And Installation on Page 40-30-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Remove the traction lock assembly. (See Removal And
discs. Installation on Page 60-120-2.)
The hold signal will be interrupted and the wedge will Figure 40-10-2
drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
File has expired.

For more information on the brake. (See TRACTION
LOCK on Page 60-120-1.)
1
Figure 40-10-1

1
Publications. N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.
1 Figure 40-10-3
P-76419
Disc Removal And Installation
WARNING
1
N-19105
support device can allow the lift arms or attachment Inspect the traction lock guides (Item 1) [Figure 40-10-3]
to fall and cause injury or death. and the brake disc for damage or wear and replace as
W-2059-0598
necessary. (See Inspecting on Page 60-120-6.)

485 of 928
BRAKE (SINGLE SPEED) (CONT’D)
Disc Removal And Installation (Cont’d)
Figure 40-10-4
File has expired.

N-19082A
Figure 40-10-5

Publications. 1
N-19083A
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-10-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

486 of 928
BRAKE (TWO-SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-1.)
Description
Disconnect and remove the engine speed control. (See
The brake discs on two-speed loaders have a rubber Removal And Installation on Page 70-20-1.)
isolator riveted to the side of the brake discs.
Remove the control panel from the loader. (See Removal
The brake is used to hold the machine in place. The And Installation on Page 50-100-2.)
brake is operated by a switch (Item 1) [Figure 40-11-1]
located on the front accessory panel. Remove the center chaincase cover. (See Center Cover
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the traction lock assembly. (See Removal And
shafts. An electric solenoid is sent power from a relay to Installation on Page 60-120-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Figure 40-11-2
discs.
The hold signal will be interrupted and the wedge will
File has expired.

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
1
For more information on the brake. (See TRACTION

LOCK on Page 60-120-1.)

Figure 40-11-1
Publications. N-19081A
The parking brake discs (Item 1) [Figure 40-11-2] are

located beneath the center chaincase cover.
Figure 40-11-3
P-76419
Disc Removal And Installation
WARNING 1
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-11-3]
and the brake disc for damage or wear and replace as
necessary. (See Inspecting on Page 60-120-6.)
W-2059-0598

487 of 928
BRAKE (TWO-SPEED) (CONT’D) NOTE: When installing the two-speed brake discs,
make sure the discs isolators are facing each
Disc Removal And Installation (Cont’d) other towards the center of the loader. The
rivets fastening the isolator to the disc are
Figure 40-11-4 orientated so the disc can be slid between the
two sprockets without interfering with the
rivets.
Disc Disassembly And Assembly

2 1
Figure 40-11-6
File has expired.

P-73918
Figure 40-11-5 2

1
P-76405
Remove the four rivets (Item 1) from the isolator (Item 2)
Publications. [Figure 40-11-6] fastened to the disc.
Remove the isolator (Item 2) [Figure 40-11-6] from the

disc.
NOTE: Make sure rubber isolator is seated tight

against disc after rivets are installed.
P-73917
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-11-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-11-4] off the sprocket

(Item 1) [Figure 40-11-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

488 of 928
DRIVE COMPONENTS
Description
File has expired.

The drive components consist of the chaincase, drive

chains, sprockets, axleshafts, hubs and a brake.
The chaincase is partially filled with hydraulic fluid to

lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for

access to the fuel tank drain plug.

489 of 928
DRIVE COMPONENTS (CONT’D) Installation: Support the flange of the axle hub and
install the two studs with a hammer. A hydraulic press
Axle Seal Removal And Installation can also be used to install the studs.
Figure 40-20-1 Figure 40-20-2
2
2
2 1
File has expired.

P-4157 P-4159
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.

Axle Hub Puller Tool
MEL1399 - Seal Driver Tool A driver tool (Item 2) [Figure 40-20-2] can be used for
MEL1242 - Power Ram (may be used if desired)
To loosen the axle hub mounting bolt (Item 1) [Figure 40-

centering the threaded rod of the puller.
Publications.WARNING
20-1], use the following procedure:
Before lifting and blocking the loader, loosen the hub

mounting bolt (Item 1) [Figure 40-20-1].
NEVER STAND IN-LINE OF THE HUB WHEN
NOTE: If the axle and bearings are being replaced, REMOVING A HUB FROM AN AXLE. The hub has a
also loosen the sprocket mounting bolt inside tapered fit on the axle end and can come off the axle
the chaincase before lifting and blocking the with great force and cause serious injury.
loader. (See Axle Sprocket And Bearings W-2186-0395
Removal And Installation on Page 40-20- 4.)
Use a wrench with the puller and remove the axle hub
from the axle tube. A spacer and a power ram can be
1.)
used between the axle and the tool if available, instead of
the wrench, threaded rod and driver tool.
Remove the front tire/wheel assembly.
Remove the hub mounting bolt (Item 1) [Figure 40-20-1]

and washer from the axle.
Installation: Tighten the hub mounting bolt to 725 - 800

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

[Figure 40-20-1].
Use a wheel mounting nut on each stud and remove the

two studs with a hammer.

490 of 928
DRIVE COMPONENTS (CONT’D) Figure 40-20-5
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
File has expired.

P-4161 the following procedure:
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair

Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Use updated files from Bobcat Place the new axle seal over the axle and into the axle
tube.
Publications. Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
1 Reverse removal procedure to install the axle hub and

wheel assembly.
P-4181
Drill a small hole in the axle seal.
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end in the axle seal.
Remove the axle seal.

491 of 928
DRIVE COMPONENTS (CONT’D) 20-6]. (See Front Cover Removal And Installation on
Page 40-30-1.)
Axle Sprocket And Bearings Removal And
Installation Figure 40-20-7
The tools listed are needed for the following procedure:
MEL1242 - Power Ram

MEL1202B - Axle Bearing Service Set
NOTE: The procedure shown is for removing the

front axle, bearings and sprocket. This
procedure can also be used for the rear axle,
bearings and sprocket. (See Rear Cover
Use jackstands to support the rear of the loader. (The 1

loader wheels should remain on the ground.)
File has expired.

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

40-20-7].

the lift arms are secured by an approved lift arm 1.)
Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
Publications. W-2059-0598
Remove the axle hub. (See Axle Seal Removal And
Remove the sprocket mounting bolt (Item 1) [Figure 40-
Raise the operator cab. (See Raising on Page 10-30-1.) 20-7].
Remove the control panel. (See Removal And Installation Installation: Tighten the sprocket mounting bolt to 300 -
on Page 50-100-2.) 330 ft.-lb. (407 - 447 N•m) torque.
Figure 40-20-6
P-34255
Remove the eight front cover mounting bolts (Item 1) and

the front cover (Item 2) from the chaincase [Figure 40-

492 of 928
DRIVE COMPONENTS (CONT’D) Installation: Pack both axle bearings with grease before
installing them.
Installation (Cont’d) Figure 40-20-10
Figure 40-20-8
File has expired.

P-4170
1
P-4158A
A bearing puller (Item 1) [Figure 40-20-10] is needed for
the following procedure:
Install the MEL1242 power ram (Item 1) [Figure 40-20-8]

between the two sprockets. Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [Figure 40-20-
Put a spacer between the power ram and axle. Push the
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure
10].
Publications.
until the axle is free from the sprocket and inner bearing.
Figure 40-20-9
2
1
P-4162A
Remove the drive chain from the sprocket (Item 1)

[Figure 40-20-9] and remove the sprocket from the
chaincase.
Remove the inner bearing (Item 2) [Figure 40-20-9] and

remove the axle from the axle tube. (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20-
4.)

493 of 928

Installation (Cont’d)
4
3
Figure 40-20-11
P-4169
Installation: A piece of round tubing (Item 1) [Figure 40-
File has expired.

P-4171
20-12] is needed to install the bearing on the axle shaft.
The tubing needs to measure approximately 0.500 in.
(12,7 mm) to 1.0 in. (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 in. (53,3
Be sure the bearing puller makes good contact with the mm) and the outside diameter should not be over 2.400

inner race of the bearing and press the bearing off the in. (60 mm),
mounting surface of the axle.

Be sure to hold onto the axle during removal as it will
slide freely along the axle shaft after removal from the
A bearing puller (Item 2) [Figure 40-20-12] is also
needed to install the bearing on the axle.
Publications.
bearing mounting surface and until the bearing contacts
the spline on the shaft.
Put the tubing (Item 1) on the bearing puller (Item 2)
[Figure 40-20-12].
Press the splined end of the axle free from the bearing Put the bearing (Item 3) [Figure 40-20-12] on the tube as
[Figure 40-20-11]. shown.
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
Be sure to hold onto the axle during installation, as it will

slide freely along the axle shaft after the spline end has
passed through the bearing and until it reaches the
bearing mounting surface on the axle.

494 of 928

Figure 40-20-13
2
1
P-4179
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-15] on the slide hammer.
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated After the bearing cup tool is inside the axle tube, pull the
[Figure 40-20-13]. tool against the bearing cup and tighten the nut (Item 2)
Figure 40-20-14
[Figure 40-20-15] on the tool.
Figure 40-20-16
Publications.
P-4172
P-4180
Use the tools provided in the MEL1202B Axle Bearing

Service Set for bearing cup removal and installation. A Use the slide hammer and remove the bearing cup from
slide hammer is also necessary for this procedure. the axle tube [Figure 40-20-16].
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-14].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].

495 of 928
DRIVE COMPONENTS (CONT’D) Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
Axle Sprocket And Bearings Removal And tool.
Secure the tool to the threaded rod with a nut [Figure 40-
Figure 40-20-17 20-18].
Hold the inside nut (Item 3) [Figure 40-20-17] with a

1 wrench and tighten the outside nut as shown in photo
2 [Figure 40-20-18].
Tighten the nut until the bearing cup is seated.
Figure 40-20-19
File has expired.

P-4174A
Figure 40-20-18

1
P-4173
Publications. To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
Put the bearing cup tool on the short rod.

2
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [Figure 40-20-19].
P-4164
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.
Use the bearing cup installation tools (Item 1) [Figure 40-
20-17] and (Item 1) [Figure 40-20-18] and the long
threaded rod (Item 2) [Figure 40-20-18] from the service
set to install the inner and outer bearing cups.
Put the inner bearing cup in the axle tube (Item 2)

[Figure 40-20-17].
Put the installation tool (Item 1) [Figure 40-20-17] in the

axle tube.
Install the long threaded rod (Item 2) [Figure 40-20-18]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-17].
Secure the tool to the threaded rod with a nut (Item 3)

[Figure 40-20-17].

496 of 928
Chain Removal And Installation 2
WARNING
1
W-2059-0598
P-54227
support device.(See Installing on Page 10-20-1.)
Remove the parking brake disc (Item 1) [Figure 40-20-
1.) File has expired.

Lift and block the loader. (See Procedure on Page 10-10- 20]. (See Disc Removal And Installation on Page 40-10-
1.) or (See Disc Removal And Installation on Page 40-11-
1.)
Raise the loader operator cab. (See Raising on Page 10-
30-1.) Remove the six carrier mounting bolts (Item 2) [Figure

40-20-20] from inside the chaincase.


125 - 140 ft.-lb. (170 - 190 N•m) torque.
Publications.

Figure 40-20-21
on Page 50-100-2.)

Installation on Page 60-110-3.) 1
Remove the front (or rear) chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the front (or rear) axle and sprocket. (See Axle
Sprocket And Bearings Removal And Installation on P-54226
Page 40-20-4.)
Tip the end of the sprocket on the motor carrier toward

the rear of the loader and remove the rear drive chain
from the sprocket.
NOTE: It may be necessary to tie the front drive chain

up as shown in photo [Figure 40-20-21], so the
carrier/motor assembly can be moved enough
to free the rear drive chain (Item 1) [Figure 40-
20-21] from the sprocket.
Remove the front drive chain from the chaincase.

497 of 928
DRIVE COMPONENTS (CONT’D)
Chain Removal And Installation (Cont’d)
Figure 40-20-22
File has expired.

B-13504A
The tool listed is needed for the following procedure:

MEL1037 - Chain Link Tool

Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
Publications.
Use MEL1037 Chain Link Tool and #80 chain adapter.
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22]. Tighten the
threaded rod of the chain link tool to 130 ft.-lb. (176 N•m)
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

498 of 928
CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Description on Page 40-20-1.) 2

30-1.) 3
3
P-34255
DANGER
Remove the front chaincase cover mounting screws
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are machined recesses (Item 3) [Figure
40-30-1] on the bottom side of the cover to
AVOID DEATH
P-90328 help pry the covers off.
Installation: Apply polyurethane sealer to mating

•
Publications.
surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage. Tighten the mounting
screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
D-1009-0409
WARNING
W-2059-0598

499 of 928
CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Procedure on Page 30-2].
10-30-1.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
File has expired. support device. Failure to use an approved lift arm
P-90328 W-2059-0598
AVOID DEATH

Figure 40-30-3
•
1
Publications.
D-1009-0409
2
3 3
on Page 50-100-2.)
1
Figure 40-30-2 3 3
P-66980
4
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
1 Remove the center chaincase cover (Item 2) [Figure 40-

30-3] from the loader.
2
3 NOTE: There are machined recesses (Item 3) [Figure
40-30-3] on the bottom side of the cover to
help pry the covers off.
P-66969
If loader is equipped with SJC, skip to [Figure 40-30-3]. screw threads to stop oil leakage. Tighten the mounting
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

500 of 928
CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
support device. (See Installing on Page 10-20-1.) 3 3
1
Raise the loader operator cab. (See Raising on Page 10- 2
30-1.)
DANGER 3 3
P-66959
Remove the rear chaincase cover mounting screws (Item
File has expired. 1) [Figure 40-30-4].
Remove the rear chaincase cover (Item 2) [Figure 40-

P-90328 30-4].
AVOID DEATH

NOTE: There are machined recesses (Item 3) [Figure
• Disconnecting or loosening any hydraulic 40-30-4] on the bottom side of the cover to
•
help pry the covers off.
Publications.
D-1009-0409
screw threads to stop oil leakage. Tighten the mounting
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Removal And Installation on
Page 30-70-2.)
If loader is equipped with high flow, remove the high flow

valve. (See Removal And Installation on Page 20-150-4.)
Disconnect the front steering linkage bars from the rear

linkage bars. (See Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.

501 of 928
File has expired.

Publications.

502 of 928
MAINFRAME
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . 50-120-1 SAFETY &
MAINTENANCE
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . 50-121-2
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . . 50-40-2 DRIVE
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . 50-40-4 SYSTEM
File has expired.

BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . .
50-41-1
50-41-1
50-41-3
MAINFRAME
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . 50-41-4


ELECTRICAL
SYSTEM &
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-140-1
50-140-3
ANALYSIS
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
Publications.
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-140-3
50-140-1
ENGINE
SERVICE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2 SPECIFICATIONS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . .50-111-1

Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-111-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . .50-111-5
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . .50-111-4
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . .50-111-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-111-5
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Mount Removal And Installation . . . . . . . . . . . . . . . . 50-112-3

503 of 928
MAINFRAME (CONT’D)
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-13
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-100-7
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-17
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 50-100-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
File has expired.

CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-4

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-91-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-91-1
Publications.
Foot Pedal Linkage Disassembly And Assembly. . . . . . . . . . . . . .50-91-3
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .50-91-2
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . .50-91-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

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

Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-2
Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . .50-50-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . .50-20-4
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . .50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

504 of 928
MAINFRAME (CONT’D)
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . 50-31-4
Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . 50-31-2
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-2
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . 50-31-5
REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 50-70-2
File has expired.

Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . 50-10-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Publications.
WINDOW (CAB DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1

Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . 50-133-2
Removal And Installation (Special Applications Window) . . . 50-133-4
Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Installation (Continuous Molding). . . . . . . . . . . . . . . . . . . . . . 50-130-3
Installation (Split Molding) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

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


505 of 928
File has expired.

Publications.

506 of 928
SEAT BAR Figure 50-10-3
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
1
The seat bar is located in the operator cab.
Figure 50-10-1
N-18572
1 1
Remove the seat bar mounting nuts (Item 1) [Figure 50-
File has expired. 10-3] (both sides).
Installation: Tighten the nuts to 25 - 28 ft.-lb. (33,9 - 38

N•m) torque.

2.)
Use updated files from Bobcat P-85239 Figure 50-10-4
Publications.
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2 1
P-85238
1
Remove the seat bar (Item 1) [Figure 50-10-4] from the

operator cab.
P-85237
Reverse the above procedure to install the seat bar into
the operator cab.
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]
from the cab harness.
Lower the seat bar.

507 of 928
SEAT BAR (CONT'D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] and [Figure 50-10-6] to 25 - 28 ft.-lb. (33,9 - 38
Disassembly And Assembly N•m) torque.
5 5
4 6 4 6
7
3
2
7
3
8
9
10 1 2
File has expired.

P-85232 P-85231

4 5 9 8
6 4
3 3 5
6
10
Publications. 2 7
1
2
P-85233 P-85234
Assemble the parts as shown for the left side of the seat
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-5] and [Figure 50-10-
bar pivot assembly [Figure 50-10-7] and [Figure 50-10-
6].
8].
Seat Bar Mount (Item 1)
Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3)
Pivot Bushing (Item 3)
Seat Bar (Item 4)
Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5)
Seat Bar (Item 5)
Pivot Bushing (Item 6)
Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7)
Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10)
50-10-7] and [Figure 50-10-8] to 25 - 28 ft.-lb. (33,9 - 38
N•m) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-5] and [Figure 50-10-6] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.

508 of 928
SEAT BAR (CONT'D) Figure 50-10-10
Compression Spring Disassembly And Assembly 5 6
Figure 50-10-9
4 7
2
3
2
1 P-85236
Disassemble and assemble the seat bar compression
File has expired. P-85235 spring and parts as shown in [Figure 50-10-10].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-9] and [Figure 50- Bushings (Items 2)
10-10] out of the clevis. Spring (Item 3)

Clevis (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Retaining Pin (Item 5)
threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
Bushing (Item 6)
Cotter Pin (Item 7)
Publications.
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

509 of 928
File has expired.

Publications.

510 of 928
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-66826 P-66827
1 Remove the cab nut and holddown plate (Item 1) [Figure
File has expired. 50-20-2] (both sides).

N•m) torque.

Figure 50-20-3
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].
WARNING
P-66828
support device. Failure to use an approved lift arm Raise the operator cab (See Raising on Page 10-30-1) to
support device can allow the lift arms or attachment release the tension on the gas cylinder.
W-2059-0598 Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Raise the lift arms. (See Installing on Page 10-20-1.)
Install an approved lift arm support device.

511 of 928
OPERATOR CAB (CONT’D) Figure 50-20-6
Gas Cylinder Removal And Installation (Cont’d) DUAL GAS CYLINDER
Figure 50-20-4
1 2
P-43354A
Loosen the front screw (Item 1) and remove the rear
File has expired. screw (Item 2) [Figure 50-20-5] and [Figure 50-20-6]
from the gas cylinder mounting bracket.

P-31966

Install a strap (Item 1) [Figure 50-20-4] from the operator
Publications.
cab to the loader mainframe to prevent the cab from
tipping forward when the gas cylinder(s) are removed.
Figure 50-20-5
SINGLE GAS CYLINDER
P-48262A

512 of 928
Gas Cylinder Removal And Installation (Cont'd) DUAL GAS CYLINDER
Figure 50-20-7
1
P-66829
Remove the retaining pin(s) (Item 1) [Figure 50-20-8]

and [Figure 50-20-9] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-8]

and [Figure 50-20-9] from the operator cab.
Rotate the mounting bracket forward to relieve any

remaining tension on the gas cylinder(s) [Figure 50-20- Reverse the above procedure to install the gas cylinders
7]. onto the operator cab.
Remove the front screw (Item 1) [Figure 50-20-7] from
the gas cylinder mounting bracket.
Publications.
Installation: Tighten the screws to 100 - 130 in.-lb. (11,3
- 14,7 N•m) torque.
Figure 50-20-8
SINGLE GAS CYLINDER
P-66830

513 of 928
OPERATOR CAB (CONT’D) Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Figure 50-20-10
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
2 cylinders. If the operator cab is tilted forward without
1 the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796
Remove the operator cab gas cylinder(s). (See Gas

Cylinder Removal And Installation on page 50-20-1.)
File has expired.

P1008
Figure 50-20-12
Remove the clevis (Item 1) and washer (Item 2) [Figure

50-20-10] from the end of the gas cylinder.

Remove the gas cylinder from the outer housing.

Assembly: Install a replacement cylinder inside the
cylinder housing.
P-66828
P1006
Use the hoist connected to the operator cab grab handles

Apply a small amount of thread-locker on the threads of to lower or (raise) the operator cab when the gas
the cylinder rod [Figure 50-20-11]. cylinders are disconnected [Figure 50-20-12].
Reinstall the washer and clevis on the cylinder rod.

514 of 928
Figure 50-20-13
1
N-19231
Install lift eye (Item 1) [Figure 50-20-15] (both sides) to
File has expired. P-66831 the cab.
Figure 50-20-16
Remove screw (Item 1) [Figure 50-20-13] from the cab
ground.

torque.
Remove any tie-straps connected to the harness [Figure
1
50-20-13].
Publications.
Figure 50-20-14
P-31966
1
Remove the strap (Item 1) [Figure 50-20-16] preventing
P-66829
the cab from tipping forward.
Lower the cab.

Remove the bolt (Item 1) [Figure 50-20-14] from the cab
ground. Start the engine.
Remove the lift arm support device. (See Removing on

Page 10-20-2.)
Stop the engine.

515 of 928
Figure 50-20-17
2
1 1
N-19202
P-66832
Remove the rear mounting bolt (Item 1) [Figure 50-20-
File has expired. 18] (both sides) and nut from the operator cab.
Installation: Tighten the bolt and nut to 25 - 35 ft.-lb. (34

- 47 N•m) torque.

Figure 50-20-19

Publications. 1
P-31967
Connect the slings (Items 1 and 2) [Figure 50-20-17] to a

chain hoist. P-66831
Lift the operator cab up and forward.
Disconnect the cab harness connector (Item 1) [Figure

50-20-19].
Installation: Tighten connector screw to 30 - 35 in.-lb.

(3,39 - 3,96 N•m) torque.
Remove the operator cab from the loader.
Reverse the above procedure to install the operator cab.

516 of 928
OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1 1
1 2
N-20729

Raise the operator cab. (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Item
1 and 2) [Figure 50-30-3] and peel back or cut insulation

Remove the four seat mounting nuts (Item 1) [Figure 50- to gain access to the head.
30-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
Figure 50-30-4
N•m) torque.
Publications.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Item 1 and 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54

ft.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 50-
P10564 P10563 30-4] to 34 ft.-lb. (46 N•m) torque.
Repeat for other half of seat belt and guide

Lower the cab and install one of the mounting washers
and a nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.

517 of 928
File has expired.

Publications.

518 of 928
OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
1 2
N-20974
NOTE: Assure seat tethers are securely fastened to
File has expired. N-20647 seat belt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising on Page 10-30-1.) Figure 50-31-4

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
N•m) torque.
Figure 50-31-2
Publications.
1
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P10564 P10563
Lower the cab and install one of the mounting washers

and a nut [Figure 50-31-2].
NOTE: With the seat removed, the cab will raise.

seat.

519 of 928
OPERATOR SEAT (SUSPENSION) (CONT’D) Remove the seat belt.
Slide Rail Removal And Installation Installation: Tighten the mounting nuts to 58 - 62 ft.-lb.
(78,6 - 84 N•m) torque.
Figure 50-31-5
Lower Cushion Removal And Installation
Figure 50-31-7
1 1
2 1
2
1
1
File has expired.

N-18587

N-18579

Remove the operator seat. (See Removal And
Installation on Page 50-31-1.) Press the two buttons (Item 1) [Figure 50-31-7] and
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5].
[Figure 50-31-8] and lift the seat cushion.
Publications.
Remove the slide rail (Item 2) [Figure 50-31-5] from the
bottom of the seat frame.

seat slide rail.
Seat Belt Removal And Installation
Figure 50-31-6
N-20974
Remove the nut (Item 1) [Figure 50-31-6] from the seat

belt mount.

520 of 928
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-10
Lower Cushion Removal And Installation (Cont’d)
Figure 50-31-8
1 1
N-18580
Inspect the seat ride adjustment [Figure 50-31-10].

seat back.
Figure 50-31-9

Publications.
N-18581
Remove the cushion (Item 2) [Figure 50-31-8] from the

seat frame (Item 1) [Figure 50-31-9].

521 of 928
OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
Back Cushion Removal And Installation Figure 50-31-13
Figure 50-31-11
2
1
P-43118
File has expired.

N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50- Remove the operator seat. (See Removal And
31-11] and tilt the seat back all the way forward. Installation on Page 50-31-1.)

Figure 50-31-12 Remove the seat shock mounting bolts (Item 1) [Figure
Use updated files from Bobcat 50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-13].
Publications. Reverse the removal procedure to install the operator

seat shock.
1 1
N-18578

31-12] from the seat back and remove the back.

seat back.

522 of 928
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation
Remove the operator seat. (See Removal And

Figure 50-31-14
File has expired. 1

P16285

Remove the mounting nut (Item 1) [Figure 50-31-14]
Remove the end release buckle (Item 2) [Figure 50-31-
14]
Publications.
Installation: Be sure tether strap (Item 3) [Figure 50-31-
14] is on the seat belt stud behind the end release
buckle.
Figure 50-31-15
P16284

Remove the seat belt retractor (Item 2) [Figure 50-31-
15]
Installation: Be sure tether strap (Item 3) [Figure 50-31-
15] is on the seat belt stud behind the seat belt retractor.

523 of 928
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-31-16
OUTSIDE OF CAB
File has expired.

P16131
Remove the mounting bolt (Item 1) [Figure 50-31-16]

Figure 50-31-17
1
2
Publications. P16126
INSIDE OF CAB
P16128
Remove the shoulder harness retractor (Item 1) [Figure

50-31-17]
Installation: Line up the bolt (Item 1) [Figure 50-31-16]

with the mounting bracket (Item 2) [Figure 50-31-17] on
the inside of the cab.

524 of 928
BOB-TACH (HAND LEVER) Figure 50-40-2
Description
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach uses two
manually operated, spring assisted, locking wedge and
lever assemblies to secure the attachment the Bob-Tach. 1
2
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.
Figure 50-40-1
N-18545
Remove the pivot pin (Item 1) [Figure 50-40-2] from the
File has expired. tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
1

Loosen the bolt (Item 2) [Figure 50-40-2] at the Bob-
Tach pivot pin.
Use updated files from Bobcat Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -
260 N•m) torque.
Publications. N-18544
Figure 50-40-3
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

nut from the tilt cylinder rod end pin (both sides). 1
Installation: Tighten the retainer bolt and nut to 25 - 30

P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-40-3] out of the Bob-Tach frame. This allows
grease to escape when driving the pivot pins into the
Bob-Tach frame.

525 of 928
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)
File has expired.

N-18547 [Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-40-4] to Figure 50-40-7
push the pivot pin into the Bob-Tach frame.

Remove the bolt.
Bob-Tach.
Use a long punch to push the pivot pin all the way into the
1
Publications.
Remove the Bob-Tach from the lift arms.
Remove the Bob-Tach pivot pin (both sides).
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
N-18560
Remove the Wedge (Item 1) [Figure 50-40-7].
Always replace bent or broken wedges.
N-18558
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.

526 of 928
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-10

(Cont’d)
Figure 50-40-8
3 N-18563
2 Use a punch and hammer to drive the roll pin (Item 1)
File has expired.

1
N-18561
[Figure 50-40-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Bob-Tach

lever and wedge [Figure 50-40-10].
Remove the lever mounting nut (Item 1), washer (Item 2),

spring (Item 3) and lever (Item 4) [Figure 50-40-8].

N•m) torque.
Figure 50-40-9
Publications.
2 4
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.

527 of 928
BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-11
2 1
File has expired.

N-18557
Remove the Power Bob-Tach. (See Removal And


Use a seal pick to remove seal (Item 1) [Figure 50-40-

11] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-11]
Publications.
with a driver tool and hammer.

528 of 928
BOB-TACH (POWER) Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
Description secure the clamp.
The Bob-Tach is the section of the loader lift arm that Remove the retainer bolt (Item 3) [Figure 50-41-1] and
attachments mount to. The Power Bob-Tach option uses nut from the tilt cylinder rod end pin (both sides).
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to Installation: Tighten the retainer bolt and nut to 25 - 28
the Bob-Tach. ft.-lb. (34 - 38 N•m) torque.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
lever assemblies by pressing a switch on the front
accessory panel. The switch activates the Power Bob-
Tach block to allow flow into or out of the hydraulic
cylinder connected to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the

gear pump.
File has expired.

The Bob-Tach is located on the front of the loader
connected to the loader lift arms.

Figure 50-41-1
Publications.
2 3
P-48131
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

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

[Figure 50-41-1].
NOTE: The hose with the 45 degree end (Item 1)

[Figure 50-41-1] is connected to the base end
fitting on the cylinder.

529 of 928
BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
N-18547
2
Strike the head of the bolt (Item 1) [Figure 50-41-4] to
File has expired.

P-48185 push the pivot pin into the Bob-Tach frame.
Remove the bolt.

Remove the pivot pin (Item 1) [Figure 50-41-2] from the
tilt cylinder rod end (both sides). Use a long punch to push the pivot pins all the way into

the Bob-Tach frame.
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Remove the Bob-Tach from the lift arms.
Remove the Bob-Tach pivot pin (both sides).

Tach pivot pin.
Publications.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -
260 N•m) torque.
Figure 50-41-3
P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-41-3] out of the Bob-Tach frame. This allows
the grease to escape when driving the pivot pins in to the
Bob-Tach frame.

530 of 928
BOB-TACH (POWER) (CONT’D) Figure 50-41-7
Figure 50-41-5
N-18560
1
Remove the Wedge (Item 1) [Figure 50-41-7].
File has expired.

P-48135
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-41-8
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and

wedge.

Figure 50-41-6
Publications.
1
1
2
3
5
4
P-48135
Remove the washers and bolts (Item 1) [Figure 50-41-

N-18559 8].

Use a punch and hammer, remove the roll pin (Item 1) N•m) torque.
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].

N•m) torque.

531 of 928
BOB-TACH (POWER) (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-11

(Cont’d)
Figure 50-41-9
2 1
4
N-18557
3 2
File has expired.

N-20625 Remove the Power Bob-Tach. (See Removal And
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), Use a seal pick to remove seal (Item 1) [Figure 50-41-

or clevis (Item 4) [Figure 50-41-9] are damaged, put the 11] on the Bob-Tach.
assembly in a vise.

Remove the bolt and replace the damaged parts as
needed.
Remove and replace bushing (Item 2) [Figure 50-41-11]
with a driver tool and hammer.
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-41-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge [Figure 50-41-10].

532 of 928
LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation
Figure 50-50-1 1
P-31969A
File has expired. N-18851 the stabilizer link pivot pin.
Figure 50-50-4
Lower the lift arms.


Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-1]. 2
Publications.
NOTE: The Bob-Tach and front wheel are removed in
photo [Figure 50-50-1] for clarity purpose
only. The Bob-Tach and front wheel do not
1
need to be removed to remove the stabilizer 3

link.
Figure 50-50-2
P-31968A
Use a slide hammer (Item 1), remove the stabilizer link

pivot pin (Item 2) [Figure 50-50-4].
1
Remove the stabilizer link (Item 3) [Figure 50-50-4] from
the lift arm.
2 Reverse the above procedure to install the stabilizer link.
N-18813

the stabilizer link pivot pin.
Remove the stabilizer link pivot pin (Item 2) [Figure 50-

50-2].

533 of 928
LIFT ARMS (CONT’D) Figure 50-50-6
Link Removal And Installation
Figure 50-50-5
1
2
P-31974
Connect a chain and chain hoist on the lift arm link
File has expired.

N-18806 [Figure 50-50-6].

Lower the lift arms. Stop the engine. nut from the lift arm link pivot pin.

Remove the retainer bolt (Item 1) [Figure 50-50-5] and Figure 50-50-7
nut from the lift arm pivot pin.

Publications.
WARNING
Wear safety glasses to prevent eye injury when any 1
P-31975
W-2019-0907
Open the rear door.
Raise the radiator cover part way to gain access to the

pivot pin.
Lower the rear grille. Close the rear door.
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
Reverse the removal procedure to install the lift arm link

on the loader.

534 of 928
Figure 50-50-8
N-18850
Mark the tubelines for correct installation (both sides).
File has expired. P-31849 Pull the tubelines down, disconnect the hoses (Item 1)
[Figure 50-50-10] (both sides).
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.

Remove the Bob-Tach frame from the lift arms. (See Figure 50-50-11

Install jackstands under the rear of the loader [Figure 50-
50-8].
Figure 50-50-9Publications.
1
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-11].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Remove the tubeline clamps (Item 1) [Figure 50-50-9]

under the lift arms (both sides).

535 of 928
Figure 50-50-12
1
P-34136
Remove the tilt cylinder mounting bolt base end (Item 1)
File has expired.

N-18792 [Figure 50-50-14].

Remove the three front step mounting bolts (Item 1)
[Figure 50-50-12]. Remove the tilt cylinders and tilt tubelines from the

loader.
Figure 50-50-13
Publications.
1
N-18793
N-18851
Remove the tilt port block mounting bolt (Item 1) [Figure

50-50-13] under the step. Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-15].

536 of 928
Figure 50-50-16
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
File has expired. N-18806 pin (Item 1) [Figure 50-50-18] (both sides).
Strap the lift cylinders to rear of the uprights.

nut from the lift arm pin (both sides).

Use a drift pin and hammer remove the lift arm pivot pin

Figure 50-50-17
Publications.
1
P-31972

nut from the lift cylinder rod end pivot pin (both sides).

537 of 928
LIFT ARMS (CONT’D) Connect a nylon lift strap, chain and chain hoist to the lift
arms (Item 1) [Figure 50-50-19] and [Figure 50-50-20].
Figure 50-50-19 the stabilizer pivot pin.
Use a slide hammer, remove the stabilizer pivot pin (Item

3) [Figure 50-50-19] (both sides).
Remove the chain from the front axle.
Remove the lift arms from the loader.
1 Reverse the removal procedure to install the lift arm.
File has expired.

2

3

Publications. P-31971A
Figure 50-50-20
P-31970A

538 of 928
REAR GRILLE Figure 50-60-3
Figure 50-60-1
2
P-48130
Installation: Line up the tab (Item 1) on the grille with the
File has expired.

P-48251 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grille.

Figure 50-60-2

1
Publications.
P-48252
Lift up on the rear grille (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grille away from the loader.

539 of 928
File has expired.

Publications.

540 of 928
REAR DOOR (TAILGATE) Figure 50-70-3

1
Figure 50-70-1
2
3
2
P-34606
1
Remove the top and bottom door hinge mounting bolts
File has expired.

P-68264 (Item 1) [Figure 50-70-3] and nuts.
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) in the top hinge as shown
50-70-1] from the engine harness. [Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the mounting bolts and nuts to 25 -
the door. (See Rear Removal And Installation on Page
60-60-2.)
28 ft.-lb. (34 - 38 N•m) torque.
Lift the door away from the loader frame and put the door
Figure 50-70-2
Publications. flat on the floor.
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

541 of 928
REAR DOOR (TAILGATE) (CONT’D) Striker Disassembly And Assembly
Striker Removal And Installation Earlier Models
Earlier Models Figure 50-70-6
Figure 50-70-4
2 2
3
4
1
1
File has expired.
P-31126
P-31320
Remove the lock nut (Item 1) [Figure 50-70-6].
Remove the rollers (Item 2) and the spacer (Item 3) from

Later Models
the bolt (Item 4) [Figure 50-70-6].
Figure 50-70-5
Use updated files from Bobcat Check the parts for wear and replace as needed.

1Publications. - 38 N•m) torque.
Later Models
Figure 50-70-7
2
3
P-76970A
4
Remove the two striker mount bolts (Item 1) [Figure 50- 1
70-4] and [Figure 50-70-5].
Remove the striker assembly from the loader.

P-31320A
Remove the lock nut (Item 1) [Figure 50-70-7].
Remove the roller (Item 2) and the spacer (Item 3) from

the bolt (Item 4) [Figure 50-70-7].
Check the parts for wear and replace as needed.

- 38 N•m) torque.

542 of 928
REAR DOOR (TAILGATE) (CONT’D) NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
Striker (Adjusting) the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
WARNING
Open the door.
Installation: Tighten the mounting bolts (Item 1) [Figure
Never service or adjust the machine when the engine
50-70-8] and [Figure 50-70-9] to 90 - 100 ft.-lb. (125 -
is running unless instructed to do so in the manual.
W-2012-0497
135 N•m) torque.

Earlier Models
Tighten both striker mount bolts (Item 1) [Figure 50-70-8]
Figure 50-70-8 to 90 - 100 ft.-lb. (125 - 135 N•m) torque.
1 File has expired.

1
Later Models
Figure 50-70-9
P-76970A
Loosen the striker assembly mount bolts (Item 1) [Figure

50-70-8] and [Figure 50-70-9].
Align the striker assembly in the center of the mounting

holes.

543 of 928
REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-12
Latch Removal And Installation
Figure 50-70-10
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-12]
File has expired.

P-31125 from the rear door.
Disconnect the spring (Item 1) [Figure 50-70-10] from

the rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-10] from
the latch.
Figure 50-70-11
Publications.
3
1
P-31127
Remove the spring (Item 1) [Figure 50-70-11] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-11] from

the door handle.

544 of 928
FUEL TANK Figure 50-80-3

2
Figure 50-80-1
P-28143

Remove the engine/hydrostatic pump assembly from the
Remove the cover (Item 1) [Figure 50-80-1] which is 70-10-9.)
installed over the fuel drain near the rear of the

chaincase. Remove the two mounting bolts (Item 1) [Figure 50-80-
3] from the battery holder.
Installation: Tighten the cover mounting bolts to 190 -
240 in.-lb. (21,5 - 27 N•m) torque. Installation: Tighten the battery holder mounting bolts to
190 - 240 in.-lb. (21,5 - 27 N•m) torque.
Figure 50-80-2
Publications. Remove the battery holder (Item 2) [Figure 50-80-3]
from the loader.
Figure 50-80-4
1 1
P1619
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
P-28144
Remove the mounting bolts (Item 1) [Figure 50-80-4]

from the fuel tank retainer bracket.
Installation: Tighten the mounting bolts to 190 - 240 in.-

lb. (21,5 - 27 N•m) torque.

545 of 928
FUEL TANK (CONT’D) Fuel Level Sender Removal And Installation
Figure 50-80-5
P13870
File has expired.

P13876
Loosen the fuel level sender (Item 1) [Figure 50-80-6]
with a wrench.
Disconnect fuel sender.
Turn the fuel level sender out and remove it from the fuel

Disconnect fuel venthose. tank. Check the fuel level sender for damage and replace
if necessary.
Disconnect fuel fillhose.
Lift the fuel tank up and remove the tank from the loader
Installation: tighten the fuel level sender to 50 - 60 in.-lb.
(5,7 - 6,8 N•m) torque.
[Figure 50-80-5].
Publications.

546 of 928
FUEL TANK (CONT’D)
Fuel Fill Screen Removal And Installation
Figure 50-80-7
2
1
Remove the clamp (Item 1) [Figure 50-80-7] and remove

the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.

Figure 50-80-8

Publications. 1
P13875
Remove the fuel fill screen (Item 1) [Figure 50-80-8]

from the tank. Check the screen for damage and replace
if necessary.
Remove the fuel supply screen (Item 1) [Figure 50-80-8]

from the hose. Check the screen for damage and replace
if necessary.

547 of 928
File has expired.

Publications.

548 of 928
CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
WARNING P-26008
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
File has expired.

the pedal linkage.
Check the rubber bushing in the pedal for wear and

to fall and cause injury or death. replace as needed.
W-2059-0598

Figure 50-90-2

Raise the operator cab. (See Raising on Page 10-30-1.) 1
Publications.
DANGER
P-34375
P-90328 Remove the two mounting bolts (Item 1) [Figure 50-90-

2] from the pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

549 of 928
CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
2
1
P-34376
Remove the crossbar from the pivot [Figure 50-90-5].
File has expired.

P-66969A
Installation: Check the nylon bushing (Item 1) [Figure
50-90-5] for wear and replace as needed.
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.

Remove the crossbar pivot bolt (Item 2) [Figure 50-90-
3].
Figure 50-90-4
Publications.
P-34260
Remove the hairpin clip and cross-pin (Item 1) [Figure

50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

550 of 928
CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-8
Linkage Removal And Installation (Cont’d)
Figure 50-90-6
P-34258
Remove the hairpin clip and cross-pin (Item 1) [Figure
File has expired. P-66969 50-90-8] from the control valve tilt spool.
Figure 50-90-9
disconnect the lift foot pedal linkage from the crossbar

linkage.

Figure 50-90-7
1
Publications.
1
P-26008

disconnect the lift foot pedal.
P-24759

disconnect the lift foot pedal.

551 of 928
CONTROL PEDALS AND LINKAGES (CONT’D) Tilt the pedal back and forth until an acceptable “neutral”
angle is achieved on the pedal.
Pedal (Adjusting)
Tighten the two mounting bolts (Item 1) and pivot bolt
After installing the pedal, adjust the pedal angle so that (Item 2) [Figure 50-90-11] on the pedal assembly to
there is clearance under the rear of the pedal. The valve standard torque.
spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-90-10
File has expired.

P-34375
Publications.
Loosen the two mounting bolts (Item 1) [Figure 50-90-
10] from the pedal mounting bracket.
Figure 50-90-11
2
1
P-26008
Loosen the bolt (Item 2) [Figure 50-90-11] and nut on the

pedal linkage.
Check the rubber bushing in the pedal for wear and

replace as needed.

552 of 928
CONTROL PEDALS (ACS) Remove the foot pedal and sensor assembly from the
loader.
Description
Figure 50-91-3
The control pedals send an electronic pulse to the
actuators on the control valve. The electronic pulse tells
the actuators to move the lift or tilt spools on the control
valve.
The control pedals are located on the lower mainframe at

the operators feet.
1
Foot Sensor Removal And Installation
Figure 50-91-1
File has expired.

P-21927
P-21936
Remove the two bolts (Item 1) [Figure 50-91-3] from the
foot sensor shield.

Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2
N•m) torque.
1
Pull the pin (Item 1) [Figure 50-91-1] holding the foot

pedal linkage to the sensor.
Disconnect the two connectors (Item 2) [Figure 50-91-1]

from the sensor and lock solenoid.
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].

553 of 928
CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-5
Figure 50-91-4
1
P-21940
File has expired.

P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6

Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque.
Remove the two bolts (Item 2) [Figure 50-91-4] from the
1
Publications.
bracket and sensor assembly.

P-21935A
N•m) torque.
Remove the sensor assembly.
P-21934
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.

554 of 928
CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Linkage Disassembly And Assembly
Figure 50-91-7
Remove the bolt (Item 1) holding the linkage (Item 2) to

the side of the foot pedal [Figure 50-91-7].

Figure 50-91-8

Publications.
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].

555 of 928
File has expired.

Publications.

556 of 928
CONTROL PANEL
Description
Figure 50-100-1
File has expired.

Publications.
P-54658
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. The returning force of the torsion bushings.
bellcranks have grease fittings.
NOTE: Torsion bushings need to be replaced if torn
The forward travel is adjusted by drift adjustment bolts. or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
The bellcranks are attached to steering linkage bars with made. Do not fully tighten torsion bushing
rubber torsion bushings pressed into the bellcranks. bolts again until all steering adjustments have
Bellcranks mount to the control panel. been made first.
Steering linkage bars are a two-piece design. Steering Sequence of steering adjustments:
linkage bars are adjustable in length for “full travel
adjustment”. 1. Set neutral of pintle arms, “creep”
2. Set full travel at steering linkage bars
Steering linkage bars attach to the pintle arms where a 3. Set drift at drift adjustment bolts
rubber torsion bushing is pressed into the pintle arms.

557 of 928
CONTROL PANEL (CONT'D) Figure 50-100-2
2 1
DANGER 3
P-48462
P-90328
AVOID DEATH Raise the lift arms and install an approved lift arm
•
File has expired.

unless supported by an approved lift arm Remove the engine speed control. (See Removal And

D-1009-0409
Use updated files from Bobcat Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-100-2].
WARNING
Publications. Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
W-2059-0598
WARNING
P-48277
W-2017-0286
Disconnect the control harness connectors (Item 4)

control levers.

558 of 928
CONTROL PANEL (CONT'D) Remove the fuse/relay shield mounting screws (Item 3)
[Figure 50-100-5].
Figure 50-100-4 N•m) torque.
Remove the fuse/relay shield (Item 4) [Figure 50-100-5]
Figure 50-100-6
2 2
1 1

P-26325


[Figure 50-100-4].
Remove the fuse/relay block [Figure 50-100-6].
Publications.
40 ft.-lb. (47,5 - 54,2 N•m) torque.
Figure 50-100-5
1 1
P-26323
Remove the fuse cover mount screws (Item 1) [Figure

50-100-5].
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)

torque.
Remove the fuse/relay cover (Item 2) [Figure 50-100-5].

559 of 928
CONTROL PANEL (CONT'D) Remove the control panel mounting bolts (Item 1)
[Figure 50-100-7], [Figure 50-100-8] and [Figure 50-
Removal And Installation (Cont'd) 100-9] from both sides of the control panel.
Figure 50-100-7 Installation: Tighten the control panel mounting bolts to

15 - 20 ft.-lb. (20 - 27 N•m) torque.
Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
1
File has expired.

P-26326
Figure 50-100-8

Publications. 1
1
P-26327
Figure 50-100-9
11
P-26329
P-26328 P-26329

560 of 928
CONTROL PANEL (CONT’D) Shaft Removal And Installation
Shock Removal And Installation NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Figure 50-100-10 Photo [Figure 50-100-11] shows the control
panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-100-10].
1
Remove the steering shock mounting nuts (Item 2)
3 [Figure 50-100-10].
Figure 50-100-11

from the end of the shock connected to the steering

linkage. 3

from the other end of the shock connected to the bracket
on the control panel.
1 2
P-48278
Publications.
(34 - 38 N•m) torque. Remove Control Handle Lever (Item 1) [Figure 50-100-
11]. (See Lever Removal And Installation on Page 50-
110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

100-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 -

38 N•m) torque.
Remove the steering shaft from the control panel.

561 of 928
CONTROL PANEL (CONT’D)
Shaft Disassembly And Assembly
Figure 50-100-12
2
2
1
2
File has expired.

P-4154
Disassemble the right and left steering bellcranks

(Item 1) from the cross shaft assembly [Figure 50-100-

12].

Assembly: Install new nylon bushings (Item 2) [Figure
50-100-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
Publications.
installing the right and left bellcranks.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.
Figure 50-100-13
1
P-26331
To remove the steering shaft mounting bracket (Item 3)

[Figure 50-100-11], remove the three mounting bolts
(Item 1) [Figure 50-100-13] from the front of the control
panel.
Remove the steering shaft mounting bracket.
(20 - 27 N•m) torque.

562 of 928
CONTROL PANEL (CONT’D) Installation: Align the marks on the steering linkage
Linkage Removal And Installation 40 ft.-lb. (47,5 - 54,2 N•m) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjustment procedure
WARNING must be performed. See Page 50-100-13 for
Linkage Neutral (Adjusting) procedure.
W-2059-0598
WARNING
File has expired.

W-2017-0286

Publications.
1.)
Figure 50-100-14
2 2
1 1
P-54609


[Figure 50-100-14].

563 of 928
CONTROL PANEL (CONT’D) Figure 50-100-17

7
Figure 50-100-15 6 8
3 1 4
1
2
5
2
P-48630
The centering plate/centering spring assembly consists

2
File has expired.
P-48631 of the following parts:
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-15]. 1 Bolt

2 Bushings
Remove the bolt/spring assembly.

Installation: Tighten the centering spring bolt and a
NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
3
4
Washer
Bushing Spacer
5 Spring

7
Lock Nut
Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-100-16] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.

564 of 928
Linkage Removal And Installation (Cont’d) SOLID CAMS
Figure 50-100-18
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
If the surface of any of the four solid pintle cams (Item 1)
File has expired.P-48629 are worn, loosen the bolt (Item 2) and rotate the cams 1/4
turn [Figure 50-100-19].
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-18]. 19] from the pintle.

If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
blocks.Use updated files from Bobcat

bolts (Item 2) [Figure 50-100-18]. Remove the centering 54,2 N•m) torque.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Publications.
Installation: Tighten the centering block bolts to 35 - 40
ft.-lb. (47,5 - 54,2 N•m) torque.
100-19].
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-19].
centering plate.
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled.

565 of 928
Figure 50-100-20
ROLLER CAMS 2
2
1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
File has expired.

P-54617 2) [Figure 50-100-22].
Remove the bolts and washers (Item 1) [Figure 50-100-

20] from the pintle.

Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -

54,2 N•m) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-20].
Figure 50-100-21
Publications.
1
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-100-21].
NOTE: The washers (Item 2) [Figure 50-100-21] are

hardened, and should only be replaced
through Bobcat Parts.

566 of 928
CONTROL PANEL (CONT’D) Pintle Arm Disassembly And Assembly
Linkage Removal And Installation (Cont’d) Figure 50-100-24
Figure 50-100-23 2
1
3
1
P-54625

Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-24] and inspect the pintle solid cams
NOTE: When installing the pintle base (Item 1) onto for damage or excessive wear.
the pump shaft, the cutouts on the pump shaft

will not line up with the bolt (Item 3) [Figure Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
50-100-23]. 54,2 N•m) torque.
Installation: Install the pintle base (Item 1) onto the
pump shaft (Item 2) [Figure 50-100-23]. The top of the
Figure 50-100-25
Publications.
pintle base should be level with the top of the pump shaft.
Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. 3
2
NOTE: After installing the linkage onto the

hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
See Page 50-100-13 for Linkage Neutral
(Adjusting) procedure. 2
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-100-

25] are used on ACS loaders only.
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-25].
Inspect the torsion bushing (Item 3) [Figure 50-100-25]

for damage and replace as needed.
Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2

N•m) torque.

567 of 928
Pintle Arm Disassembly And Assembly (Cont’d)
Figure 50-100-26
4 1 3
2 2
3 P-48619
Using a bushing driver (Item 1) remove the torsion
File has expired.

P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-27].
Remove the base pintle (Item 1) [Figure 50-100-26] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure

50-100-27] into the pintle arm using the same procedure
Remove the retaining bolt (Item 2), adjusting screw (Item as the removal.
3) and neoprene dampener (Item 4) [Figure 50-100-26]
from the base pintle. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
[Figure 50-100-26]. Publications.

Inspect parts for wear and damage, replace as needed arm should be the same.
NOTE: Anti-seize should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.

568 of 928
Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following 1

procedure:
MEL1563 or 6689779 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)

1.)
P-48448
Figure 50-100-28
Loosen the bolt/nut (Item 1) [Figure 50-100-29] only until
File has expired.

3
the tension is released from the torsion bushing.
Figure 50-100-30

1
2
Tool that may assist in the neutral adjustment [Figure 50-

100-28].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-28] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-30].
A steering centering block (Item 3) [Figure 50-100-28] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-100-30] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

569 of 928
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-31
2
P16121
2 Using the remote start tool, turn the key (Item 1) [Figure
File has expired.

P-54614 50-100-33] to the run position.
Move the traction lock override switch (Item 2) [Figure

Loosen the two bolts (Item 1) holding the right centering 50-100-33] so the traction function is unlocked. (The
block. Move the right hand centering block (Item 2) traction lock override switch light will be ON.) On a

[Figure 50-100-31] until both pintle cams contact the standard loader the wedge brake will unlock.
centering block.

NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left
NOTE: When the engine is started, the wheels/tracks
may begin to move.
properly. Publications.
centering block will also become aligned NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
3 release the hydraulic brake.
Using the remote start tool, turn the key (Item 1) [Figure
50-100-33] and start the engine and run at low idle.
1
Tighten bolts (Item 3) [Figure 50-100-32] to 35 - 40 ft.-lb.
(47,5 - 54,2 N•m).
2
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-31] and [Figure
50-100-32].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-28] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
32] around both centering blocks.
Lock the C-Clamp in place.

570 of 928
CONTROL PANEL (CONT’D) NOTE: This procedure is shown for neutral
adjustment on the left side of the loader. The
Linkage Neutral (Adjusting) (Cont’d) procedure is the same for the right side
neutral adjustment.
Start the neutral adjustment procedure with the left
pump first and complete the neutral adjustment for Turn the adjustment screw (Item 1) [Figure 50-100-35]
the left pump before adjusting the right pump. counterclockwise until forward creep is seen.
Figure 50-100-34 Turn the adjustment screw (Item 1) [Figure 50-100-35]

counterclockwise to a point between forward and reverse
where there is zero creep.
Stroke the left steering lever to forward and allow the

2 1 lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.
File has expired.

P-48632

Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-34].) Loosen the bolts enough to
Publications.
allow free movement between the pintle arm and the
pintle base.
NOTE: If the bolts are too loose or too tight, the

neutral adjustment may be affected.
Figure 50-100-35
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.

571 of 928
CONTROL PANEL (CONT’D)
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-36
1
2 2 1
File has expired.

P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).

Repeat the adjustment procedure for the right pump.

Torque the right pump pintle adjustment lock bolts (Item
2) [Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).
Publications.
Test both levers by moving them backward and forward
and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels/

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-36] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). Repeat for the
three remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre applied
Loctite®.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Page 50-100-17.)

572 of 928
Linkage Travel (Adjusting)
NOTE: When the linkage travel adjustment procedure 2

is being done as part of the loader neutral
adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448
support device. Failure to use an approved lift arm Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
File has expired.

W-2059-0598
(Item 2). The bolt (Item 2) [Figure 50-100-37] must be
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm Figure 50-100-38

Use WARNING
updated files from Bobcat 1
Publications.
Put jackstands under the front axles and rear corners 2
W-2017-0286

1.) P-54613

Loosen the nut (Item 1) only until the tension is released
Pre-load tension in the torsion bushings must be from the torsion bushing (Item 2) [Figure 50-100-38].
removed before adjusting the steering linkage.
The bolt must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.

573 of 928
Linkage Travel (Adjusting) (Cont’d)

2
Figure 50-100-39
1 3 4
P-51174
Move the right side steering lever forward and install a
File has expired.

P-37574 15/16 in. (24 mm) thick spacer (Item 1) between the
center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-41].
Remove access plug from the top of the control panel.
This will allow the pintle arms to move freely while

Turn the control lever drift adjustment bolts (Item 1) adjusting the steering linkage for full forward travel
[Figure 50-100-39] (one on each control lever) out until it speed.
is flush with the bottom of the nut.
Figure 50-100-40
Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure
50-100-41].
3 2
4
1
P-51173
1
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) Before adjusting the linkage, check that the base pintle
[Figure 50-100-40]. arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] and tighten to 35
- 40 ft.-lb. (48 - 54 N•m) torque. There should be no play
between the pintle arm and the square pump shaft.
Also check that the cam mounting nuts or bolts (Item 4)

[Figure 50-100-40] are tight, 35 - 40 ft.-lb. (48 - 54 N•m)
torque.

574 of 928
CONTROL PANEL (CONT'D) Figure 50-100-45
Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-43
1 1 1
P-51175
Remove the spacer (Item 1) [Figure 50-100-45].

Disconnect the remote start tool. (See REMOTE START
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
43] on each steering linkage bar.
Figure 50-100-46

Figure 50-100-44
Publications.
1
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35 - 40

ft.-lb. (47,5 - 54,2 N•m) [Figure 50-100-46].
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-100-44]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 35 - 40 ft.-lb.

(47,5 - 54,2 N•m) torque.
Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

575 of 928
CONTROL PANEL (CONT'D) If the drift is excessive to the right, turn the left
adjustment bolt in.
Linkage Travel (Adjusting) (Cont'd)
NOTE: When using the drift adjustment bolts, only
Figure 50-100-47 adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
2 Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.

1
Re-install the plug in the drift bolt access hole after
adjustment.
File has expired.

P-48448
Tighten the two bolts and nuts (Items 1 and 2) [Figure

50-100-47] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at

the steering bell cranks.

Figure 50-100-48
1 Publications.
P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-48] in until it
touches the U-bolt holding the control lever.
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. of

“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-48] in.

576 of 928
CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The SJC control panel has two electronic handles that
control the steering, lift, and tilt functions. There is no Remove the engine speed control. (See Removal And
mechanical linkages connecting to the hydrostatic pumps Installation on Page 70-20-1.)
or the control valve.
Figure 50-101-1
The control panel is connected to the lower mainframe
and wraps around and underneath the operator seat.
WARNING 1

File has expired.

W-2017-0286
P-73451

Remove the lift arm bypass control knob and rubber
Use DANGER
updated files from Bobcat washer (Item 1) [Figure 50-101-1].
Figure 50-101-2
Publications. 2
1
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 4
3 3
support. Replace if damaged. P-64319
D-1009-0409
Remove the fuse cover mount screws (Item 1) [Figure
50-101-2].
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)

torque.
WARNING Remove the fuse/relay cover (Item 2) [Figure 50-101-2].
Never work on a machine with the lift arms up unless Remove the fuse/relay shield mounting screws (Item 3)
the lift arms are secured by an approved lift arm [Figure 50-101-2].
support device can allow the lift arms or attachment Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
to fall and cause injury or death. N•m) torque.
W-2059-0598
Remove the fuse/relay shield (Item 4) [Figure 50-101-2]

577 of 928
CONTROL PANEL (SJC) (CONT’D)
Figure 50-101-3
1 1
File has expired.

P-64309
Remove the control panel mount screws (Item 1) [Figure

50-101-3] from the both sides of the control panel.

Installation: Tighten the control panel mounting screws

to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-101-4
Publications.
1
P-73293
Disconnect the right and left joystick wire harness

connectors (Item 1) [Figure 50-101-4].
Remove the control panel from the loader.

578 of 928
CONTROL HANDLE / LEVER Figure 50-110-2
Description
The control handles/levers are used to control the

forward and reverse travel.
The control handles/levers are mounted to the control

panel.
Lever Removal And Installation

1 1
Figure 50-110-1 2
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure
File has expired. 50-110-2] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-2] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-3] on the front of the control panel.
1
P-48462 Installation: Tighten the U-bolts so the lever can not be
moved either right or left when seated in the operator
Publications.
Disconnect the electrical connectors from the control
lever [Figure 50-110-1].
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.

579 of 928
CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Figure 50-110-3
File has expired.

N-18884
To replace the rubber boot (Item 1) [Figure 50-110-3] on

the control panel, remove the control lever (See above

procedure).

Drill out the four rivets (Item 2) [Figure 50-110-3] located
on the flange of the rubber boot and remove the old boot.
Publications.
Install the new boot and reinstall the control lever.

580 of 928
CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation

forward and reverse travel and the lift and tilt
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are
located in the base of the control handle/levers.

panel.
1
Figure 50-111-1
P-21864
File has expired.

1 Loosen the nuts (Item 1) [Figure 50-111-2].
Installation: Tighten the u-bolts so the lever can not be


seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
P-21879
Publications.
Handle Sensor (Item 1) [Figure 50-111-1]. 2
P-21837
Tilt the control handle (Item 1) [Figure 50-111-3] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-3].

581 of 928
CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-111-6
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-4
1
P-21860
2
Remove the handle lock solenoid connector (Item1)
File has expired.

P-21836 [Figure 50-111-6] from the clip.
NOTE: Pry out with a small screw driver and push the
Disconnect the harness connector (Item 1) [Figure 50- connector down.
111-4] from the handle sensor connector.

Figure 50-111-7
Disconnect the harness connector (Item 2) [Figure 50-

111-4] from the handle lock solenoid connector.
Figure 50-111-5
1
Publications.
1
5
4
2
1
P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-7] from the handle sensor.
Installation: Tighten screws to 32 - 38 in.-lb. (3,6 - 4,3

Remove the handle sensor connector (Item 1) [Figure N•m) torque.
50-111-5] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screw driver and push the handle sensor, remove the one plastic spacer (Item 3),
connector down. the spring (Item 4) and washer (Item 5) [Figure 50-111-
7].

582 of 928
Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-8 2
P-21878
1
Figure 50-111-11
2
3
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor.

Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m)
torque.
Figure 50-111-9
Publications. 7
4 1
3 8
P-21799
1
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-10] and [Figure
3 7 50-111-11] to assure proper return of the control handle
to neutral and minimize harness movement.
5 6
NOTE: Route wires (Item 2) [Figure 50-111-10] and
2
P-21882 [Figure 50-111-11] as shown away from stop
strap (Item 3) [Figure 50-111-10] and [Figure
50-111-11] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-9]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-9]

can only be replaced as a complete assembly.
Check the spacer (Item 2) and screws (Item 3), mounting

pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
(Item 7), stop strap (Item 8) and replace as needed
[Figure 50-111-9].

583 of 928
Handle Removal And Installation
Figure 50-111-12
1
1 N-17384
Remove the rubber handle cover (Item 1) [Figure 50-
File has expired.

P-21879 111-14] from the handle.
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page

50-111-1.)

Figure 50-111-13 1
Publications. 1 2 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure
P16534 50-111-15] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lb.

Remove the switch handle (Item 1) [Figure 50-111-13]. (4 N•m) torque.
(See Switch Handle Installation on Page 60-130-6.)

584 of 928
CONTROL HANDLE / LEVER (ACS) (CONT'D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-18
Figure 50-111-16
1
1
1
2
1 N-22667

Disconnect the electrical connectors (Item 1) [Figure 50-
111-18] from the control lever switch handle.
Remove the handle sleeve (Item 1) and bushings (Item
2) from the handle [Figure 50-111-16]. Remove the electrical connectors from the control lever

switch handle. (See Handle Sensor Connector
Check all parts for wear and replace as needed. Disassembly And Assembly on Page 60-130-3.)
Figure 50-111-17
Publications.
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-17] that

connects the handle to the handle sensor for wear,
replace as needed.

585 of 928
Lever Removal And Installation (Cont'd)
Figure 50-111-19
2
1
P13734
2
The control lever (Item 1) [Figure 50-111-21] must be
File has expired.

N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-111-21] can be

Figure 50-111-20 replaced separately from the control lever.

Publications.
18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-19]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-19]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 in. [Figure 50-111-20].
Remove the control lever from the cross shaft and control
panel.

586 of 928
CONTROL HANDLE / LEVER (ACS) (CONT'D)
Boot Removal And Installation
Figure 50-111-22
To replace the rubber boot (Item 1) [Figure 50-111-22]

on the control panel, remove the control lever. (See Boot


Drill out the four rivets (Item 2) [Figure 50-111-22]
located on the flange of the rubber boot and remove the
old boot.
Publications.
Install the new boot and reinstall the control lever. (See
Boot Removal And Installation on Page 50-110-2.)

587 of 928
File has expired.

Publications.

588 of 928
CONTROL HANDLE / LEVER (SJC) Figure 50-112-2
Description

forward and reverse travel and the lift and tilt functions.

panel.
1
Joystick Testing
Figure 50-112-1
P-64298
At the back side of the control panel, locate the left
File has expired. joystick wire connector (Item 1) [Figure 50-112-2].
Figure 50-112-3

1
Publications.
procedure:
3
2
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563 or 6689779-Remote Start Tool
Multimeter
P-28312
Disconnect the joystick harness connector (Item 1) from
Raise the operator cab. (See Raising on Page 10-30-1.) the loader wiring harness (Item 2) [Figure 50-112-3].
Connect the remote start tool to the loader. (See Install the test harness (Item 3) [Figure 50-112-3]
REMOTE START TOOL KIT-MEL1563 on Page 10-60- between the two connectors.
1.)
Turn the remote start key to ON position without starting
the loader.
Check the voltage between pin 3 and pin 5 on the joystick

test harness (Item 3) [Figure 50-112-3].
The voltage should be between 2.45 and 2.55 volts.

589 of 928
CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Removal And Installation
Joystick Testing (Cont’d) Figure 50-112-5
Figure 50-112-4
1
1
P-73247
File has expired.

P-64328
Lift the rubber boot (Item 1) [Figure 50-112-5].
Repeat the procedure at the right joystick wiring harness Figure 50-112-6
connector (Item 1) [Figure 50-112-4]. (If needed.)

1
Publications.
1
P-73248
Remove the four screws (Item 1) [Figure 50-112-6] to lift

the joystick control from the base.
Installation: Tighten the four screws to 35 - 40 in.-lb.

(4,0 - 4,5 N•m) torque.

590 of 928
CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-9
Joystick Removal And Installation (Cont’d)
Figure 50-112-7
1
1
P-64303
Remove the two control lever mounting bolts (Item 1)
File has expired. P-73240 [Figure 50-112-9].
The mounting bolts are secured with lock-nuts on the

Disconnect the joystick connector (Item 1) [Figure 50- back of the control panel. Once removed, they need to be
112-7] from the harness connector. replaced with new.

Joystick Mount Removal And Installation Figure 50-112-10
Figure 50-112-8
Publications.
1
P-76992
P-64328
Remove the control lever from the loader [Figure 50-
112-10].
Disconnect the joystick wiring harness connectors (Item
1) on both the right and left hand joysticks [Figure 50- Remove the bolts (Item 1) [Figure 50-112-10] to remove
112-8]. the control lever from the loader.

591 of 928
File has expired.

Publications.

592 of 928
ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
2 1
1
2
P-66819

Remove the top mounting screw (Item 1), and loosen the
two bottom mounting screws (Item 2) [Figure 50-120-3]
Remove the top mounting screw (Item 1), and loosen the from the front access panel.
two bottom mounting screws (Item 2) [Figure 50-120-1]

from the front access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the front access panel from the loader.
Publications.
Remove the front access panel from the loader.
Figure 50-120-2
Figure 50-120-4
1 1
1
1
1 P-66821
1
P-66820
Remove the seven mount screws (Item 1) [Figure 50-
120-4] from the rear access panel.
120-2] from the rear access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the throttle lever assembly (Item 2) [Figure 50-
120-4]from the access panel.
Remove the rear access panel from behind the steering
panel, remove the panel from the loader. Remove the rear access panel from behind the steering
panel, remove the panel from the loader.

593 of 928
File has expired.

Publications.

594 of 928
ACCESS PANEL (INSIDE) (SJC) Move the lever assembly a slight amount toward the
center of the loader, to allow clearance for the panel to be
Removal And Installation (Left) removed.
Raise the lift arms and install an approved lift arm Remove the inside rear access panel from the loader.
Figure 50-121-1
1
2
File has expired.

P-64299

Remove the top mounting screw (Item 1) and loosen the
two bottom screws (Item 2) [Figure 50-121-1].
Publications.
Installation: Tighten the screws to 15 - 20 ft.-lb. (20-27
N•m) torque.
Remove the inside front access panel from the loader.
Figure 50-121-2
1 1
P-64310

121-2]
Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.

595 of 928
ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-5
Removal And Installation (Right)


2
1
Figure 50-121-3
P-64327
Loosen the two bottom mount screws (Item 1) [Figure
File has expired. 50-121-5] from the front inside access panel.
Remove the top mount screw (Item 2) [Figure 50-121-5]

from the front inside access panel.

P-64300 Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
121-3], from the foot throttle assembly.
Remove the inside front access panel from the loader.
Publications.
N•m) torque.
Figure 50-121-4
P-64313
Disconnect the foot operated speed control linkage (Item

1) [Figure 50-121-4] from the hand operated speed
control lever arm.
Remove the foot operated speed control assembly from

the loader.

596 of 928
ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-8
Removal And Installation (Right) (Cont’d)
Figure 50-121-6
1 2
P-34553A
Lift the speed control pin (Item 1) from the notch (Item 2)
File has expired. P-34548 in the speed control rod [Figure 50-121-8].
Figure 50-121-9
Remove the two mount screws (Item 1) [Figure 50-121-
6] from the hand operated speed control lever.


N•m) torque.
Figure 50-121-7
Publications. 1
P-34549
At the bottom right side of the control panel, remove the

keeper and pin (Item 1) [Figure 50-121-9] that connects
the speed control linkage arm to the speed control rod.
P-34551
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-121-7].

597 of 928
ACCESS PANEL (INSIDE) (SJC) (CONT’D)
Removal And Installation (Right) (Cont’d)
Figure 50-121-10
File has expired.

P-34550
Remove the mount bolt and nut (Item 1) [Figure 50-121-

10] from the speed control linkage arm.

Remove the speed control linkage arm (Item 2) [Figure

50-121-10] from the access panel.
Figure 50-121-11
Publications.
1
P-64309
Remove the five mount screws (Item 1) [Figure 50-121-

11] from the access panel.

N•m) torque.
Move the lever assembly a slight amount toward the

center of the loader, to allow clearance for the panel to be
removed.
Remove the inside rear panel from the loader.

598 of 928
WINDOW (REAR) Installation (Split Molding)
Removal Clean the area before installing the rubber molding.
Figure 50-130-2
WARNING
W-2019-0907 1
Figure 50-130-1
Install the rubber molding (Item 1) [Figure 50-130-2]

1 around the edge of the rear opening in the operator cab.

If replacing the rubber molding (Item 1) [Figure 50-130-
Use updated files from Bobcat 2] cut off the excess molding.
Figure 50-130-3
Publications.
P-64994
Pull on the tag (Item 1) [Figure 50-130-1] on the rear

window to remove the rubber cord.
Using gloves, push the rear window out the rear of the 1
operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
P16015A
installing a new window.
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-3]
into the molding on the inside of the operator cab.
Install the safety tag in the top center of the cord.

599 of 928
WINDOW (REAR) (CONT’D) Figure 50-130-6
Installation (Split Molding) (Cont’d)
Figure 50-130-4
1 1
P16013
Use the plastic stick (Item 1) [Figure 50-130-6] to
File has expired.

P-64997 position the locking tab into the groove to secure the
window in the molding.
Apply liquid soap in the rubber molding (Item 1) [Figure Tapping the window corners will help seat the window in
50-130-4] to make installation easier. the molding.

Install the window from the outside of the operator cab.

Install a lower corner of the rear window into the corner of
the molding. [Figure 50-130-4].
Publications.
Align the other lower corner of the window in the molding.
Work the window downward until the window is fully

seated in the lower portion of the molding.
Figure 50-130-5
P-64998
Use a plastic stick (Item 1) [Figure 50-130-5] under the

molding lip to guide the window into the molding groove.

600 of 928
WINDOW (REAR) (CONT’D) Figure 50-130-9
Installation (Continuous Molding)
Clean the area before installing the rear window

assembly.
Figure 50-130-7
1
1
P-64997
Install the rear window assembly from the outside of the
File has expired. operator cab into the window frame.
Install a lower corner of the rear window assembly into

P-85229 the corner of the window frame (Item 1) [Figure 50-130-
9].

Install the rubber molding (Item 1) [Figure 50-130-7] Work the window assembly downward until the window is
around the edge of the rear window.
Figure 50-130-8
fully seated in the lower portion of the window frame.
Publications. WARNING
2
1 of the following conditions exist:
W-2019-0907
P-85228
Apply liquid soap to the rubber molding (Item 1) [Figure

50-130-8] to make installation easier.
NOTE: Install the window assembly with the narrow

edge (Item 2) [Figure 50-130-8] toward the
inside of the loader.

601 of 928
WINDOW (REAR) (CONT’D)
Installation (Continuous Molding) (Cont’d)
Figure 50-130-10
File has expired.

P-85230
Apply light pressure to the outside of the window

assembly holding it tight up against the window frame.

Use a multipurpose tool (Item 1) [Figure 50-130-10]

under the molding lip to guide the window assembly into
the window frame.
Publications.
NOTE: Tapping the window with a rubber hammer
will help seat the window assembly in the
window frame.
Figure 50-130-11
P16015A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-11]
with the safety tag into the molding on the inside of the
operator cab.
NOTE: Verify the safety tag is located in the top

center of the window.

602 of 928
WINDOW (TOP)
Figure 50-131-1
1 1
Position the window in the recess area.

Install the bolts (Item 1) [Figure 50-131-1] through the
window grommets, the nylon bushings and through the

cab holes.
Figure 50-131-2
Publications.
1
1
1
1
N-20950
From inside the operator cab, install and tighten the

knobs (Item 1) [Figure 50-131-2] on the window bolts.

603 of 928
File has expired.

Publications.

604 of 928
WINDOW (SIDE) Figure 50-132-3
Figure 50-132-1
2
N-20814
NOTE: [Figure 50-132-3] is shown with the washer
File has expired. P-66024 and knob removed to illustrate the direction of
movement.
Release the latch (Item 1) [Figure 50-132-1] and slide Move the window slide rail using the two thumb pads
the front window back towards the rear of the operator (Item 2) [Figure 50-132-2] and [Figure 50-132-3]

cab. towards the rear of the operator cab and then down
towards the bottom of the operator cab.
Figure 50-132-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
Publications. window is secure and does not fall. Make sure

the slide rails are in alignment and the window
is positioned in the top track during
1 1 installation.
Remove the front side window from the operator cab.
2 2
P-66019
From inside the operator cab, loosen the knobs (Item 1)

[Figure 50-132-2] and [Figure 50-132-3] on the window
slide rail bolts.

605 of 928
WINDOW (SIDE) (CONT’D)
Figure 50-132-4
2
1
File has expired.

P-66021
Installation: When installing the window make sure the

slide rail (Item 1) adjoins the front stationary slide rail

(Item 2) [Figure 50-132-4].

Figure 50-132-5
Publications.
1
P-66020
The rear side window sets in a recessed groove.
NOTE: The window should be secured to prevent

damage when the bolt (Item 1) [Figure 50-132-
5] is loosened.
Loosen the bolt (Item 1) [Figure 50-132-5] on the rear

side window.
Remove the rear side window.

606 of 928
WINDOW (CAB DOOR) Figure 50-133-3
Removal (Standard Window)
Figure 50-133-1
3
2
1
1 1
1 S0363
Push the window out at any corner of the window (Item 1)
NOTE: The window may fall when pushing on the

Remove the wiper arm assembly (Item 1) [Figure 50- corners. Have a second technician assist you
133-1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)

[Figure 50-133-1].
Secure the wiper motor inside the cab.
Publications.
Figure 50-133-2
N-20171
Pull the plastic loop (Item 1) [Figure 50-133-2] at the top

of the window to remove the rubber cord.

607 of 928
WINDOW (CAB DOOR) (CONT’D) Figure 50-133-6
Installation (Standard Window)
Clean the area before installing the rubber molding.
Figure 50-133-4
1
P-66059
Apply liquid soap in the rubber molding to make
File has expired.

P-66058
installation easier.
Install the window from the outside of the door frame.
Install a lower corner of the rear window (Item 1) [Figure

Install the rubber molding (Item 1) [Figure 50-133-4] 50-133-6] into the corner of the molding.
around the edge of the front door frame starting at the

bottom of the door frame.
If replacing the rubber molding (Item 1) [Figure 50-133-

Align the other lower corner of the window in the molding.
Work the window downward until the window is fully
Figure 50-133-5
Publications.
4] cut off the excess molding. seated in the lower portion of the molding.
Figure 50-133-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-133-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-133-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.

608 of 928
WINDOW (CAB DOOR) (CONT’D)
Installation (Standard Window) (Cont’d)
Figure 50-133-8
File has expired.P-66049A
Use the plastic stick (Item 1) [Figure 50-133-8] to

position the locking tab into the groove to secure the

window in the molding.

Tapping the window corners will help seat the window in
the molding.
Publications.
Figure 50-133-9
P-66051
Install the wiper motor (Item 1) and wiper arm assembly

(Item 2) [Figure 50-133-9].

609 of 928
WINDOW (CAB DOOR) (CONT’D)
Removal And Installation (Special Applications

Window)
Replace the Lexan glazing under the following

conditions:
• When the glazing is four years old;
• When the glazing becomes yellow or hazed;
• Is scratched on either side with scratches that can be

felt with the fingernail;
• Has cracks coming from the edges or mounting holes.

or fine cracks on the surface area;
• Has contacted any fluids that have caused

cloudiness.
Figure 50-133-10
File has expired.

1
Publications.
P-66101
Remove window from loader.
NOTE: The Special Applications window is held on by

the brackets only, it does not sit in the rubber
molding. During Removal the window may fall
as the mounting bolts are loosened.
Remove the five mounting brackets and bolts (Item 1)

[Figure 50-133-10].

610 of 928
CAB DOOR Figure 50-140-2
Description
The standard cab door is available as an option or dealer

installed kit. The Special Application Kit Door or Forestry
Door kit are available for use with certain attachments.
Figure 50-140-1
3
2
4 File has expired. 1

Open the cab door.
P-76520
P-76526
Publications.
Remove the gas spring (Item 1) [Figure 50-140-1] from
the threshold.
Lift the door (Item 1) [Figure 50-140-2] off the hinges.
Disconnect the electrical harnesses (Items 2 and 3)

[Figure 50-140-1].
Disconnect the washer bottle hose (Item 4) [Figure 50-

140-1].

611 of 928
CAB DOOR (CONT’D) Aligning
Figure 50-140-3 WRONG WRONG
2 1
P-76523A P-76524A
CORRECT
CORRECT

2
1
Publications. 1
1
Remove the four bolts and nuts (Item 2) [Figure 50-140-
3] from the cab.
P-76522A P-76525A
Remove the hinges (Item 1) [Figure 50-140-3] from the

cab. When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-4] between the
Installation: Install the hinges (Item 1) on the cab and door and the cab or the striker and the latch.
use the bolts and nuts (Item 2) [Figure 50-140-3] to
secure the hinges. Tighten to 7 - 7.9 ft.-lb. (9,6 - 10,7 If adjustment is needed. (See Adjusting on Page 50-140-
N•m) torque. 3.)
When the striker or latch is adjusted properly there will be

no gap (Item 1) [Figure 50-140-5] between the door and
the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Checking Operation on Page 50-140-3.)

612 of 928
CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-8
Figure 50-140-6
1 P-76683

Sit in operator’s seat. Turn key ON. (Standard Key
Panel), press RUN / ENTER button (Deluxe
Loosen the two bolts (Item 1) [Figure 50-140-6] and Instrumentation Panel), lower seat bar and close the
adjust the latch as needed. door. Press the PRESS TO OPERATE LOADER button
(Item 1) [Figure 50-140-8].

NOTE: For the initial adjustment, position the latch

towards the bottom of the door.
Figure 50-140-7
Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will flash, an audible tone will sound,
and the message [door] will appear in the display.
Publications. Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will go out and the display will return to
machine hours.
P-76516
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-7].
NOTE: For the initial adjustment, position the striker

towards the front of the machine.
After adjusting the striker and latch recheck the

alignment of the door sensor. (See Aligning on Page 50-
140-2.)

613 of 928
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Publications.

614 of 928
ELECTRICAL SYSTEM & ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SAFETY &
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 MAINTENANCE
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1 DRIVE

Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2 SYSTEM
Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
File has expired.

Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . 60-210-3
ELECTRICAL

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 SYSTEM &
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
ANALYSIS
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . 60-20-2

Publications.
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
ENGINE
SERVICE
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
SPECIFICATIONS
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

615 of 928
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED -
Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING). . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC) . . . . . 60-100-2
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-11
File has expired.

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Attachment Control Information (Deluxe Instrumentation Panel). . . . . . . 60-180-2
Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . 60-180-1
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Publications.
Actuator Connector Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 60-130-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . .60-130-11
Handle Lock Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 60-130-10
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

616 of 928
ELECTRICAL / HYDRAULIC CONTROLS (ACS). . . . . . . . . . . . . . . 60-141-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-141-2
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . .60-141-3
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-142-2
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
File has expired.

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7

Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . 60-10-9
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Publications.
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . .60-10-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-8
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Deluxe Instrumentation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Keyless Start Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Removal And Installation (Left And Right) . . . . . . . . . . . . . . . . . . . 60-50-6
Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Standard Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2

617 of 928
MAINTENANCE CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . 60-190-1

Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . 60-191-1

Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
File has expired.

Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Bobcat Interlock Control System (BICS) Circuit Test . . . . . . . . . . 60-110-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Publications.
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . .60-150-1
Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . 60-150-1
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
STEERING DRIFT COMPENSATION. . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

618 of 928
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1


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619 of 928
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620 of 928
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Publications. Dealer Copy -- Not for Resale
621 of 928
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622 of 928
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623 of 928
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624 of 928
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625 of 928
WIRING SCHEMATIC 7100
TO MAINFRAME
C TO OPTIONS
POWER BOB-TACH
SOLENOID NC NO
TO MAINFRAM ADDITIONAL
OPTIONS 2650
C606
F A 7000 A A 9.8 ohms HARNESS POWER / GROUND
C103
6600 G D 2760 B B C B A
(ACCESSORY POWER)
C601
BACK-UP
SOURCE FOR KITS
6410 E C
S175 (S/N A3L520001 AND ABOVE) ALARM C489A C220A C489B
C607
6310 A B 7010 B B POWER BOB-TACH A B C B A A B
6510 D SOLENOID
E 2770 A A
87A 87
30
A B C
C220B
H
2230
6200
1520
6700
TO BRAKE LIGHT
1500
2200
1510
2210
9.8 ohms 1730 6600
(PRINTED AUGUST 2009) 2600 B HARNESS 7151691
TO TO
C407
C474
V-1200 6320 A A 6320 TO SJC HARNESS 4210 2730 MAINFRAM TAILGATE
85
86
POWER BOB-TACH HARNESS - TO
2620
HARNESS HARNESS
2610
6610
6320
6620
6410
6330
2640
6510
TAILGATE
6700
Printable Version Click Here 7112290 BRAKE LIGHT HARNESS 7151696 HARNESS BRAKE LIGHT C103A C103B
2670
6340
HARNESS 7151691
HARNESS (For
2630 6210 (FOR SJC MODELS ONLY) All Models A B C D E F G H A B C D E F G H
E F C A B D F E D C B A C407A
Except SJC)
A
C602 C603 LEFT WORK RIGHT WORK
A
OPEN
OPEN
OPEN
6000
2000
7100
6210
6110
6010
6000
2010
7100
6230
6130
6530
6320
B A C230A
E F C A B D F E D C B A A
C800 A
B A
(TO "D" PIN)
(TO "B" PIN)
6430
C410
C431
6500
4640 DELUXE TAILGATE RIGHT HEAD LIGHT HARNESS 7152108
2 2 6810 6800 A A 6420

HARNESS - 7139785 SSL 7-PIN LIGHT 6 6 2130 2130 B B 2110
C170
STOP TURN TAIL STOP TAIL TURN REGISTRATION CAN CONNECTOR SIDE MARKER 5 5 6830 6830 C C 6220
LEFT TAILLIGHT RIGHT TAILLIGHT LAMP
KEY "RUN" D 9800 D BLINKER 4 4 6820 6820 D D 6440
ADVANCED HAND CONTROL UNSW POWER 2 1160 F 3

1
3 OPEN OPEN E
F
E
F
6510 6530
CAN SHIELD C 9700 C 1 OPEN OPEN OPEN

FLOAT HARNESS - 6727328 TO MAINFRAME SW POWER 1 1710 E To Mainframe To Ground
Harness A 2 6810 6800 A A 6330
CAN LOW B 9600 A
7100 C B B B
CAN HIGH A 9500 B LIGHT 6 2130 2130 2120
2650
C180
F C C C
GROUND 3 2700 G SIDE MARKER 5 6830 6830 6120
C103
G 7-PIN D D D
Connector BLINKER 4 6820 6820 6340 6320
BACK-UP E on Loader C666 C426 ATTACHMENT
CONNECTOR E 3 OPEN OPEN E E 6520
STROBE OR ALARM 6310 A Boom
BEACON F 1 OPEN OPEN F F OPEN
D
CONTROL HARNESS - 6718426 HARNESS 7152108
6310
2030
6410
2020
LEFT HEAD LIGHT
6200 H
2600 B
2 1
87A 87 86 87A 87 86
C609 A B
2620
HARNESS 7153090
FRONT WIPER
2610
6320
6330
2640
2 1 TO
File has expired.

M BOTTLE AND TANK
STROBE/BEACON
6340
2670
TO OPTIONS FRONT WIPER 30 85 30 85
2630 6210 MOTOR
6700 E C668 OR C670 1 2 2 1
GROUNDS
2775
6300
6400
TO OPTIONS A C604 C605 LEFT WORK RIGHT WORK
M 2010
(4 WAY FLASHER) C 1 2 2 1
1010
1400
1020
1410
2000 2020
2 2785 2780 D
C669
C622 2030 REGISTRATION
7200 or YEL
7150 or DGN
2765 or BRN
1 6440 F
L X
3 6540 B
STANDARD TAILGATE A B A B
EXTERIOR CAB HARNESS - ROAD LIGHTS

HARNESS - 7109403 To Starter "B" Terminal
LEFT TAILLIGHT RIGHT TAILLIGHT TO OPTIONS (EUROPE ONLY)
2745
Left Marker Fuse 10A
6718872 (DELUXE ACCESSORY) 1010
Right Marker Fuse 10A
3 7310 HARNESS 7141369
PARK
HIGH
2 2735 2755 B B
C610
C667
5 7160 C C
SSL 7-PIN
C426 To Mainframe 1 7210 A A
DOOR SENSOR
Harness

CAN CONNECTOR D F C E A B G 6 7180 7180
2 2 2 2
4 4710 1 1 4720 1 1
C412
B 2785 87A 87 86
9800
1160
9700
1710
9500
9600
2710
A 1420
WIPER HARNESS DOOR HARNESS 30 85
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN 7117322 7104465
C402 C490
B 2740
2700
1420
UNSW POWER 2 1160 RED/WHT 2720 H GROUND
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD A 1720
Publications.
SW POWER 1 1730 RNG 1720 B SW POWER ACD
Machine A 1720
CAN LOW B 9620 PUR 9610 E CAN LOW B 2720
Connector
CAN HIGH A 9520 PUR 9510 D CAN HIGH
GROUND
C666
3
7-PIN
2730
ATTACHMENT
BLK C
A
OPEN
OPEN Dealer Copy -- Not for Resale
C 7200
G OPEN
C427
CONNECTOR
J B 6415
N
BOOM-MOUNTED A 6515
ACD CONNECTORS
SW POWER K 1740
B 6000
GROUND B 2740 C703 J2 - 10-PIN BLACK
C OPEN
C401
E OUTPUT E 5100 5100 C E OUTPUT TO D 6410
F OUTPUT F 5350 5350 H F OUTPUT MAINFRAME
E OPEN
C404
B
G OUTPUT G 5400 5400 J G OUTPUT
A 6510
ACD 7100 A
H OUTPUT H 5050 5050 B H OUTPUT
6510
Output
C OUTPUT C 5300 5300 G C OUTPUT
6510
Connector BACK-UP ALARM
D OUTPUT D 5150 5150 D D OUTPUT SWITCHES
A OUTPUT A 5250 5250 F A OUTPUT 7110 TO 87A 87 86
MAINFRAME 87A 87 86
M OUTPUT M 5200 5200 E B OUTPUT
C402
1720 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
2720 B 30 85
ID (K TO P) P 5510 5450 K K OUTPUT 30 85
BACK-UP ALARM
C506
2780
14-PIN
6020
ATTACHMENT C704 J3 - 10-PIN GRAY
SWITCHES HARNESS -
ADDITIONAL POWER
6010
2790
CONNECTOR CONNECTOR
5900 J ID #1
C491
B
5500 A ID #2 7107544 1740 A
B ID #3
ACD
C ID #4 Input
D ID #0 Connector SJC HORN / BLINKER
E OPEN
HARNESS - 7151940
C433
C433
F OPEN A RNG A
G OPEN C LGN C
H OPEN B BLK B
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN - +
ADVANCED HAND CONTROL

SSL 7-PIN
C426 To Mainframe
JUMPER HARNESS - 6728742
CAN CONNECTOR Harness
D F C E A B G TO ATTACHMENT
TO ATTACHMENT
B
B
J
9800
1160
1710
9500
9600
2710
9700
J
N
N
P
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN M TO OLDER
P LEFT RIGHT
MODEL ATTACHMENTS M TO OLDER FLASHER FLASHER
UNSW POWER F 1160 RED/WHT 2720 H GROUND A LIGHT LIGHT
C506
MODEL ATTACHMENTS
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD C
C506
D WHT S
SW POWER E 1730 RNG 9 1720 B SW POWER ACD D S
C BRN LT
C623
9 Machine A BRN LT
C623
CAN LOW B 9620 PUR 9610 E CAN LOW E BLK TM
14 Connector to
CAN HIGH A 9520 PUR 9510 D CAN HIGH E BLK TM TO OPTIONS
Engine F DBL CENTER
2790
2795
(EXTERIOR CAB)
GROUND G 2730 BLK 13 C OPEN Compartment F DBL CENTER
G RED GD
Connector 7-PIN A OPEN G RED GD 6440 1
C669
on Loader C666 ATTACHMENT
CONNECTOR G OPEN
H
L
YEL
RNG
RT
H YEL RT 2785 2
Boom L 6540 3
J K RNG
BOOM-MOUNTED K
SW POWER
N
K 1740
ACD CONNECTORS
GRADER HARNESS - 4 WAY FLASHER
GROUND B 2740 C703 J2 - 10-PIN BLACK
GRADER HARNESS - HARNESS - 6718873
E OUTPUT E 5100 5100 C E OUTPUT
6707303 6706391
F OUTPUT F 5350 5350 H F OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
Output
C OUTPUT C 5300 5300 G C OUTPUT TO HORN
Connector to
D OUTPUT D 5150 5150 D D OUTPUT CONNECTOR
Engine
C412
A OUTPUT A 5250 5250 F A OUTPUT Compartment 2750 B

M OUTPUT M 5200 5200 E B OUTPUT HORN RELAY 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
12 2770
85 86
7200
ID (K TO P) P 5510 5450 K K OUTPUT
87
11 2750 30
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A 2760 ADDITIONAL POWER
CONNECTOR
Connector CONNECTOR
C490
5900 J ID #1 E 85 86 2740 B
on Loader 2780 6415
87
Boom 5500 A ID #2 D 6410 6410 30 1740 A
C411
87A 6020 RED = RED BATTERY FEED 1000-1999 RED, RED/WHT, RNG
B ID #3 C WIRES CONNECT BY
ACD RNG = ORANGE GROUND 2000-2999 BLK
C LETTER ACROSS MONITORING 3000-3999 LBL
ID #4 Input B 6000 BLK = BLACK
TO AWS TO MAINFRAME LBL = LIGHT BLUE CONNECTORS HYDRAULIC 4000-4999 LGN
Connector to
C401or
D ID #0 A 6510 B C A A B ATTACHMENT CONTROLS 5000-5999 YEL

C402
CONTROLS DBL = DARK BLUE

Engine RIGHT BLINKER
C489
DELUXE ATTACHMENT E OPEN

Compartment RELAY C497
2720
1720
B
A TO OPTIONS
DOME LIGHT
LGN = LIGHT GREEN
DGN = DARK GREEN
B A
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
F OPEN SWITCH ENGINE 8000-8999 TAN
CONTROL HARNESS - 2790
85 86
6515
YEL = YELLOW
SOME CONNECTOR COMMUNICATION 9000-9999 PUR
C608
G OPEN 87 A RED PNK = PINK

6510 30 WHT = WHITE BODIES NOT SHOWN
626 of 928
6732730 H
K
OPEN
OPEN
87A 6010 B BLK
BRN = BROWN
TAN = TAN
FOR DRAWING CLARITY
Rev. none
AWS HORN/BLINKER HARNESS - 6726662 DOME LIGHT PUR = PURPLE
GRY = GRAY
V-1200 (7-23-09)
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
File has expired.

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
- +
Publications.
BATTERY - Used for supplying and SWITCH - Single Pole - Double
Throw (ON-OFF-ON) - This switch
storing electrical power for the
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
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
on switch application.
G electrical current to supply voltage to
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.

627 of 928
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
4 5
positions.
File has expired. 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.
Publications.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
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
3
700 3
710 SPLICE (•) - Used to show when
3
110 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.)

628 of 928
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
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
B
File has expired.
TEMPERATURE SENDER - Provides
a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at

high and low setting.)

A
B
TEMPERATURE SWITCH - The
switch opens or closes at a
predetermined temperature to active
Publications.
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

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

629 of 928
Standard Cab Harness Connectors
C 212
File has expired.

C 434
C 482
408 C 499

C 479
C 129 C 480

C 209 S1
S2
T3
Publications. C 435
SW1
C 500
C 408
MS2660

630 of 928
Deluxe Cab Harness Connectors
C 212
SW9
C670 SW8
SW7 C 483
S3
S4
C 611
C 630
C 635
File has expired.

T5 C 434
T6 *C 129 C 482
408 C 479

S1
C 40
T2 S2

C 209 C 40
T1
T3
Publications. C 480
SW1
SW2
SW3
C 435 SW4
C 408 SW5
SW6
MS2441

631 of 928
Mainframe Harness Connectors
CC426
408
C 405
T1
T6
T8
C 486 T4
T5
C 112 C 40
T3
C 108
File has expired. C 350
408
C 408
C 113
C 135

C 107 C 446
C 103 Use updated files from Bobcat

C 105
C 407-1
C 407-2
C 478
C 489
Publications.
C 606
C 406
C 415
C 423
J1
C 101 J2
C 413
C 414 C 126
C 416 C 419 C 404
C 417 C 420 C 409 C 410
C 418
C 421 C 411
C 422 C 412
C 425
C 492
MS2179

632 of 928
Description
Figure 60-10-1
P-13849
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by

fuses located in the cab on the steering control panel,
and a 100 amp master fuse [Figure 60-10-1] in the

engine compartment on the left side of the engine, under
the air cleaner. The fuses will protect the electrical
system when there is an electrical overload. The reason
Publications.
for the overload must be found before starting the engine
again.

633 of 928
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge.
Alternator will not charge.
Starter will not turn the engine.
File has expired. 1, 2, 3, 4, 5
1, 2, 5
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.
Publications. 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.

634 of 928
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuse And Relay Location / Identification 11

1 9 13 15 17
5
Figure 60-10-2
2 6 18
1
3 7 19
8 16 20
4 10 12 14
7159779
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure

60-10-2]. A decal is inside the cover to show location and
amp ratings. N-19660

Remove the cover to check or replace the fuses. The location and sizes are shown below and [Figure 60-
10-3].
Publications. RE
F
DESCRIPTION AMP
RE
F
DESCRIPTION AMP
1 Unswitched 25 11 Front & Marker R

Horn Lights
2 ACS/AWS/SJC 5 12 Fuel Shutoff R
Switched
3 Alternator & 25 13 Rear Lights R
Accessories
Back-up Alarm
4 Attachments 25 14 Traction R
5 Heater & Air 25 15 Glow Plugs R
Conditioning
6 Front & Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Traction 30
8 Bobcat 25 18 Fuel Shutoff 30
Controller
9 Heater & Air R 19 Power Plug 15
Conditioning
10 Switch Power R 20 ACS/AWS/SJC 25
Unswitched
R - Relay

635 of 928
Solenoid Testing
Figure 60-10-4
File has expired.

P9175


for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.

Publications.

636 of 928
BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
File has expired.

If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
installing a new or used battery [Figure 60-20-2].
When installing the battery in the loader, do not touch any

W-2065-0807 metal parts with the battery terminals.

Connect the negative (-) cable last to prevent sparks.
Open the rear door.

Figure 60-20-1
Connect and tighten the battery cables.
Install and tighten the battery hold down.
Publications.
3
2
WARNING
1
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
P-76740
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Disconnect the negative (-) battery cable (Item 1) [Figure lean over battery while boosting, testing or charging.
60-20-1].
Battery gas can explode and cause serious injury.
Remove the battery hold down clamp (Item 2) [Figure W-2066-0705
60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.

637 of 928
BATTERY (CONT’D) BATTERY (CONT’D)
Servicing Using A Booster Battery (Jump Starting)
Figure 60-20-3 If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF or the STOP button must be

pressed. The booster battery must be 12 volt.
WARNING
P-09589
File has expired.
P-09590 from batteries. When jumping from booster battery
The battery cables must be clean and tight [Figure 60- Do not jump start or charge a frozen or damaged
20-3]. Check electrolyte level in the battery. Add distilled battery. Warm battery to 60°F (16°C) before

water as needed. Remove acid or corrosion from battery connecting to a charger. Unplug charger before
and cables with sodium bicarbonate (baking soda) and connecting or disconnecting cables to battery. Never
water solution.
Put Battery Saver (6988074) or grease on the battery
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
Publications.
terminals and cable ends to prevent corrosion.
Figure 60-20-4
W-2066-0705
WARNING
Batteries contain acid which burns eyes and skin on 2
contact. Wear goggles, protective clothing and 4
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
minutes.

of water or milk! DO NOT induce vomiting. Get 3 1
W-2065-0807
P-31860

638 of 928
Connect the end of the first cable (Item 1) [Figure 60-20-
4] 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 loader starter.
Connect the end of the second cable (Item 3) [Figure 60-

20-4] to the negative (-) terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
File has
IMPORTANT expired.
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
Publications.
connected wrong.
I-2023-1285

639 of 928
File has expired.

Publications.

640 of 928
ALTERNATOR Belt Replacement
Belt Adjustment Loosen the alternator mounting and adjustment bolts

(Item 1 and 2) [Figure 60-30-1] and loosen the belt all
Stop the engine. the way.
Raise the operator cab. (See Raising on Page 10-30-1.) Remove the belt and install a new belt.
Figure 60-30-1 Adjust the belt as shown above.
1
File has expired.
P-24543

Loosen the alternator mounting bolt (Item 1) [Figure 60-
30-1].
Publications.
Loosen the adjustment bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 5/16 in. (8,0 mm)
movement at the middle of the belt span with 15 lb. (66
N) of force.
Tighten the adjustment bolt and mounting bolt.

2.)

641 of 928
ALTERNATOR (CONT’D) If the charging system malfunctions check the following:
Charging System Inspection Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) Replace belt if
worn or deteriorated.
WARNING Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
AVOID INJURY OR DEATH Check the fuse for the alternator in the fuse panel. If fuse
Batteries contain acid which burns eyes and skin on is burned, find the cause and repair / replace. If fuse is in
contact. Wear goggles, protective clothing and doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
In case of acid contact, wash immediately with water. water as needed. (Does not apply to maintenance free
In case of eye contact get prompt medical attention batteries.)
minutes. Verify the charge of the battery. Make sure battery is fully
charged.
File has expired.

of water or milk! DO NOT induce vomiting. Get
Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
W-2065-0807
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

WARNING
terminal.
Publications.
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
from batteries. When jumping from booster battery
Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
IMPORTANT
disconnected.
• Battery cables are connected when using a fast
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

642 of 928
ALTERNATOR (CONT'D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-3
Figure 60-30-2
P-34951

Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-3] off the alternator.
Open rear door.
Turn the remote start tool key to the ON position.

Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Figure 60-30-4
1.)
Turn the engine on with the remote start tool and run at
Publications.
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-2].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test. 1 2
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test. P-34954
Check the voltage across the “L” terminal (Item 1) and

ground (Item 2) [Figure 60-30-4]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
OK then remove alternator for replacement or repair.

643 of 928
ALTERNATOR (CONT'D)
High Voltage Testing
Figure 60-30-5
File has expired.

P-34955
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-5] off the alternator.

Check the continuity between the “S” terminal (Item 1)

[Figure 60-30-5] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-5].
There should be continuity. If no continuity, replace wire
harness.
Publications.
If voltage is still above 14.7 volts at 70° F (Alternator
Temperature), then remove alternator for replacement or
repair.

644 of 928
ALTERNATOR (CONT'D) Figure 60-30-7
Removal And Installation 2

3
IMPORTANT
disconnected.
• Battery cables are connected when using a fast 1
• Extra battery cables (booster cables) are P-34952
connected wrong.
I-2023-1285
Remove the adjustment bolt (Item 1) [Figure 60-30-7]
Figure 60-30-6 File has expired. from the mounting bracket.
Remove the alternator belt (Item 2) [Figure 60-30-7]

from the alternator pulley.

At the top of the alternator, remove the mounting bolt
(Item 3) [Figure 60-30-7].
1 Remove the alternator from the loader.
Publications.
2
P-34951
Place jackstands under the rear corners of the loader.
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-30-6] from

the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2) [Figure

60-30-6] from the alternator.

645 of 928
ALTERNATOR (CONT'D)
Figure 60-30-8
1. Alternator 11. Bearing
2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1 6
4 7 13 14
2
3
12 File has expired.
5
11
10

9
8
Publications. 18
17
16
15
C-3529B

646 of 928
STARTER Figure 60-40-2
Testing
Figure 60-40-1 Bat

S
M
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)
File has expired.

A-1992 between the M terminal and the BAT terminal [Figure 60-
40-2].
The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.

The battery must be at full charge. If the starter does not turn, the starter is defective.

The cable connections on the battery must be clean and
tight.
Publications.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.

647 of 928
STARTER (CONT’D)
Figure 60-40-3
4
2
1
File has expired.
P-34385

Remove the negative (-) and positive (+) cables from the
battery.

Disconnect the ground wire (Item 1) [Figure 60-40-3]
from the starter.
Publications.
Disconnect the engine harness power wire and positive
(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-3].
Installation: Tighten the nut to 10.8 - 12.3 ft.-lb. (14,7 -

16,7 N•m) torque.
Disconnect the tan wire (Item 3) [Figure 60-40-3] from

the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-40-3]

from the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-40-3]

from the starter.
Remove the starter from the engine.
Installation: Tighten the three mounting bolts to 25 - 28

Reverse the removal procedure to install the starter.

648 of 928
STARTER (CONT'D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32
File has expired. 7*
15
37
14

16 20

19 18
17
5 8
Publications. 14
12
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
36. Bracket
24
37. Bearing
* Not serviceable parts B-16488

649 of 928
File has expired.

Publications.

650 of 928
INSTRUMENT PANELS
Left Panel
Figure 60-50-1
3 12
2
7 16
1
4 13
11 15
6
File has expired.
5
8 9 10
14

17
18 19
20
Publications.
21 22
23
P-76459C
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

651 of 928
INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (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 & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11
12
13
PARKING BRAKE
File has expired.
The light comes on when the loader cannot be driven.
RIGHT DIRECTION INDICATOR (Option) Indicates right turn signals are ON.
SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)

15 FUEL Fuel level low or sensor error.
16
17 LIGHTS
FUEL GAUGE Shows the amount of fuel in the tank.
Press once for FRONT work lights and REAR taillights. (Left green
LED will light.) Press a second time to add REAR work lights. (Left and
Publications. right green LEDs will light.) Press a third time to turn all lights off. (Left
and right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to engage the auxiliary hydraulics. (Left green LED will
light.) Press a second time to disengage.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine RPM
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
or joystick(s) to move the loader forward or backward when using the
backhoe attachment or for service. (See TRACTION LOCK
OVERRIDE in this manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ System when the seat bar is down and
operator is seated in operating position. Button will light.
Press and hold three seconds to engage Drive Response and
Steering Drift Compensation. (See DRIVE RESPONSE and
STEERING DRIFT COMPENSATION in this manual.)
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* For further description on Service Codes. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

652 of 928
INSTRUMENT PANELS (CONT'D) Keyless Start Panel
Standard Key Panel Figure 60-50-3
Figure 60-50-2
2 3
4
5
6
P-90816A
File has expired. S4498
This machine may be equipped with a Standard Key

This machine may be equipped with a Keyless Start
Panel [Figure 60-50-3].
Panel [Figure 60-50-2]. 1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An

The Standard Key Panel is used to turn the loader’s asterisk will show in the left panel display screen for
electrical system on and off, and to start and stop the each key press.
engine.
Use updated files from Bobcat 2. LOCK Key: Used to lock keypad. The lock key will
display a red light to indicate a password is required
Publications. to start the loader. (See Password Lockout Feature

on Page 60-191-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. START Button: Used to start the engine.
5. STOP Button: Used to stop the engine and shut

down the loader electrical system.
6. RUN Button: Used to turn on the loader electrical

system.

653 of 928
INSTRUMENT PANELS (CONT'D) 9. Keypad: The numeric keypad has two functions:
- To enter a number code (password) to allow starting
Deluxe Instrumentation Panel the engine.
- To enter a number as directed for further use of the
Figure 60-50-4 Display Screen.
10. Start Button: Used to start the engine.
11. Run / Enter Button: Used to turn on the loader’s
electrical system.
1 7 Figure 60-50-5
4
5
2 3 6
ENTER PASSWORD
File has expired.

9
8 LANGUAGES

B-16165
The first screen you will see on your new loader will be as
10 11 B-15553N
shown in [Figure 60-50-5].
When this screen is on the display you can enter the
Publications.
This machine may be equipped with a
Instrumentation Panel [Figure 60-50-4].
Deluxe password and start the engine or change the Display
Screen setup features.
1. Display Screen: The Display Screen is where all
NOTE: Your new loader (with Deluxe Instrumentation
system setup, monitoring, troubleshooting and error
Panel) will have an Owner Password. Your
conditions are displayed.
dealer will provide you with this password.
2. Bobcat Main Controller Error: Indicates Change the password to one that you will
communication error between Bobcat Main Controller easily remember to prevent unauthorized use
and Deluxe Instrumentation Panel. (See of your loader. (See Changing The Owner
DIAGNOSTIC SERVICE CODES on Page 60-90-1.) Password on Page 60-190-1.) Keep your
3. Display Error: Indicates communication error password in a safe place for future needs.
between instrument panel and Bobcat controller.
(See DIAGNOSTIC SERVICE CODES on Page 60- Change Language: Press the Selection Button at the end
90-1.) of the arrow [Figure 60-50-5] to go to the next screen.
4. BobCARE PMSM Icon: Indicates planned Use the Keypad to select the number of the language.
maintenance is due. (See MAINTENANCE CLOCK
on Page 60-200-1.) Press EXIT. The screen will return to [Figure 60-50-5].
You can then enter the password and start the engine.
5. Engine Air Filter Icon: Indicates engine air filter
requires service.
See CONTROL PANEL SETUP for further description of
6. Hydraulic Filter Icon: Indicates hydraulic filter screens to setup the system for your use. (See
requires service. CONTROL PANEL SETUP on Page 60-180-1.)
7. Selection Buttons: The four Selection Buttons allow
you to select items from the Display Screen and scroll NOTE: Pressing the EXIT key will go to the previous
through screens. screen and you can continue pressing until
8. Stop Button: Used to stop the engine and shut down you get to the initial (home) screen.
the loader’s electrical system. SHORTCUT: Press the “0” (zero) key to get to
the home screen immediately.

654 of 928
INSTRUMENT PANELS (CONT'D) Front Panel
Side Panel Figure 60-50-7
Figure 60-50-6 1 2 3 4 5 6 7 8
B-15993Q
OR
9
7 8 9
1 2 3 4 5 6
B-15993R
NOTE: Parking Brake (Item 4) [Figure 60-50-7] is

File has expired.P-76602 standard on all loaders.
REF
. DESCRIPTION FUNCTION / OPERATION
REF
NO.

. DESCRIPTION FUNCTION / OPERATION
NO. 1 ADVANCED Press the top to select Hand
1 Use updated files from Bobcat
POWER PORT Provides a 12 volt receptacle
for accessories.
CONTROL
SYSTEM (ACS)
(Option)
Controls; bottom to select Foot
Controls.
2
3 Publications.
NOT USED
FRONT WIPER
(Option)
---
Press the bottom of the switch
to start the front wiper (press
2
3
NOT USED
POWER
---
Press and hold the up arrow to
BOB-TACH disengage the Bob-Tach
and hold for washer fluid).
(Option) wedges. Press and hold the
Press the top of the switch to
down arrow to engage the
stop the wiper.
wedges into the mounting
4 REAR WIPER Press the bottom of the switch frame holes.
(Option) to start the rear wiper (press
4 PARKING Press the top to engage the
and hold for washer fluid).
BRAKE (Standard PARKING BRAKE; bottom to
Press the top of the switch to
on all loaders) disengage.
stop the wiper.
5 HYDRAULIC Press the top to engage
5 NOT USED ---
BUCKET Hydraulic Bucket Positioning;
6 NOT USED --- POSITIONING bottom to disengage.
7 FAN MOTOR Turn clockwise to increase fan (Option)
(Option) speed; counterclockwise to 6 HAZARD LIGHTS Press the top to turn the
decrease. There are four (Option) HAZARD LIGHTS ON; bottom
positions; OFF-1-2-3. to turn OFF.
8 NOT USED --- 7 ROTATING Press the top to turn the
9 TEMPERATURE Turn clockwise to increase the BEACON (Option) ROTATING BEACON ON;
CONTROL temperature; counterclockwise bottom to turn OFF.
(Option) to decrease. 8 NOT USED ---
9 SELECTABLE Press the top to select ‘ISO’
JOYSTICK Control Pattern; bottom to
CONTROLS select ‘H’ Control Pattern.
(SJC) (Option)

655 of 928
INSTRUMENT PANELS (CONT’D) Removal And Installation (Left And Right)
Front Panel Removal And Installation Figure 60-50-10
Figure 60-50-8
1
1
1
P-76985
File has expired.

P-26255

10].
8]. Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded

Installation: Be careful to not overtighten the front holes in the panels.
accessory panel mounting bolts to prevent damage to the
plastic panel.
Figure 60-50-9
Publications.
1
2
1
P-76987
P-26251 Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-11] from
Pull the front accessory panel down and disconnect the the panel.
wire harness connector(s) (Items 1 and 2) [Figure 60-50-
9] from the switches. Remove the panel from the loader cab.
Remove the panel.
Reverse the procedure to install the front accessory

panel.

656 of 928
INSTRUMENT PANELS (CONT’D) Figure 60-50-14
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-12
1
N-20142
NOTE: The instrument panel (Item 1) [Figure 60-50-

14] must be replaced as a complete unit.

Figure 60-50-15
12].

Installation: Be careful to not overtighten the instrument

holes in the panels.
Figure 60-50-13
Publications. 1
P-76986

15].
1 Installation: Be careful to not overtighten the instrument

holes in the panels.
N-20163
Pull the right instrument panel down and disconnect the

the panel.
Remove the panel from the loader cab.

657 of 928
INSTRUMENT PANELS (CONT'D)
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-16
File has expired.

P-76982
Pull the left instrument panel down and disconnect the

the loader alarm.

Disconnect the wire harness connector (Item 2 and 3)

[Figure 60-50-16] from the loader instrument panel.
Remove the instrument panel from the loader.
Publications.

658 of 928
Key Switch Removal And Installation
Remove the right side instrument panel. (See Removal

And Installation (Left And Right) Page 60-50-7)
Disconnect the key switch wiring harness.
Figure 60-50-17
File has expired.

1

P-76989

Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure
60-50-17] from the switch.
Publications.
Remove the ignition switch from the control panel.

659 of 928
Alarm Removal And Installation
Figure 60-50-18
File has expired.

Remove the left side instrument panel.
P-76988
Remove the retaining nut (Item 1) [Figure 60-50-18]

from the loader alarm.

Remove the alarm from the loader instrument panel.
Publications.

660 of 928
LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1 1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the
File has expired. N-19348 socket.
Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative(-) cable from the battery. (See

Remove the light housing (Item 1) [Figure 60-60-1] from
the operator cab.
1
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.

661 of 928
LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-6
Figure 60-60-4
1 2 1
1
3
P-66221
File has expired.

P-68264
Remove the screws (Items 1) [Figure 60-60-6] from the
light cover.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb NOTE: The wires for the switch will hold the light

assembly a 1/4 turn. cover. Do not pull the light cover to far away
from the light housing to prevent damage to
Figure 60-60-5
Use updated files from Bobcat the wires.
Move the light cover to allow access to the bulb.
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
Reverse this procedure for installation.

Remove and replace the bulb (Item 1) [Figure 60-60-7]
from the light housing.

662 of 928
BOBCAT CONTROLLER (GATEWAY AND
AUXILIARY)
Description
The Gateway and Auxiliary controller provide information

to all other controllers. All loaders have a Gateway and
Auxiliary controller.
The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.
File has expired.

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663 of 928
AUXILIARY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
File has expired.

J1A J1B

Publications.
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

664 of 928
Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8
9
4110
OPEN
LGN
NA
File has expired.
TRACTION LOCK RELAY SIGNAL
NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR

12 OPEN NA NA
13
14
4150
8550
LGN
TAN
TRACTION LOCK RELAY FEEDBACK
GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16
17
3700
6210
Publications.
LBL
PINK
AIR FILTER SENDER SIGNAL
REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

665 of 928
J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8
9
9210
9110
PUR/WHT CAN LO 0
PUR/WHT CAN HI 0
File has expired.
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL

12 3100 LBL FUEL SENDER SIGNAL
13
14
4410
9500
LGN HYD LOCK SOLENOID SIGNAL
PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16
17
2510
3010 LBL
Publications.
BLACK COMPUTER GROUND
SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL

666 of 928
Auxiliary Controller
1 1
34 26
File has expired.J2A J2B

Publications.
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

667 of 928
J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8
9
OPEN
OPEN
NA
NA
NA
NA
File has expired.
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT

12 4820 LGN LEFT HANDLE PADDLE LEFT
13
14
4910
OPEN
LGN
NA
RIGHT HANDLE RIGHT ROCKER UP
NA
15 OPEN NA NA
16
17
OPEN
OPEN
NA
NA
Publications.
NA
NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

668 of 928
J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8
9
9220
9120
PURPLE
File has expired.
CAN LO 0
PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13
14
4340
OPEN
LGN
NA
FRONT BASE SOLENOID SIGNAL
NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16
17
2540
4310
Publications.
BLACK
LBL
AUXILIARY CONTROLLER GROUND
RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

669 of 928
BOBCAT CONTROLLER (GATEWAY AND Figure 60-70-3

support device. (See Installing on Page 10-20-1.) 2
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.) 1
Figure 60-70-1
P-76642
Unplug the two harness connectors (Item 1) [Figure 60-
1 File has expired. 70-3] from the Gateway controller.
Unplug the two harness connectors (Item 2) [Figure 60-

70-3] from the Auxiliary controller.
1

NOTE: The connectors are keyed and will only plug
in one way.
Remove the mount bolts (Item 1) [Figure 60-70-1]. 1 1
Remove the panel from the loader.
Figure 60-70-2
2 2
1
1 P-66928A
Remove the controller mounting bolts (Item 1) [Figure

60-70-4] from the left fender.
Loosen the controller mounting bolts (Item 2) [Figure 60-

1 70-4].
Installation: Tighten the controller mounting bolts to 12 -

P-76643 14 ft.-lb. (16 - 19 N•m) torque.
Lift and remove the Gateway and Auxiliary controllers

Remove the mount bolts (Item 1) [Figure 60-70-2] and from the loader.
remove the panel.

670 of 928
BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS

or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.
The ACS controller is located behind the right side

access panel near the operators right foot.
File has expired.

Publications.

671 of 928
BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
D
J1
C
File has expired.
J1
J3
J2

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 FOR-
WARD
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 FOR-
WARD
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

672 of 928
BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-3
Figure 60-71-1
P-21840
File has expired.P-21839 3] from the controller.
Remove the controller from the loader.

Loosen the bottom bolts and remove the top bolt on the
right front panel [Figure 60-71-1]. NOTE: The calibration procedure must be followed

when replacing actuator or ACS Controller.
Remove the right front panel (Item 1) [Figure 60-71-1] (See CALIBRATION on Page 60-160-1.)
from the loader.
Figure 60-71-2
Publications.
1
P-21843
Disconnect the wiring harness connectors (Item 1)

[Figure 60-71-2] from the controller.

673 of 928
File has expired.

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674 of 928
BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same used on the ACS
drive functions. system.
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operators right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the Gateway controller in an SJC
system. All these controllers are capable of software
upgrades.
File has expired. HYDRAULIC

RIGHT DRIVE MOTOR
HAND CONTROL
PANEL

ACS
CONTROL
Use updated files from Bobcat LIFT / TILT
ACTUATORS
SPEED
SENSOR
Publications.
INTERNAL CAN BUS
GEAR ENGINE
SERIAL TT BUS
PUMP
RIGHT
JOYSTICK
ISO
SWITCH FWD / REV
SWASH PLATE
SENSORS
LEFT
JOYSTICK
AUXILIARY DRIVE
LEFT PUMP
CONTROL
HAND SPEED
PANEL SENSOR
EXTERNAL
CAN BUS ACD
GATEWAY CONTROL
CONTROL HYDRAULIC
MOTOR MS2582S

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BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification
File has expired.

Publications.
P-64295

676 of 928
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
File has expired.

Publications.
P-64296

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BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-2
WARNING 1

W-2059-0598
P-64322
Pull the controller out from the fender and loosen the
File has expired.


connector screw (Item 1) [Figure 60-72-2] to release the
connector.
Installation on Page 70-20-1.) Installation: Tighten the connector screw to 30 - 35 in.-

lb. (3,39 - 3,96 N•m) torque. DO NOT OVERTIGHTEN!

Remove the inside access panels (right side). (See
Removal And Installation (Right) on Page 50-121-2.)
Figure 60-72-1Use updated files from Bobcat

Publications.
1
P-66835
Remove the top controller mounting bolt (Item 1). Loosen

the two bottom controller mounting bolts (Item 2) [Figure
60-72-1] from the right side fender.
Lift and remove the controller from the fender.

(16 - 19 N•m) torque.

678 of 928
SPEED SENSORS (SJC) Testing
Figure 60-80-1
1
P-28302

procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loader’s controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness

drive motor is rotating. The end of the sensor is magnetic [Figure 60-80-2]
and counts the magnetic pulses as a rotating disc,
end. Use updated files from Bobcat

attached to the motor carrier shaft, rotates by the sensor MEL1563 or 7003031-Remote Start Tool Kit
Multimeter
Publications.
The speed sensor is sealed with an O-ring (Item 1)
[Figure 60-80-1] to keep hydraulic oil inside the motor
carrier and dirt out.

1.) or (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-60-1.)

679 of 928
SPEED SENSORS (SJC) (CONT'D) Take a voltage reading, with the multimeter, at the speed
sensor test harness, between pin 1 and pin 3 (Item 2)
Testing (Cont’d) [Figure 60-80-4].
Figure 60-80-3 The voltage should be approximately 5 volts.
Repeat the procedure for the opposite side speed

sensor. (If needed.)
3
File has expired.

P-64762
Locate the speed sensor (Item 1) [Figure 60-80-3] on the

top of the right or left hydrostatic motor carrier.

Remove the transmission cover screw (Item 2) [Figure

60-80-3], to loosen the connector clamp.

torque.
Figure 60-80-4
Publications.
P-64976
Disconnect the speed sensor wire connector (Item 3)

[Figure 60-80-3] from the loader harness wire connector.
Connect the speed sensor test harness (Item 1) [Figure

60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
Turn the remote start key to ON position without starting

the loader.

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SPEED SENSORS (SJC) (CONT'D) Figure 60-80-7
Figure 60-80-5 1
1 P-64764
Lift the speed sensor (Item 1) [Figure 60-80-7] out from
File has expired.P-64762 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Raise the lift arms and install an approved lift arm support Figure 60-80-8


Remove the two, speed sensor mount bolts (Item 1)
[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Publications.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
2
P-64765
1
Remove the speed sensor [Figure 60-80-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure

60-80-6], to loosen the connector clamp.

torque.
Disconnect the speed sensor electrical harness

connector (Item 2) [Figure 60-80-6].

681 of 928
SPEED SENSORS (SJC) (CONT'D) Figure 60-80-11
Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)
File has expired.

P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-9].

Figure 60-80-10
Publications. 1
2
1
P-26296A P-26295
Installation: The alignment pin (Item 1) at the bottom of

the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue

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DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes.
The Service Codes will aid your dealer in diagnosing
conditions which can damage your machine. Figure 60-90-2
Figure 60-90-1
Press TOOL / SETUP
2 B-16163
Press OWNER UTILITIES
B-24288
File has expired.

1 P-76455G
Enter PASSWORD (owner or master)
on Keypad
then press ENTER
to Continue
B-24290
Press the INFORMATION button (Item 1) to cycle the

DATA DISPLAY (Item 2) [Figure 60-90-1] until the

service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the
DATA DISPLAY.
Press SERVICE CODES
Publications.
NOTE: Corroded or loose grounds can cause
multiple service codes and / or abnormal
symptoms. All instrument panel lights
B-24291
Press NEXT to view the next 8

flashing, alarm sounding, headlights and Service Codes. (A total of 40 Codes
taillights flashing, could indicate a bad can be stored.)
ground. The same symptoms could apply if B-24298
the voltage is low, such as loose or corroded
battery cables. If you observe these
symptoms, check grounds and positive leads
first. The Display Panel will list the Code Number, (CODE)
hourmeter reading when the error occurred (HOUR), and
the User (USER) who was logged in to operate the
machine when the error occurred [Figure 60-90-2].
A total of 40 Codes can be stored. When more than 40

codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.

683 of 928
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-3 The following word errors may be displayed:
2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.
(Item 2) [Figure 60-90-3]. File has expired.

Service Codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed A8503 ACD output ‘F’ error OFF

A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003
A8005
A8006
ACD output ‘A’ error OFF
ACD output ‘A’ short to battery
ACD output ‘A’ short to ground
A8506
A8507
A8532
ACD output ‘F’ short to ground
ACD output ‘F’ open circuit
ACD output ‘F’ overcurrent
A8007
A8032
A8102
Publications.
ACD output ‘A’ open circuit
ACD output ‘A’ overcurrent
ACD output ‘B’ error ON
A8602
A8603
A8605
ACD output ‘G’ error ON
ACD output ‘G’ error OFF
ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high

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Service Codes List (Cont’d)

D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535
D7536
D7537
File has expired.
Right rear wheel angle sensor out of range low
Left rear wheel angle sensor out of range low
Sensor supply 1 out of range low
D7585
D7586
D7587
Sensor supply 1 out of range high
Sensor supply 2 out of range high
Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF

D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541
D7542
D7543
Right swash plate sensor out of range high
Right swash plate sensor out of range low
Left forward drive solenoid error ON
D7592
D7593
D7594
Right swash plate sensor reversed
Right speed sensor unresponsive
Left speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545
D7546
D7547
Publications.
Right forward drive solenoid error ON
Right reverse drive solenoid error ON
Right front steer extend short to battery
D7596
D7597
D7598
Right speed sensor reversed
Controller programmed
In drive calibration mode
D7548 Left front steer extend short to battery D7599 In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent

685 of 928

H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic/Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807
H2905
H2906
File has expired.
Diverter rod solenoid open circuit
High-flow solenoid short to battery
High-flow solenoid short to ground
M0422
M0509
M0510
Engine oil pressure out of range low
Hydraulic charge pressure low
Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low

H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128
H3648
H3913
Interrupted power failure
ACD multiple
Left joystick grip no communication
M0521
M0522
M0610
Hydraulic charge pressure out of range high
Hydraulic charge pressure out of range low
Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928
H3948
H4013
Publications.
Left joystick failure
Left joystick multiple
Right joystick grip no communication
M0613
M0615
M0618
Engine speed no signal
Engine speed shutdown
Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure

686 of 928

M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807
M1832
M2005
File has expired.
Lift spool lock open circuit
Lift spool lock overcurrent
Two-speed primary short to battery
M4803
M4807
M4902
Front light relay error OFF
Front light relay open circuit
Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit M4907 Rear light relay open circuit

M2032 Two-speed primary overcurrent M5002 Front light output error ON
M2102
M2103
M2107
Glow plug output error ON
Glow plug output error OFF
Glow plug output open circuit
M5003
M5007
M5028
Front light output error OFF
Front light output open circuit
Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202
M2203
M2207
Publications.
Starter output error ON
Starter output error OFF
Starter output open circuit
M5103
M5107
M5128
Rear light output error OFF
Rear light output open circuit
Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF

687 of 928

M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224
W3231
W3232
ACS calibration failed
Tilt actuator fault
Tilt actuator wiring fault
File has expired. W3264
W3265
W3266
Pedal lock short to battery
Sensor supply voltage out of range
Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle/pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error

W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236
W3237
W3238
Lift actuator fault
Lift actuator wiring fault
Lift handle wiring fault
W3271
W3274
W3275
Right hand drive short to battery
Left joystick X-axis out of range
Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240
W3241
W3249
Publications.
Lift handle / pedal not in neutral
No communication
Lift actuator short to ground
W3277
W3905
W4005
Remote control information error
Left joystick X-axis not in neutral
Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral

688 of 928
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Figure 60-100-1
1 2 3
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel (Items 1,
Publications.
2, 3) [Figure 60-100-1] of the loader cab.
The Press To Operate button (Items 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

689 of 928
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
Figure 60-100-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 2 3 PRESS TO OPERATE LOADER button.
7. Engage parking brake and move steering levers or

joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
6 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
brake is disengaged.
5
Inspecting The Lift Arm Bypass Control
4
File has expired. 8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop engine. Turn lift arm bypass control knob
P-76459A clockwise 1/4 turn. Pull up and hold lift arm bypass
control knob until lift arms slowly lower.
1. Sit in operator’s seat. Turn key to RUN or press RUN

button. Lower seat bar and disengage parking brake. Inspecting Deactivation Of Lift And Tilt Functions

Press the PRESS TO OPERATE LOADER button
(Item 4). Two BICS™ lights (Items 1 and 2) [Figure
60-100-2] [SEAT BAR AND LIFT & TILT VALVE] on
(ACS and SJC)
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
Publications.
left instrument panel must be OFF. The PRESS TO
OPERATE LOADER button will light.
LOADER button.
10. Raise lift arms about 6 feet (2 meters) off the ground.
2. Raise seat bar fully. All three BICS™ lights (Items 1,
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT 11. Turn key OFF or press STOP button, and wait for the
VALVE AND PARKING BRAKE] on left instrument engine to come to a complete stop.
panel must be ON. The PRESS TO OPERATE
LOADER button light will turn OFF. 12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
Inspecting Deactivation Of The Auxiliary Hydraulics (foot pedal, hand control or joystick) to lower the lift
System (Engine STOPPED - Key ON) arms. Lift arms must not lower.
3. Sit in operator’s seat, lower seat bar and press the 13. Move the control (foot pedal, hand control or joystick)
PRESS TO OPERATE LOADER button (Item 4). to tilt the bucket (or attachment) forward. The bucket
Press the auxiliary hydraulics button (Item 5). The (or attachment) must not tilt forward.
auxiliary hydraulics light will be ON (Item 6) [Figure
60-100-2]. Raise the seat bar. The light must be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

WARNING
brake and fasten seat belt.
5. Start engine and operate at low idle. Press the The Bobcat Interlock Control System (BICS) must
PRESS TO OPERATE LOADER button. While deactivate the lift, tilt and traction drive functions. If it
raising the lift arms, raise the seat bar fully. The lift does not, contact your dealer for service. DO NOT
arms must stop. Repeat using the tilt function. modify the system.
W-2151-0394

690 of 928
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
File has expired.

SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting Chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into
place.

3. Check pins in connectors for pins pushed back or bent.

4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
5. Possible low or high voltage.
Publications.

691 of 928
File has expired.

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692 of 928
SEAT BAR SENSOR problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
Description
The seat bar sensor is part of the BICS system. The seat
bar sensor sends a signal that indicates whether the seat
bar is in the down or up position.
WARNING
The sensor is located on the left side of seat bar. Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
Troubleshooting adjustments can cause injury or death.
W-2004-1285
assistance in locating and correcting BICS system
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
File has expired.

1. Check sensor wire connection.
SOLUTION SUGGESTIONS
2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.

3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.

5. Check magnet collar magnets for contamination such as metal particles.
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693 of 928
SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on
File has expired.

N-18463 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:

Connect the seat bar adapter sensor leads (MEL1567) to

the sensor tester.
Disconnect the seat bar sensor connector (Item 1)

1
[Figure 60-110-1].
Figure 60-110-2
Publications.
P-4699
1
Lower the seat bar. The Sensor Test light (Item 1)

N-19557 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
N-19558 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. See inset Replace the Seat Bar Sensor. (See Removal And
[Figure 60-110-2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. circuit test. (See Bobcat Interlock Control System (BICS)
Circuit Test on Page 60-110-5.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

694 of 928
SEAT BAR SENSOR (CONT'D) Installation: Tighten the mounting bolt to 50 - 70 in.-lb.
(5,6 - 7,9 N•m) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-
Figure 60-110-5 110-6] and nut.
Remove the seat bar (Item 1) [Figure 60-110-5] from the

loader. (See Removal And Installation on Page 50-10-1.)

Figure 60-110-6

Publications.
3
N-19219
Remove the mounting bolt (Item 1) from the seat bar

mount (Item 2) [Figure 60-110-6].

695 of 928
SEAT BAR SENSOR (CONT'D)
Figure 60-110-7
2
1
3
File has expired.

N-19383
Remove the keyed plastic bushing (Item 1) magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)

[Figure 60-110-7].

IMPORTANT
Publications.
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [Figure 60-110-7]
of the seat bar.
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar

sensor.

696 of 928
SEAT BAR SENSOR (CONT'D) When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-9] on the sensor tester to
Bobcat Interlock Control System (BICS) Circuit Test the Present position.
Figure 60-110-8 NOTE: The sensor test light (Item 3) [Figure 60-110-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Use Sensor Testers (MEL1428) and seat bar sensor

tester adapter (MEL1567) for the following procedure:

Connect the seat bar sensor tester adapter MEL1567 to

the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
Publications.
[Figure 60-110-8].
Figure 60-110-9
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-9] inline

to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE

ENGINE.
If there is no power light on the sensor tester, check the

tester or wiring harness.

697 of 928
SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test

(Cont’d)
Figure 60-110-10
File has expired.

P-76459
The BICS seat bar indicator light (Item 1) [Figure 60-110-

10] should illuminate.

Figure 60-110-11
Publications.
1
P-4699
Move the toggle switch (Item 1) [Figure 60-110-11] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-10] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.

698 of 928
TRACTION LOCK problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
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 BICS System.
WARNING
Troubleshooting Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
The following troubleshooting chart is provided for adjustments can cause injury or death.
assistance in locating and correcting BICS system W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11

File has expired.
1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp. fuse.

4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See
Fuse And Relay Location / Identification on Page 60-10-9.)

5. To test the solenoid, the pull coil should be about 0.3 ohm and the hold coil should be about 10.9 ohm.
6. Check brake solenoid and cover mounting hardware for the correct torque.
Publications.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel RPM sensor and wiring.
12. Check the Display Panel for an error code. (See Electrical System Service Manual)
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.

699 of 928
TRACTION LOCK (CONT'D) Figure 60-120-2
WARNING
1
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat P-68140
Company parts if repair is necessary.
W-2165-0100
Remove the bracket (Item 1) [Figure 60-120-2] from the
File has expired.

30-1.)
chaincase cover.
Installation: Apply polyurethane sealer to the bolt

threads and tighten the mounting bolts to 25 - 28 ft.-lb.
Figure 60-120-1
(34 - 38 N•m) torque.

Be sure the solenoid mounting bracket is installed in the
2
same position. The solenoid mounting surface has a
slight angle which tips the top of the solenoid toward the
rear of the loader when installed correctly. See inset
photo [Figure 60-120-1].
Figure 60-120-3
1
P-66958
2
NOTE: The loader control panel and linkage crossbar
have been removed for clarity purpose only.
The traction lock can be removed without
removing the control panel.

120-1] from the electric solenoid mounting bracket. P-68141
Installation: Tighten the mounting screws to 80 - 90 in.-

Remove the traction lock assembly (Item 1) [Figure 60-
120-3] from the chaincase.
Remove the electric solenoid (Item 2) from the chaincase
Inspect gasket (Item 2) [Figure 60-120-3], replace if
cover [Figure 60-120-1].
necessary.

700 of 928
TRACTION LOCK (CONT'D) Installation: Thoroughly clean and dry the shaft
mounting bolt (Item 1), the shaft (Item 5) and wedge
Removal And Installation (Cont'd) (Item 4) [Figure 60-120-5]. Use Loctite® #242 when
assembling these parts to the traction lock assembly.
Figure 60-120-4
Figure 60-120-6
4 1
3 2
P-68142
Remove and inspect the compression spring (Item 1) and

spring cap washer (Item 2) [Figure 60-120-4] for wear or Inspect the guides (Item 1) [Figure 60-120-6] for wear or

damage. Replace if necessary. The spring may also stay damage. Replace if necessary.
with the shaft when the electric solenoid and bracket are

removed from the chaincase.
Installation: Install the compression spring (Item 1)

If replacement is necessary, remove the center
chaincase cover. Remove the screws (Item 2) [Figure
60-120-6] and pry the center cover off.
solenoid. Publications.
[Figure 60-120-4] on the collar located on the electric
Installation: Apply polyurethane sealant to the screw
threads and center chaincase cover. Tighten screws to
Inspect the shaft (Item 3) and wedge (Item 4) [Figure 60- 15 - 20 ft.-lb. (20 - 27 N•m) torque.
120-4] for scoring and deep scratches, replace if
damaged. (Item 3) [Figure 60-120-4] from the
chaincase.
Figure 60-120-5
4 5
3
2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-120-5]. Inspect all parts for
damage or wear. Replace if necessary.

701 of 928

1
3
Figure 60-120-7
1
2
2
P11332
Installation: Thoroughly clean the polyurethane from the
File has expired.

P11331 chaincase cover (Item 1), bolts (Item 2) and traction lock
guides (Item 3) [Figure 60-120-9] and dry.
NOTE: Bolt (Item 1) is on the rear of the chaincase Figure 60-120-10

cover, notice the direction of the groove (Item

2) [Figure 60-120-7] in the traction lock
guides.

Figure 60-120-8
Publications.
1
P11333
Installation: Apply a bead of polyurethane on the

1
traction lock guides and bolts [Figure 60-120-10].
P11330
To remove the traction lock guides remove the four bolts

(Item 1) [Figure 60-120-8].

702 of 928
TRACTION LOCK (CONT'D) Lower operator cab. (See Lowering on Page 10-30-2.)
Removal And Installation (Cont'd) Perform the BICS inspection procedure. (See BOBCAT
INTERLOCK CONTROL SYSTEM (BICS) on Page 60-
Figure 60-120-11 100-1.)
INCORRECT CORRECT
3
2
N-19106
Install the traction lock guides (Item 1) to the chaincase

cover (Item 2) [Figure 60-120-11] using the four bolts

(removed earlier).

Do not tighten at this time.
Figure 60-120-12
Publications.
1
P11337
Install the traction wedge assembly (Item 1) into the

solenoid and traction lock guides (Item 2) [Figure 60-
120-12].
After the bolts have been tightened recheck to make sure

the shaft assembly is moving freely in the guides.
Remove the wedge assembly (Item 1) [Figure 60-120-

12].
NOTE: The wedge assembly must slide freely in the

grooves of the guides. Tighten the four guide
bolts to 90 - 100 ft.-lb. (123 - 135 N•m) torque.

703 of 928
Inspecting
Figure 60-120-13
1
P-68145
1 Check the wire connections at the engine flywheel RPM
File has expired.

P-76674 speed sensor (Item 1) [Figure 60-120-14].
NOTE: When the Traction Lock Override Button is

Fasten the seat belt, disengage the parking brake switch, activated, the Traction Lock Override Control
press the PRESS TO OPERATE LOADER Button (Item System will NOT engage the Traction Lock if
1) [Figure 60-120-13] and raise the Seat Bar fully. Move

the engine stops.
the steering levers slowly forward and backward. The

TRACTION lock (Item 4) [Figure 60-120-13] should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button (Item 1) [Figure 60-120-13].
See Adjusting on Page 60-170-1 for Flywheel RPM
sensor adjustment.
Publications.
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The TRACTION
Fasten the seat belt, disengage the parking brake pedal,
press the green PRESS TO OPERATE Button and raise
the Seat Bar fully. Move the control levers slowly forward
lock should be engaged. and backward. The Traction lock should be engaged.
Lower the Seat Bar. Press the green PRESS TO
NOTE: The TRACTION light on the left instrument OPERATE Button.
panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER Engage the parking brake pedal and move the control
Button is pressed and the parking brake is levers slowly forward and backward. The Traction lock
disengaged. should be engaged.

704 of 928
CONTROL SYSTEM (ACS)
Description
The (ACS) Actuator Control System system is an option

that allows the operator to quickly switch between foot
and hand control modes.
The ACS control uses the electric actuators on the main

hydraulic control valve to control the lift and tilt spools in
the hydraulic control valve, foot sensors, handle sensors
and a specially designed control handle.
Hand controls contain a locking solenoid which lock

when the switch on the center control panel is switched
to foot mode.
Foot controls also contain solenoids which lock when the

switch on the center control panel is switched to hand
mode.
File has expired.
Both the hand and foot controls contain sensors that
relay information to the ACS controller as to which
function should be activated and how far the spool should

be moved.

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705 of 928
CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller.
The ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The
controller also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
File has expired.

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706 of 928
CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
2
3
1
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]
File has expired.P16578

and pull the wire from the connector.
Installation: Install the wires into the connector as listed

below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be

removed from the handle sensor wires, using the 1-Terminal - Red
following procedure.

Figure 60-130-2
2-Terminal - Black
3-Terminal - Green
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1
1
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

707 of 928
Switch Handle Removal
Figure 60-130-4
1
3
2
P13735
1
2
Using a pointed tool, press down on the tab (Item 1)
File has expired.

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.


130-4] from the handle sensor connector.
Figure 60-130-5
Publications.
1
P13725 P13732

harness connector (Black) that connects to the handle
1
lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

708 of 928
Switch Handle Removal (Cont'd)
Figure 60-130-8
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
File has expired.

P13735 3 and 4) [Figure 60-130-10] from the loader wiring
harness connectors.
Using a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.

Figure 60-130-9

1
Publications. 2 2
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Items 1 Using a small screwdriver, lift the handle tabs (Item 2)
and 2) [Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

709 of 928
CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2 Tape 1/2 of Wires

Tape back 1/2 of Wires
P-24233
P-21699
File has expired.

N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 6 in. piece of heat shrink

tubing placed over the end of the wires. Remove the heat
Cut the wires (Item 2) [Figure 60-130-12] below the shrink tube from the end of the wires before routing the
switch handle and remove switch handle.
NOTE: Only cut the wires if the switch handle is bad

harness through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
Publications.
and needs replacement. If the switch handle is
good and just needs to be removed for control
handle or lever replacement, then remove the
wires for protection.
Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle and harness up through the top through the control lever tube.
of the lever tube.
Figure 60-130-13
P-24234
If the harness has been cut: pull the harness (Item 1)

[Figure 60-130-13] out through the bottom of the control
lever tube.

710 of 928
CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont'd) Right Switch Handle
Figure 60-130-15 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
1 C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
File has expired.P-21700A C-Terminal - Purple/White
Left Switch Handle

Install the new switch handle and wires from the top of
the control lever. Ten-Pin Connector

A-Terminal - Orange
Route wire (Item 1) [Figure 60-130-15] through the

casting, along side the handle sensor and into the control
lever tube.
B-Terminal - Dk. Blue
C-Terminal - White
D-Terminal - Purple
E-Terminal - Yellow/Red
Publications.
NOTE: Do not pull the wire harness tight. Allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
F-Terminal - Tan
G-Terminal - Pink
H-Terminal - Orange/Black
returns to neutral position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
2 B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
1 A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Remove tape from wires for installation and install the 6

in. of heat shrink tube (Item 1) [Figure 60-130-16]
approximately 3 in. into the control lever. Apply heat to
the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

711 of 928
Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
P13735
1 Install the wires into the connectors as listed below:
File has expired.

N-17779
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18
1-Terminal - Red / White

2-Terminal - Black / White
3-Terminal - Purple / White
1
Figure 60-130-20
Publications.
3 1
N-17772
2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
connectors.
P13735
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow / Red

2-Terminal - Open
3-Terminal - Orange / Black

712 of 928
Switch Handle Installation (Cont'd)
Figure 60-130-21
N-17741
Installation: Install the wires into the connector as listed
File has expired.

P-21804 below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Connect the handle harness connectors to the sensor Lift and Tilt Actuator
and lock solenoid connectors [Figure 60-130-21]. 1. Terminal-Black / Green-Larger diameter wire (16

gauge)
Actuator Connector Disassembly And Assembly 2. Terminal-Green / Larger diameter wire (16 gauge)
NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
3. Terminal-Red / Green-Larger diameter wire (16
gauge)
4. Terminal-Open
Publications.
Figure 60-130-22
5. Terminal-Red-Smaller diameter wire (18 gauge)
6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)
1
P-66842
Check the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.

713 of 928
CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
P-21878A
1
File has expired.

P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads

and tighten solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
Figure 60-130-25
Figure 60-130-27
Publications.
1 P-21789
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for

Remove the two screws (Item 1) [Figure 60-130-25] damage. Replace as necessary.
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 -

4,3 N•m) torque.
Remove handle lock solenoid assembly from handle.

714 of 928
CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-130-28
1
File has expired.
P-24269
Remove the two bolts (Item 1) [Figure 60-130-28] from

the end of the foot sensor.

Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m)

torque. Apply Loctite® 242 to the threads.
Figure 60-130-29
Publications. 5
3
2
1
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-130-29].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-29]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

715 of 928
Foot Lock Solenoid Removal And Installation
Figure 60-130-30
P-21790
Check the O-ring (Item 1) [Figure 60-130-32] for

1
File has expired.
P-21938 damage. Replace as necessary.
Remove the two bolts (Item 1) [Figure 60-130-30] from

the foot sensor shield.

Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2
N•m) torque.
Figure 60-130-31
Publications. 1
P-21939
Disconnect the foot lock solenoid connector (Item 1)

[Figure 60-130-31] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-130-31].
Installation: Apply a drop of oil on the solenoid threads

and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque.

716 of 928
ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 5 10 11 12
6 7
13
9
4
REF. NO.
File has expired. DESCRIPTION
B-15781F / B-22178D / B-15781E
1 TURN SIGNALS (Option)

2 REAR AUXILIARY HYDRAULICS (Option)

Also: ATTACHMENT FUNCTION CONTROL
3
4
ATTACHMENT FUNCTION CONTROL
FRONT HORN
5
6
7
Publications.
STEERING LEVERS
LIFT ARM PEDAL
TILT PEDAL
8 ENGINE SPEED CONTROL
9 LIFT ARM BYPASS CONTROL
10 ATTACHMENT FUNCTION CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 TWO-SPEED CONTROL (Option)
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

717 of 928
ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D

File has expired.
Refer to the Identification Chart ACD Group 0,1,2, or 3

for more detailed information.

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718 of 928
Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8
9
File has expired.
1
1
4,5,6
4,5,6
1
1
4,5,6
4,5,6
K,G
K,H
10, 11, - -- -- K No Jumpers
12, 13,

B-16447 14 B-16448

RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
Publications.
Terminal K is activated with Key switch ON.
NOTE: For diagnostics and troubleshooting connect

the Service PC (See SERVICE PC (LAPTOP 6 5 4 2
1
COMPUTER) on Page 60-150-1.) 7
The ACD (Attachment Control Device)

automatically recognizes the use of the seven
or fourteen pin connector when connected.
3
Pressing the auxiliary hydraulics button and
moving the rear auxiliary hydraulic switch to NA1891
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

719 of 928

1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8
9
File has expired.
1
1
1
1
1
1
1
1
K,M,G
K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,

B-16447 14 B-16448

Publications.

1

3
Number Number
block.
pump.

720 of 928

1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H
10, 11, - -- -- K Jumpers K,P
12, 13,

B-16447 14 B-16448

Publications.

1

3
Number Number
block.
pump.

721 of 928

1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H
10, 11, - -- -- K Jumpers C,D
12, 13,

B-16447 14 B-16448

Publications.

1

3
Number Number
block.
pump.

722 of 928
ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 6 11 12 13
7 8
9
4
14
5
B-15781D / B-22178E / B-15781E
REF. NO. DESCRIPTION


2 REAR AUXILIARY HYDRAULICS (Option)
3
ATTACHMENT FUNCTION CONTROL
4 FLOAT CONTROL
5
6
Publications.
FRONT HORN
STEERING LEVERS AND LIFT / TILT HANDLES
7 LIFT ARM PEDAL
8 TILT PEDAL
9 ENGINE SPEED CONTROL

723 of 928
ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D

File has expired.


Publications.

724 of 928

13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14
8
9
File has expired.
1
1
4,5,6
4,5,6
1
1
4,5,6
4,5,6
K,G
K,H 3
10, 11, - -- -- K No Jumpers

P-90898 12, 13, P-90899

P-90900 14 P-90900A

Publications.

1

3
Number Number
block.
pump.

725 of 928

13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14
8
9
File has expired.
1
1
1
1
1
1
1
1
K,M,G
K,M,H 3
10, 11, - -- -- K Jumpers K,L

P-90898 12, 13, P-90899

P-90900 14 P-90900A

Publications.

1

3
Number Number
block.
pump.

726 of 928

13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14
8
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H 3
10, 11, - -- -- K Jumpers K,P

P-90898 12, 13, P-90899

P-90900 14 P-90900A

Publications.

1

3
Number Number
block.
pump.

727 of 928

13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front 11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14
8
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H 3
10, 11, - -- -- K Jumpers C,D

P-90898 12, 13, P-90899

P-90900 14 P-90900A

Publications.

1

3
Number Number
block.
pump.

728 of 928
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
10 11
18
6 7
19
B-19873A / B-15546K / B-19874A
REF. NO. DESCRIPTION


Also: SPEED MANAGEMENT
*2
3
STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
REAR AUXILIARY HYDRAULICS (Option)
*4
Publications.
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 JOYSTICKS
9 FOOTRESTS
10 ENGINE SPEED CONTROL (FOOT)
11 ENGINE SPEED CONTROL (HAND)
* 14 NOT USED
* 16 NOT USED
18 FLOAT CONTROL
* Also used as Attachment Function Control: See your attachment Operation & Maintenance Manual.

729 of 928
ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D

File has expired.


Publications.

730 of 928

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
9
File has expired.
1
1
4,5,6
4,5,6
1
1
4,5,6
4,5,6
K,G
K,H
3
10, 11, - -- -- K No Jumpers

P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

Publications.

1

3
Number Number
block.
pump.

731 of 928

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
9
File has expired.
1
1
1
1
1
1
1
1
K,M,G
K,M,H
3
10, 11, - -- -- K Jumpers K,L

P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

Publications.

1

3
Number Number
block.
pump.

732 of 928

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
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H
3
10, 11, - -- -- K Jumpers K,P

P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

Publications.

1

3
Number Number
block.
pump.

733 of 928

1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8
9
File has expired.
-
-
-
-
-
-
-
-
K,G
K,H
3
10, 11, - -- -- K Jumpers C,D

P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A

Publications.

1

3
Number Number
block.
pump.

734 of 928
SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-150-1
1 2
2
1 3
P-76450
File has expired.

P16119
procedure:
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start

Tool (Service Tool) Kit

MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Kit Includes:
7003030 - Remote Start Tool (Service Tool)
Publications.
NOTE: Make all connections with the key in the OFF
position.
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item NOTE: Make all connections with the key in the OFF
2) [Figure 60-150-1]. When connected to the loader, the position.
Service PC is used to monitor, conduct diagnostics, and
upgrade software. The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-150-2]. When
Connect the Service Tool Harness Communicator connected to the loader, the Service PC is used to
(MEL1566) (Item 3) [Figure 60-150-1] to the designated monitor, conduct diagnostics, and upgrade software.
serial port on the Service PC.
Connect the Remote Start Tool (Service Tool) Computer
NOTE: The recommended serial cable length should Service Tool Harness (Item 3) [Figure 60-150-2] to the
not exceed 15 feet. A serial cable longer than designated serial port on the Service PC.
15 feet will create a degraded signal causing
communication errors. NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
Connect the other end to the connector on the Remote 15 feet will create a degraded signal causing
Start Tool. communication errors.
Connect the Remote Start Tool to the loader. (See Connect the other end to the connector on the Remote
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Start Tool (Service Tool).
1.)
Connect the Remote Start Tool (Service Tool) to the
NOTE: Refer to BobcatNET for PC requirements and loader. (See REMOTE START TOOL (SERVICE TOOL)
the latest Service Analyzer software. KIT - 7003031 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and

the latest Service Analyzer software.

735 of 928
File has expired.

Publications.

736 of 928
CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive Controller, ACS
Controller, pump controller, hydrostatic pump, or
hydrostatic motor. Failure to calibrate after component
replacement may result in poor performance or reduced
life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
File has expired.

The Lift and Tilt Calibration (ACS) provides set points to
the ACS controller to actuate the lift and tilt valve. The Lift
[Figure 60-160-1] Excessive actuator loading can occur
if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting

controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced
valve spool misalignment.
Connect the Service PC (See SERVICE PC (LAPTOP
Publications.
performance codes are present or when replacing a
controller or actuator.
COMPUTER) on Page 60-150-1.)
If a Service PC is not available, (See Lift And Tilt

The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-11.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path can not be attained or replacing the 72° F (22° C), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a

Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

737 of 928
CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
The pin may be too large. Oversized pins exceeding
• Actuator did not fully extend/retract. During the test, 0.248 in. (6,30 mm) in diameter should be replaced.
directions. File has expired.

the spool was not able to fully stroke in both
If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
• Actuator out of neutral. The spool did not return to the 60-160-2], check the following probable causes in
neutral window during the test. Column 2 [Figure 60-160-2].

NOTE: A time out will occur if the test cannot be
completed within 8 seconds. If this happens,
retry the test.
•
•
Contamination in the spool.
The spool end cap may be defective or the centering

spring may be broken. Inspect the end cap and the
Figure 60-160-2
Publications.
Run Actuator Test
•
centering spring, replace if necessary.
The wire harness or connectors may have an

intermittent short. Check the connections and wire
Pass Fail harnesses.
Retest With Warm Hydraulic Oil • The controller may be defective, replace the
controller.
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

738 of 928
CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.
• The spool end cap may be defective or the centering

• Contamination in the spool.
File has expired.

If the initial Actuator Test results in the fail mode actuator
out of neutral, check the following.
• The actuator may be defective, replace the actuator.

• The spool end cap may be defective or the centering

• Contamination in the spool.
Publications.

739 of 928
CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
B-19874
NOTE: The Actuator Test is the preferred method to
calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-28063
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s). Move the right joystick to the forward-right corner position
Figure 60-160-3 File has expired. [Figure 60-160-4] and hold in position.

1
Publications.
P-45240
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

740 of 928
Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
1
1
P-76683
1
P-76601 P-76597A At the left panel, press the PRESS TO OPERATE Button
File has expired.

With the seat bar down, turn the ignition key ON (Deluxe
(Item 1) [Figure 60-160-6] while holding the right joystick
in position.
Instrumentation Panel press RUN/ENTER) [Figure 60- Release the joystick.
160-5].

NOTE: During the calibration cycle, the system will
NOTE: Do not start the engine. beep three times. Once the calibration is
The loader Control Pattern Switch (Item 1) [Figure 60-
160-3] will start flashing and will continue to flash until the
complete code W3224
Performed) will be generated.
(Calibration
Publications.
calibration procedure is completed. The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.

741 of 928
CALIBRATION (CONT'D) Figure 60-160-8
Hydrostatic Pump Calibration (SJC)
WARNING
Failure to use jackstands can allow the machine to 1
fall or move and cause injury or death. 1
W-2017-0286
P-76601 P-76597A
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
With the seat bar down, turn the ignition key ON (Deluxe
Operator must be in the seat and the seat bar down. Instrumentation Panel press RUN/ENTER) [Figure 60-
Figure 60-160-7 File has expired. 160-8].
NOTE: Do not start the engine.
Figure 60-160-9

1
Publications. 2
P-45238
Close the cab door. (If loader is so equipped.) P-45238
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-7] in the ISO position. The Control Pattern ISO Switch (Item 1) [Figure 60-160-
9] will start flashing.
Verify the parking brake (Item 2) [Figure 60-160-7] is
OFF.

742 of 928
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-10
B-19873
P-26476
B-19873
Move the left joystick to the reverse-right corner position
File has expired. P-26476 [Figure 60-160-12] and hold in position.
Figure 60-160-13
Move the left joystick to the forward-left corner position
[Figure 60-160-10] and hold in position.

Figure 60-160-11

Publications.
1
P-76683
1
Press the PRESS TO OPERATE LOADER Button (Item
P-76683 1) [Figure 60-160-13] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-11] while holding the left joystick in
position.
Three audible beeps will sound.
NOTE: Codes D3905 and D3907 will be displayed if

the info button is pressed four times.

743 of 928
Figure 60-160-14
1
P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-160-
File has expired.

P-26474 16] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Allow the left joystick to go to the neutral position [Figure Figure 60-160-17
60-160-14].

Figure 60-160-15
Publications.
P-90128
1
P-76683 Move the throttle (Item 1) [Figure 60-160-17] to high idle.
NOTE: If at any time, during calibration, the operator

Press the PRESS TO OPERATE LOADER Button (Item needs to stop the loader, turn the key OFF, lift
1) [Figure 60-160-15]. the seat bar, or return the joystick to the
neutral position. The calibration procedure
Three audible beeps will sound. will stop.
Start the engine from the RUN, RUN/ENTER position. To return to calibration mode, the operator
DO NOT TURN TO OFF POSITION. This would cancel must start the complete procedure from the
the calibration mode and the procedure would have to be beginning.
repeated.
If code D7572 occurs, drive functions will be
disabled until a successful pump calibration
has been completed.

744 of 928
1 2
WARNING
W-2017-0286
Figure 60-160-18 P-64321
The loader speed will “ramp up” quickly (Item 1)
File has expired. [Figure 60-160-19] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-19] until it reaches full speed and then
come to a stop.

Continue to hold the left joystick in the forward position
B-19873
until the loader wheels or tracks come to a stop and an
audible beep is heard.
Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Forward in 2 minutes or less, there
Move and hold the left joystick to the forward position was an error in the calibration procedure. The
[Figure 60-160-18] until the forward calibration is operator must shut the loader OFF, and start
completed. the calibration procedure from the beginning.

745 of 928
CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-20 the calibration procedure from the beginning.
There will be an audible beep, PRESS TO OPERATE

LOADER button light will remain on. The TRACTION
light will illuminate, the SEAT BAR, and LIFT AND TILT
lights will be off. The 75-98 error code will clear. There
should be no other codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
B-19873 neutral.
Press the PRESS TO OPERATE LOADER button. Move
File has expired.

P-26483 the left joystick to forward position [Figure 60-160-18]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-20] until the reverse calibration is 160-20] and check for normal reverse wheel or track

completed. rotation.

Figure 60-160-21 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
1 Publications. 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift can not be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-1.)
or (See Troubleshooting on Page 60-10-8.)
P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-21] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-21] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

746 of 928
Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See 1
Actuator Testing on Page 60-160-1.) 1
NOTE: This calibration procedure must be followed P-76601 P-76597A

when replacing a hydraulic control valve,
actuator or ACS controller. Failure to calibrate
after component replacement may result in Close the cab door. (If loader is equipped.)
poor performance or reduced life of
actuator(s).
Figure 60-160-22
File has expired. With the seat bar down, turn the ignition key ON (Deluxe
Instrumentation Panel press RUN/ENTER) (Item 1)
[Figure 60-160-23].
NOTE: Do not start the engine.

Figure 60-160-24

1
Publications.
P-24826
Update the loader service software to the latest version.

1
Place the rocker switch (Item 1) [Figure 60-160-22] in
the hand control mode. P-76683
Push the PRESS TO OPERATE button (Item 1) [Figure

60-160-24] to unlock the hand controls.

747 of 928
Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-25
Stroke Both Handles Fully In and Hold Them
P-76683
Push the PRESS TO OPERATE button (Item 1) [Figure
File has expired.

B-16628 60-160-26] to begin calibration.
NOTE: The ACS icon will light up and if you listen

Fully stroke both control handles in toward the center of closely the cycling of the actuators can be
the cab and hold the handles [Figure 60-160-25]. heard. The ACS icon will stay lit until the

ignition key is cycled or the loader is started
Lift the seat bar, high enough for the PRESS TO and a function is operated.
OPERATE light (Item 1) [Figure 60-160-24] to go OFF.
Lower the seat bar.

NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
Publications. complete code W3224

Performed) will be generated.
(Calibration
Release the control handles.
Calibration is complete.

748 of 928
STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to enable the BICS.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
• Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
• File has expired.

Driving on uneven terrain such as crowned road
surfaces.
6. Current drive response setting will be displayed briefly
in the data display.
NOTE: Raising the seat bar or changing control

Figure 60-161-1 mode (ISO / H) will cause the machine to

disengage from steering drift compensation.

[S-L10] [S----] [S-R10]
The last displayed setting will remain in effect
until the STOP button is pressed or the key is
turned OFF.
Publications.
[S-L10] [S----] [S-R10]
B-23580A
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

749 of 928
STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-161-2 to appear in the data display (Item 2) [Figure 60-161-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-161-3
1 2
3 4 5File has expired.

P-76456F
P-76461L
P-76461N 1 2
P-76461M

Left Joystick Right Joystick
Use updated files from Bobcat 3 4
6
Publications.
7
P-76456F
P-76461K
P-76461O
P-24820B P-24802B
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
button (Item 1) for three seconds to enter the drive
OPERATE LOADER button (Item 1) for three seconds.
response adjustment menu. Press the PRESS TO
[SET] (Item 3) will appear in the data display (Item 2)
OPERATE LOADER button (Item 1) again to adjust the
[Figure 60-161-3] and the machine will exit from the
loader’s steering drift compensation setting. The current
steering drift compensation adjustment menu.
steering drift compensation setting will appear in the data
display (Item 2) [Figure 60-161-2].
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 60-161-2]. The number will increase by one
appear in the data display (Item 2) [Figure 60-161-3] 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 STOP button is pressed or the key is
turned OFF. The machine will revert back to
the last saved setting the next time it is
started.

750 of 928
FLYWHEEL RPM SENSOR Figure 60-170-2
Description 2
The flywheel RPM sensor has a magnet located on the 1

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
main Bobcat controller which registers the RPM of the
engine.
The flywheel RPM sensor is located just above the

starter on the left side of the engine.
Code 06-13 will occur if the main Bobcat controller loses

the signal for the flywheel RPM sensor.
P-68137
The inability to unlock the traction lock (brake) is a
symptom of losing the flywheel RPM sensor signal. Not
being to read engine speed on the service tool or deluxe Turn the RPM sensor and the jam nut out from the
RPM sensor signal File has expired.

display panel is also a symptom of losing the flywheel flywheel. Set a clearance of 0.050 in. (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Adjusting
NOTE: New RPM sensors have a plastic tip which is

Figure 60-170-1 used as a gauge during installation. The
plastic tip is designed to come off after the
Use updated files from Bobcat engine is started.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 12 - 17
Publications. 1
ft.-lb. (16 - 23 N•m) torque, while holding the sensor from
turning.
P-68136
When installing the RPM sensor, turn the rpm sensor

(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-170-1] until it

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.

751 of 928
File has expired.

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752 of 928
CONTROL PANEL SETUP Examples
Right Panel Setup (Deluxe Instrumentation Panel) Figure 60-180-2

Icon Identification
Figure 60-180-1
Press
TOOL/SETUP
SELECTION
EXAMPLE
BUTTONS
Press
LOADER FEATURES
B-16162
File has expired.

Make selection by pressing the SELECTION BUTTON
adjacent to the icon [Figure 60-180-1].
ICON DESCRIPTION

LOCK/UNLOCK: Allows machine to be Press
locked/unlocked. You must lock machine to DISPLAY OPTIONS

activate security system.
When system is unlocked, the user can press
RUN/ENTER then press START to begin
Publications.
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL/SETUP: Access system options.
Use to set clock, check system warnings,
select language, set passwords, etc.
Press
? HELP: Access help on current menu item. ADJUST CONTRAST
EXIT EXIT returns you to previous level menu.
11:23 CLOCK/JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL/SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one screen.
Press
OUTLINE ARROWS: No screen available UP OR DOWN
(backward/forward). Arrow to
change contrast.
SELECTION ARROW: Use to select menu
item. Press EXIT to
NEXT Goes to the NEXT screen in series. return to
previous level
EXAMPLE: the next Active Warning screen. menu.
INFO Goes to more information about attachments.
B-16163/B16164/B-16161/B-16166/B-16167
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.

753 of 928
CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Deluxe
Instrumentation Panel)
Right Panel Setup (Deluxe Instrumentation Panel)
(Cont’d) The Deluxe Instrumentation Panel allows the user to
view information concerning the operation of Bobcat
More Examples attachments.
Clocks Figure 60-180-3
Press . . .
TOOL / SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL/SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
File has expired.
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK / UNLOCK to unlock.
Enter Password and press RUN / ENTER.
Languages

Press . . . Press

TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
ATTACHMENTS
LANGUAGES
Publications.
Select the language, press RUN / ENTER.
Press EXIT to return to previous level menu.
Vitals (Monitor the engine, hydraulic / hydrostatic, Press

electrical functions when engine is running.) RUN / ENTER BUTTON
on keypad
Press . . .
TOOL / SETUP
LOADER FEATURES.
Press
VITALS UP OR DOWN
Press SELECTION ARROW to select METRIC or Arrow to
ENGLISH (M / E) readouts scroll through
attachments
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature Press
System Voltage the keypad number
Engine Speed
of a switch to view
a description of the
The Deluxe Instrumentation Panel is easy to use. attachment function
Continue to set your own preferences for running / of the switch
monitoring your Bobcat loader.
B-16163/B16164/B-16161/B-15753A/B-15754A/B-15755A
Attachments are listed alphabetically [Figure 60-180-3].

Press the exit button to return one screen or press the “0”
(zero) key to return to the home screen immediately.

754 of 928
PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-190-1
Password Setup is available on machines with a Deluxe
Instrumentation Panel.
Press TOOL / SETUP
Password Description
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start Press OWNER UTILITIES
the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password: on Keypad
A permanent, randomly selected password set at the then press ENTER
File has expired.

factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
to Continue
password. Press PASSWORD UTILITIES

Owner Password:
Allows for full use of the loader and to setup the

Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner
or user passwords. Owner should change the
Press MODIFY OWNER
Publications.
password as soon as possible for security of the
loader.
User Password:
Allows starting and operating the loader; cannot
change password or any of the other setup features. Enter new OWNER
PASSWORD on Keypad
For the procedures to change passwords (See Changing then press ENTER
The User Passwords on Page 60-190-2.) to Continue
Re-Enter new OWNER

PASSWORD on Keypad
then press ENTER
to Continue
OWNER PASSWORD procedure

is now complete
B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294

755 of 928
PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Passwords feature so that a password does not need to be used
every time the engine is started.
Figure 60-190-2
Figure 60-190-3
Press TOOL / SETUP
Press
LOCK / UNLOCK
Press OWNER UTILITIES
on Keypad File has expired.

then press ENTER

Enter OWNER
PASSWORD
on Keypad
then press ENTER
to Continue
to Continue

Press PASSWORD UTILITIES

Publications. Press MODIFY USER
Press
UNLOCK MACHINE
Enter USER number

on Keypad (There can be up to 8
different Users, each with their
own password)
then press ENTER to Continue
Press
EXIT
Enter USER PASSWORD
on Keypad
then press ENTER to Continue
Machine is now
USER PASSWORD procedure UNLOCKED and
is now complete. Enter can be started
another USER number without using a
password
OR
Press EXIT
B-16163/P-76075/P-76076/P-76076A/P-76077
B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A

756 of 928
PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Press the RUN button to turn on the loader electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-191-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
File has expired.

Press the RUN button to turn on the loader electrical
system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.

Figure 60-191-1
Use updated files from Bobcat 1 2
P-90816B
Publications. Press the unlock key (Item 2) [Figure 60-191-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2 The loader can now be started without using a password.
P-90816B NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds. Press the RUN button to turn on the loader electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.

757 of 928
File has expired.

Publications.

758 of 928
MAINTENANCE CLOCK This message will remain for 10 seconds before reverting
back to the previous screen and will appear for 10
Description seconds every time the machine is started until the
maintenance clock is reset.
The Maintenance Clock alerts the operator when the next
service interval is due. EXAMPLE: The Maintenance Figure 60-200-3
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-200-1
File has expired.

B-16163A
3
P-76461R The Deluxe Instrumentation Panel, if equipped, will

display a wrench icon (Item 1) [Figure 60-200-3] alerting
the operator to service the machine. This icon will remain
During machine operation, a two beep alarm will sound

on the display until the maintenance clock is reset.
when there are less than 10 hours until the next planned

maintenance.
The remaining hours before maintenance is required will

NOTE: Loaders equipped with a Standard Key Panel
or Keyless Start Panel will not display the
BobCARESM PM message or wrench icon on
Publications.
appear in the data display (Item 1) for five seconds while
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-200-1] flash.
the right panel.
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 five seconds every time the machine
is started until the maintenance clock is reset.
Figure 60-200-2
1
P-76122
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

759 of 928
MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
File has expired.

The first analyzer screen has an added bar for the
Select Install (Item 1) [Figure 60-200-6] to begin sending
the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.

Figure 60-200-5
Publications. 2
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored. This will
be displayed on Deluxe Instrumentation Panel equipped
loaders when the maintenance clock is less than 10
hours until next planned maintenance.

760 of 928
Setup (Cont’d)
Figure 60-200-8
P-76112
1

Click the right arrow (Item 1) [Figure 60-200-10] to scroll
through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]

message will be displayed when the dealer information
has been transferred to the machine controller. 1

Click Back (Item 2) [Figure 60-200-8] to return to the
Bobcat Service Analyzer screen.
Publications.
Figure 60-200-9
3
4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON/OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET/RESET (Item 4) [Figure 60-200-
11] to reset and set the maintenance clock.

761 of 928
Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
File has expired.

P-76111
Select Program / Update (Item 1) [Figure 60-200-14] to
view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it can not be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-12].
Publications.
NOTE: If the interval is set to 10 hours or less, the
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

762 of 928
MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
P-76455H
File has expired.

Press the information button (Item 2) until the display
screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.

Press and hold the information button (Item 2) for seven
seconds until [RESET] (Inset) appears in the display

screen (Item 1) [Figure 60-200-16].
The maintenance clock can also be reset by clicking Set /
Publications.
Reset (Item 4) [Figure 60-200-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.

763 of 928
File has expired.

Publications.

764 of 928
BACK-UP ALARM SYSTEM Figure 60-210-2
Description
The back-up alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the 1
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
Inspecting
Figure 60-210-1 2
P-69346
1
Inspect the back-up alarm electrical connections (Item 1)
[Figure 60-210-2], wire harness (Item 2) [Figure 60-210-
2] and back-up alarm switches (if equipped) (Item 2)
File has expired. [Figure 60-210-3] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on Page 60-210-2.)

Inspect for damaged or missing back-up alarm decal
Publications.
(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.

765 of 928
BACK-UP ALARM SYSTEM (CONT’D)
Adjusting Switch Position
NOTE: Joystick equipped machines do not have

back-up alarm switches and cannot be
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-210-3
Switch Rollers contacting Bellcranks

2
File has expired. 2
1 1

Publications.
Place the steering levers in the neutral position.
Loosen the screws (Item 1) [Figure 60-210-3] securing

the back-up alarm switches.
Position the back-up alarm switch rollers so that they just

make contact with bellcranks without compressing the
switch springs [Figure 60-210-3]. Torque the screws
(Item 1) [Figure 60-210-3] securing the switches to the
bracket to 14 - 19 in.-lb. (1,6 - 2,1 N•m).
Lower the operator cab (See Lowering on Page 10-30-2.)

Inspect back-up alarm system for proper function. (See
Inspecting on Page 60-210-1.)

766 of 928
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
reverse position. File has expired.

Back-up alarm will not sound when the operator moves both steering levers in the
Back-up alarm sounds when steering levers in neutral / forward position.

1, 2, 3, 4, 5, 6, 7
2, 6, 7


1. The ground connection is not making a good contact.
2. The back-up alarm switches are damaged.
3. The alarm is damaged.
Publications. 4. The alarm or back-up switch wires are disconnected.

5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

767 of 928
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
position. File has expired.

Back-up alarm will not sound when the operator moves joystick(s) in the reverse
Back-up alarm sounds when joystick(s) in neutral / forward position.

1, 2, 3, 4, 5, 6
5, 6


1. The ground connection is not making a good contact.
2. The alarm is damaged.
3. The alarm wires are disconnected.
Publications.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

768 of 928
BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and can not be
Stop the engine and open the tailgate. adjusted.
Figure 60-210-4 Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-210-6
1
2 2
File has expired.

P-69346
1 1
Mark the wires for ease of assembly. Disconnect the

wires (Item 1) [Figure 60-210-5] from the alarm.

P-62915

Installation: Make sure the wire harness ends do not
touch the mounting bolts during assembly.
Place the steering levers in the neutral position.
Figure 60-210-5
Publications. Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch assemblies (Item 2) [Figure
60-210-6] off the mounting bracket.
1
1 Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installion of switches, adjusting the switches (See
Adjusting Switch Position on Page 60-210-2.) and
inspecting back-up alarm operation (See Inspecting on
Page 60-210-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.

769 of 928
Switch Removal And Installation (Cont’d)
Figure 60-210-7
1
3
2
3
File has expired.

P-62917
Mark the wires for ease of assembly.

Disconnect the Orange wire from the common terminal
(Item 1) [Figure 60-210-7].

Disconnect the White wire from the normally open
terminal (Item 2) [Figure 60-210-7].
Publications.
Disconnect the remaining White wires to the other switch
terminals (Item 3) [Figure 60-210-7].
Remove the switches.

770 of 928
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . 70-100-4
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . 70-100-6
Timing Gearcase Cover Removal And Installation . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . 70-100-3
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Crankshaft And Bearings Removal And Installation . . . . . 70-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . 70-90-8
File has expired.

Crankshaft Gear Removal And Installation . . . . . . . . . . . .
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston And Connecting Rod Removal And Installation . . .
70-10-6
70-90-5
70-90-1
Piston And Connecting Rod - Servicing. . . . . . . . . . . . . . . 70-90-2

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Cylinder Head Disassembly And Assembly. . . . . . . . . . . . 70-80-7
Cylinder Head Removal And Installation . . . . . . . . . . . . . . 70-80-4
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Publications.
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 70-80-1
ENGINE
SERVICE
Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . 70-80-13
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . 70-80-9
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . 70-80-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide Removal And Installation. . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3

771 of 928
ENGINE SERVICE (CONT’D)
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Blower Housing Removal And Installation (S/N A3L529999 & Below) . . . . 70-50-4
Blower Housing Removal And Installation (S/N A3L530001 & Above) . . . . 70-50-9
Fan Removal And Installation (S/N A3L529999 & Below) . . . . . . . . . . . . . . 70-50-6
Fan Removal And Installation (S/N A3L530001 & Above). . . . . . . . . . . . . 70-10-11
Hydraulic Fan Description (S/N A3L529999 & Below). . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Description (S/N A3L530001 & Above) . . . . . . . . . . . . . . . . 70-50-7
Hydraulic Fan Disassembly And Assembly (S/N A3L529999 & Below) . . . 70-50-3
Hydraulic Fan Disassembly And Assembly (S/N A3L530001 & Above) . . . 70-50-7
Hydraulic Fan Motor Removal And Installation (S/N A3L529999 & Below) . 70-50-6
Hydraulic Fan Motor Removal And Installation (S/N A3L530001 & Above) 70-50-11
Radiator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Thermostat - Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-14
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-50-13
File has expired.

Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-12
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-12
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-16

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Publications.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
ENGINE SPEED CONTROL (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

772 of 928
ENGINE SERVICE (CONT’D)
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Governor Disassembly And Assembly. . . . . . . . . . . . . . . . 70-70-7
Fuel Camshaft Removal And Installation. . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-3
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . 70-70-11
Fuel Injector Removal And Installation . . . . . . . . . . . . . . 70-70-10
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . 70-70-1
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
File has expired.

Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . .
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70-60-3
70-60-1
70-60-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 70-60-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Publications.
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION
SPEC-01) UNLESS OTHERWISE SPECIFIED.


773 of 928
File has expired.

Publications.

774 of 928
ENGINE INFORMATION
Description
This loader has a Kubota direct injected V2403-M-DI

diesel engine [Figure 70-10-1] with a displacement of
148.5 cu.in. (2,4 L). The engine is rated at an SAE Net 46
HP (34 KW) and has a closed crankcase ventilation
system.
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
File has expired.

The engine is liquid cooled with a propylene glycol/water
mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine

coolant temperature sensor and the hydraulic/hydrostatic
fluid temperature sensor.
Figure 70-10-1
Publications.
P-66084

775 of 928
ENGINE INFORMATION (CONT’D)
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles
Opening Pressure 2702 - 2916 PSI (186 - 201 bar)

Fuel Tightness Nozzle Seat Dry Nozzle at 2418 PSI (167 bar) for 10 seconds
Fuel Injection Pump
Injection Timing 6.2 - 8.2 degrees B.T.D.C.

High Idle 2760 - 2900 RPM
Low Idle 1075 - 1225 RPM
Cylinder Head
Cylinder Head Surface Distortion

Thickness of Gasket (Used)
File has expired.
0.002 (0,05) Max.
0.0453 - 0.0492 (1,15 - 1,25)
(New) 0.0512 - 0.0551 (1,3 - 1,4)
Top Clearance (Piston to Head) 0.0236 - 0.0276 (0,60 - 0,70)

Compression 427 - 469 PSI (29,4 - 32,4 bar)

Allowable Limit
Difference Between Cylinders
341 PSI (23,5 bar)
10%
Valves
Publications.
Valve Seat Width (Intake And Exhaust) 0.0835 (2,12)
O.D. of Valve Stems 0.3134 - 0.3140 (7,96 - 7,98)
I.D. of Valve Guides 0.3156 - 0.3161 (8,015 - 8,03)
Clearance Between Valve Stem And Guide 0.0016 - 0.0028 (0,04 - 0,07)
Allowable Limit 0.0039 (0,1)
Valve Clearance (Cold) 0.007 - 0.0087 (0,18 - 0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.006 (0,15)
Allowable Limit (Recess) 0.0157 (0,4)
Valve Seat Angle (Int.) 45 degrees
Valve Seat Angle (Exh.) 45 degrees
Valve Springs
Free Length 1.642 - 1.661 (41,7 - 42,2)

Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lb. (117,6 N)
Allowable Limit 22.5 lb. (100,0 N)
Inclination Allowable Limit 0.039 (1,0)

776 of 928
Specifications (Cont’d)
parentheses.
Valve Timing
Intake Valve (Open) 9 degrees B.T.D.C.

(Close) 45 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 12 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501 - 0.5506 (13,97 - 13,98)

I.D. of Rocker Arm 0.5512 - 0.5519 (14,0 - 14,02)
Allowable Limit File has expired.

Clearance Between Rocker Arm And Shaft 0.0006 - 0.0018 (0,02 - 0,05)
0.004 (0,1)
Camshaft

Journal O.D. 1.572 - 1.573 (39,93 - 39,95)

Cylinder Block Bore I.D.
Oil Clearance
Allowable Limit
1.575 - 1.576 (40,0 - 40,025)
0.002 - 0.0036 (0,05 - 0,091)
0.006 (0,15)
Cam Lobe Height

Allowable Limit
Publications.
Alignment Allowable Limit 0.0004(0,01)
1.335 (33,9)
1.333 (33,85)
End Clearance 0.0028 - 0.0087 (0,07 - 0,22)
Tappet
Clearance Between Tappet And Guide 0.0008 - 0.0024 (0,02 - 0,062)

Tappet O.D. 0.943 - 0.944 (23,96 - 23,98)
Tappet Guide I.D. 0.945 - 0.946 (24,0 - 24,021)
Cylinders
Cylinder Bore I.D. (Standard) 3.425 - 3.426 (87,00 - 87,02)

Allowable Limit (Standard) +0.006 (+0,15)
Cylinder Bore I.D. (Oversize) 3.435 - 3.436 (87,25 - 87,27)
Allowable Limit (Oversize) +0.006 (+0,15)

777 of 928
parentheses.
Piston Rings
Ring Gap (Top) 0.008 - 0.0138 (0,20 - 0,35)

Ring Gap (2nd Ring) 0.0157 - 0.0217 (0,34 - 0,55)
Ring Gap (Oil Ring) 0.0098 - 0.0177 (0,25 - 0,45)
Allowable Limit (All Rings) 0.05 (1,25)
Side Clearance of Ring Groove:
2nd Ring 0.0037 - 0.0050 (0,093 - 0,128)
Oil Ring 0.008 - 0.0021 (0,02 - 0,06)
Pistons
File has expired.
Piston Pin Bore 0.984 - 0.985 (25,0 - 25,013)

Connecting Rod
Piston Pin O.D. 0.984 - 0.985 (25,0 - 25,011)
Publications.
Small End Bushing I.D.
Clearance Between Piston Pin And Small End Bushing
Connecting Rod Alignment Allowable Limit
0.985 - 0.986 (25,025 - 25,04)
0.0006 - 0.0015 (0,014 - 0,038)
0.002 (0,05)
Oil Pump
Oil Pressure at Rated RPM 43 - 64 PSI (2,94 - 4,4 bar)

Allowable Limit 36 PSI (2,5 bar)
Idle Speed Allowable Limit 7 PSI (0,48 bar)
Clearance Between Inner Rotor And Outer Rotor 0.0012 - 0.0055 (0,03 - 0,14)
Clearance Between Outer Rotor And Pump Body 0.0043 - 0.0075 (0,11 - 0,19)
End Clearance Between Inner Rotor And Cover 0.0041 - 0.0059 (0,105 - 0,15)

778 of 928
parentheses.
Crankshaft
Crankshaft Alignment 0.0008

Allowable Limit (0,02)
Oil Clearance Between 0.0016 - 0.0047 (0,04 - 0,118)
Journal And Bearing #1
Journal O.D. #1 2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #1 2.3614 - 2.3637 (59,980 - 60,039)
Journal And Bearing #2
Allowable Limit
Journal O.D. #2 File has expired. 0.008 (0,2)
2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #2 2.3614 - 2.3632 (59,980 - 60,025)
Crank Pin And Bearing


Crank Pin O.D.
Crank Pin Bearing I.D.
1.8488 -1.8494 (46,96 - 46,98)
1.850 - 1.852 (47,0 - 47,05)
Crankshaft Side 0.006 - 0.014 (0,15 - 0,35)
Clearance
Publications.
Timing Gear
Timing Gear Backlash

Crank Gear - Idle Gear 0.0016 - 0.0044 (0,042 - 0,112)
Idle Gear - Cam Gear 0.0016 - 0.0045 (0,042 - 0,115)
Idle Gear - Injection Pump Gear 0.0016 - 0.0045 (0,042 - 0,115)
Crank Gear - Oil Pump Gear 0.0016 - 0.0043 (0,042 - 0,109)
Idle Gear Shaft O.D. 1.494 - 1.495 (37,959 - 37,975)
Idle Gear Bushing I.D. 1.494 - 1.495 (38,000 - 38,025)
Clearance Between Idle Gear Shaft And Idle Gear Bushing 0.001 - 0.0026 (0,025 - 0,066)
Idler Gear Side Clearance 0.005 - 0.019 (0,12 - 0,48)
Thermostat
Valve Opening Temperature 177° - 182° F (81° - 84° C)

Valve Fully Open 203° F (95° C)

779 of 928
parentheses.
Torque Values
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M12 x 1.25 22 - 30 ft.-lb.
(30 - 41 N•m) File has expired.
40 - 54 ft.-lb.
(54 - 73 N•m)
69 - 87 ft.-lb.
(94 - 118 N•m)
M14 x 1.5 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)

Publications.

780 of 928
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking.
Engine running rough.
Vibration.
File has expired.13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36

Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49

Poor compression.
Start and stop.
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
Publications.

781 of 928
Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump.
13. Faulty fuel injectors.
14. Broken injection pump drive.
File has expired.39. Plugged oil filter.
40. Piston seizure.
41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.

17. Poor compression. 44. Faulty thermostat.

18. Plugged fuel tank vent.
19. Incorrect grade of fuel.
20. Exhaust pipe restriction.
45. Restriction in water jacket.
46. Loose alternator belt.
47. Plugged radiator.
22. Overheating.
23. Cold running.
Publications.
21. Cylinder head gasket leaking. 48. Faulty water pump.
49. Plugged breather pipe.
50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

782 of 928
ENGINE INFORMATION (CONT’D) Remove the air cleaner. (See Housing Removal And
Engine Removal And Installation
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
DANGER Figure 70-10-2
3
4
2
P-90328
3
AVOID DEATH
•
File has expired.
P-68848
support. Replace if damaged. Remove the nut from the speed control linkage (Item 1)

D-1009-0409 and unplug the rear door harness connector (Item 2)
Use updated files from Bobcat [Figure 70-10-2].
Remove the bracket mounting screws (Item 3) so the belt

shield (Item 4) [Figure 70-10-2] can be removed.
WARNING
Publications. Installation: Tighten screws and nut to 15 - 20 ft.-lb. (20 -
Never work on a machine with the lift arms up unless 27 N•m) torque.
support device. Failure to use an approved lift arm Figure 70-10-3
W-2059-0598 1
Put jackstands under the rear corners of the loader.
2

P-66870
Disconnect the steering linkage from the hydrostatic
pump. (See Linkage Removal And Installation on Page
Remove the mounting screw (Item 1) to remove the oil
50-100-7.)
filter drip shield (Item 2) [Figure 70-10-3].
Remove the battery from the loader. (See Removal And
The drip shield is snapped into place on the filter
housing.
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-2.)
torque.

783 of 928
ENGINE INFORMATION (CONT’D) Figure 70-10-6
Figure 70-10-4
1
2
1
P-48606
3
Disconnect the engine ground strap (Item 1) [Figure 70-
File has expired.

P-66871 10-6].
Figure 70-10-7
Disconnect the temperature sender connector (Item 1)
[Figure 70-10-4] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 70-10-4]

for the differential pressure switch on the filter housing.

10-4].
Figure 70-10-5
Publications.
1
1
P-68851
Disconnect fuel line (Item 1) [Figure 70-10-7] for lift

pump.
P-66872
Disconnect radiator hose (Item 1) [Figure 70-10-5].

784 of 928
Figure 70-10-8
1
2
P-66875
3 Disconnect engine coolant hose (Item 1) [Figure 70-10-
Cap or plug all hoses and fittings.

Disconnect fuel shutoff solenoid connector (Item 1)
[Figure 70-10-8]. Figure 70-10-11

Disconnect engine oil pressure sender connector (Item 2) 1

[Figure 70-10-8].
Cut tie-strap (Item 3) [Figure 70-10-8].
2
P-67069
1
Mark and disconnect the charge pump filter outlet hose
(Item 1) [Figure 70-10-11].
3 Cap or plug all hoses and fittings.

P-68850
Disconnect glow plug wire (Item 1) [Figure 70-10-9].
Disconnect and plug fuel return line (Item 2) [Figure 70-

10-9].
Remove the tie strap (Item 3) [Figure 70-10-9] from

wiring harness clamp and move the wire harness to the
left side of loader to allow clearance for engine removal.

785 of 928
Figure 70-10-12
1
2 P-67078
Disconnect drain hose (Item 1) [Figure 70-10-14] from
File has expired.

P-67082
the hydraulic cooling fan.
Mark and disconnect the hydraulic fan motor inlet hose

Disconnect gear pump inlet hose (Item 1) [Figure 70-10- (Item 1) [Figure 70-10-14].
12].

Disconnect supply hose (Item 2) [Figure 70-10-12] from

hydraulic fluid reservoir.
Disconnect gear pump outlet hose (Item 3) [Figure 70-

Figure 70-10-15
10-12].
Publications.
2
Figure 70-10-13
1
2 1
1
2
P-68856
Mark and disconnect the drive motor hoses (Item 1)

1 [Figure 70-10-15].

NOTE: Due to the left drive motor hoses orientation,
P-67077
hoses may not be completely removed from
fittings until the engine and pump are partially
Remove the two bolts (Item 1) and move the hydraulic removed.
reservoir (Item 2) [Figure 70-10-13] out of the way. Installation: Install the left drive motor hoses prior to
alignment with engine mount bolts.
NOTE: The hydraulic fittings (Item 2) [Figure 70-10-

15] on the hydrostatic pump must be
tightened to 115 - 125 ft.-lb. (156 - 170 N•m)
torque.

786 of 928
Figure 70-10-16
P-68853
Remove the mounting bolt and nut (Item 1) [Figure 70-
File has expired. P-68858 10-18] from the right rear engine mount.

Remove the mounting bolt and nut (Item 1) [Figure 70- N•m) torque.
10-16] from the right front engine mount.

Figure 70-10-19

N•m) torque.
Figure 70-10-17
Publications.
1
2
P-28231
P-68852
1
Remove the mounting bolt and nut (Item 1) [Figure 70-

P-68857 10-19] from the left rear engine mount.

Remove the mounting bolt (Item 1) [Figure 70-10-17] N•m) torque.
and nut from the left front engine mount.
Installation: Slide the engine mount slot (Item 2) [Figure

70-10-17] in between engine mount washer and nut.
Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.

787 of 928
Figure 70-10-20
13”
1
2.5”
1-1/2” I.S. Dia. 1

2-1/2” O.S. Dia.
2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset
1” P-48737
16”
Fasten securely one end of the chain to the lifting eye
4”
NOTE: You may need to adjust the chain which

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

45° 9”
Figure 70-10-22
1”
2”
4”
Publications.
1”
.5”
.375” 1
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine/hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [Figure 70-10-20] to make the
engine removal tool.
P-48661A
Install the chain hoist on the eyelet [Figure 70-10-22] of

the removal tool.
Fasten a chain to other end of the removal tool with two

bolts as shown in (Item 1) [Figure 70-10-22]. Remove
the engine/hydrostatic pump assembly from the loader.
Reverse the removal procedure to install the engine.

788 of 928
Engine Mount Replacement

Engine
Figure 70-10-23 Mounting
Washer Bracket
1
2
Loader
3 Frame Engine
Mount
4
5 Snubbing Spacer
Washer
MC-1765A
6
7 Install the new engine mount as shown in the cut away
File has expired.MC-1771A side view [Figure 70-10-24].
Tighten the mounting bolts to 70 ft.-lb. (95 N•m) torque.

Use the following procedure to install new engine
mounts:

Remove the existing mount from the engine. Refer to

engine removal and installation for engine mount
locations.
Publications.
Replace all four engine mounts two front and two rear.
Use the parts shown to install the new engine mounts

[Figure 70-10-23]:
Square Nut - (Item 1) - Used on left side engine mounts
Hex Nut - (Item 2) - Used on right side engine mounts
Mount Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Snubbing Washer - (Item 6)
Mounting Bolt - (Item 7)

789 of 928
Compression - Checking

procedure:
MEL10630 - Engine Compression Kit
MEL1631 - Compression Adapter
The engine must be at operating temperature.
Figure 70-10-25
P-51938
Connect the compression gauge to the adapter [Figure
File has expired. 70-10-27].
Make sure the engine speed control is fully backward

(engine idle).
1 Disconnect the fuel stop solenoid.

Use updated files from Bobcat Measure compression when cranking engine with the
starter motor.
If the measurement is below the allowable limit, check

P-51932
Publications.
Disconnect the air cleaner inlet hose (Item 1) [Figure 70-
the cylinder, piston ring, top clearance, valve and cylinder
head.
10-25] from the intake manifold. Compression Pressure should be 427 - 469 PSI (29,4 -
32,3 bar)
Remove the glow plugs. (See Glow Plugs Removal And
Allowable Limit (minimum) is 341 PSI (23,5 bar)
No more than 10% variance among cylinders.
Figure 70-10-26
Figure 70-10-28
P-51936
P-51937
P-51939
Install the correct compression adapter (Item 1) [Figure

70-10-26] into the cylinder head. Push the button on the compression gauge to release
pressure [Figure 70-10-28]. Connect the fuel stop
solenoid.

790 of 928
ENGINE SPEED CONTROL Raise the operator cab. (See Raising on Page 10-30-1.)
Removal And Installation Remove the two mounting screws (Item 1) [Figure 70-
20-1] from the speed control mounting bracket.
DANGER Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.
Installation: Tighten the mounting bolts (Item 2) [Figure

70-20-1] evenly until the speed control lever moves back
and forth at a comfortable tension.
Figure 70-20-2
P-90328
AVOID DEATH
•
File has expired.

D-1009-0409 1
WARNING
Publications.
Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [Figure 70-20-
2] from the control.
support device. Failure to use an approved lift arm Installation: Be sure to install the speed control rod in
support device can allow the lift arms or attachment the bottom hole of the speed control lever.
W-2059-0598 Figure 70-20-3
Figure 70-20-1
1 1
2
P-34156
P-48565 Installation: Install the stop bracket (Item 1) [Figure 70-

20-3] in the same location. It is necessary for the front
and rear stop on the bracket to be located correctly.
Raise the lift arms and install an approved lift arm device.
(See Installing on Page 10-20-1.) Reverse the removal procedure to install the engine
speed control.

791 of 928
File has expired.

Publications.

792 of 928
ENGINE SPEED CONTROL (SJC) Figure 70-21-3

Figure 70-21-1
P-64313
1 Disconnect the foot speed control linkage (Item 1)
File has expired. [Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

P-73686

1] from the right side foot rest.
Publications.
Remove the foot rest, from the loader.
Figure 70-21-2
P-73687
Remove the two screws from the mount (Item 1) [Figure

70-21-2].
Remove the rubber grommet (Item 2) [Figure 70-21-2].

N•m) torque.

793 of 928
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6

1
Figure 70-21-4 2 4 4
1 3 5 3
P-34654A
The parts that go into the pivot arm (Item 1) are the bolt
File has expired.

P-34550 (Item 2), washers (Items 3), fiber washers (Items 4), and
spacer (Item 5) [Figure 70-21-6].
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.

Figure 70-21-5

1
Publications.
1
P-73685
P-34549 Remove the two screws (Item 1) [Figure 70-21-7] from

the hand speed control lever assembly.
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
that attaches the pivot arm to the speed control cable. N•m) torque.
Remove the speed control pivot arm from the loader.

794 of 928
ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Figure 70-21-8
1
1
P-64305

foot speed control assembly.
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader. Figure 70-21-11

Slide the hand speed control lever (Item 1) [Figure 70-

21-8] forward and lift, and disconnect the assembly from
the speed control rod clevis.
Figure 70-21-9
Publications.
1
P-64305A
2
1 Remove the bushing/nut (Item 1) [Figure 70-21-11] from
the pedal lever.
P-73688
Installation: When installing the hand speed control, be

sure the speed control lever and pin (Item 1) fit in the
notch (Item 2) [Figure 70-21-9] of the speed control rod
clevis.

795 of 928
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
File has expired.

P-34657 the speed control.
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing/nut.

Remove the foot pedal lever (Item 2) and linkage rod

(Item 3) [Figure 70-21-12].
Figure 70-21-13
Publications.
2
P-64307
1
The pivot assembly shown disassembled [Figure 70-21-

15].
NOTE: No lubrication is necessary or recommended

P-34658 on the engine speed control.
Reverse the disassembly procedure to assemble the

Remove the fiber washer (Item 1) and washer (Item 2) (SJC) speed control.
[Figure 70-21-13] from the pivot bolt.

796 of 928
MUFFLER Figure 70-30-2
Remove the rear grille. (See Removal And Installation on

Page 50-60-1.)
1
Figure 70-30-1
P-54044
3
Remove the right side mounting bolt (Item 1) [Figure 70-
File has expired. 2

30-2] from the muffler.
Installation: Tighten the muffler mounting bolts to 25 -

1 28 ft.-lb. (34 - 38 N•m) torque.

P-54058 Remove the muffler from the loader.

Remove the exhaust pipe clamp (Item 1) from the muffler
(Item 2) [Figure 70-30-1].
Reverse the removal procedure to install the engine
muffler.
Publications.
Disconnect the exhaust pipe from the muffler.
Remove the left side mounting bolt (Item 3) [Figure 70-

30-1] from the muffler.

797 of 928
File has expired.

Publications.

798 of 928
AIR CLEANER Figure 70-40-3

1
Figure 70-40-1
1
2
P-54049
Remove the lower mounting bolt (Item 1) and engine
File has expired. P-54046 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Remove the two upper mounting bolts (Item 3) [Figure
70-40-1] from the air cleaner sensor on the air cleaner. 70-40-2] from the top mount of the air cleaner.

Figure 70-40-2 Installation: Tighten the three mounting bolts to 15 - 20
Use updated files from Bobcat ft.-lb. (20 - 27 N•m) torque.
Remove the air cleaner from the engine compartment.
Publications. 1
Reverse the removal procedure to install the air cleaner.
P-54054
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.
Loosen the clamp (Item 2) [Figure 70-40-2] from the

hose on the engine manifold.

799 of 928
File has expired.

Publications.

800 of 928
ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation
Remove the rear grille. (See Removal And Installation on

Page 50-60-1.)
Remove the oil cooler. (See Removal And Installation on 1

Page 20-100-1.)
WARNING
P-68848
AVOID BURNS
Do not remove radiator cap when the engine is hot. Open the drain valve (Item 1) [Figure 70-50-2] on the
You can be seriously burned.
File has expired.
W-2070-1203
engine block and drain the coolant into a container.
Figure 70-50-3
Figure 70-50-1

1
1
2
Publications.
P-48571
P-54001
Loosen the hose clamp (Item 1) [Figure 70-50-3] from

Loosen the radiator cap (Item 1) [Figure 70-50-1] from the left side radiator hose and disconnect the hose from
the pressurized expansion tank. the radiator.
Remove the radiator mounting bolt (Item 2) [Figure 70-

50-3].
Installation: Tighten the radiator mounting bolt to 11-13

ft.lb. (15-17 N•m) torque.

801 of 928
ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4 2
1
1
P-54062
Figure 70-50-7
File has expired.

P-54048
Loosen the hose clamp (Item 1) [Figure 70-50-4] from 1 2

the left side radiator hose and disconnect the hose from 1

the radiator.
Figure 70-50-5
Publications. 3
P-54311
Remove the two rubber stops (Item 1) [Figure 70-50-6]

and [Figure 70-50-7] from the top of the radiator.
1 2
Disconnect the overflow hose (Item 2) [Figure 70-50-6]
and [Figure 70-50-7].
P-54050
Lift the radiator (Item 3) [Figure 70-50-7] up and remove
from the machine.
Remove the radiator mounting bolt (Item 1) and block off
plate (Item 2) [Figure 70-50-5].
Installation: Tighten the radiator mounting bolt to 11 - 13

ft.-lb. (15 - 17 N•m) torque. Use sealant on the block off
plate and bolt head (Item 2) [Figure 70-50-5].

802 of 928
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly (S/N
A3L529999 & Below)
Hydraulic Fan Description (S/N A3L529999 & Below)
Figure 70-50-8
The proportioning valve meters the flow through the fan
motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors. 2
The hydraulic fan is used to cool the engine and

hydraulic/hydrostatic systems. The hydraulic fan consist
of a fan and hydraulic motor that is controlled by a
proportioning valve.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field. The
adjustment screw is sealed with a tamper
evident white material, if this screw has been 1
adjusted the proportioning valve must be
File has expired.

P-68126
replaced.
If the flow from the proportioning valve is NOTE: The seals, O-rings and coil nut on the
determined inaccurate it must be replaced proportioning valve (Item 1) are available by
with a new one from Bobcat Service Parts. ordering from Bobcat Service Parts. The fan

motor (Item 2) [Figure 70-50-8] must be
The fan speed is determined by the engine coolant replaced as an assembly if damaged.
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (RPM’s)
can range from 0 to 4000 RPM’s.
Publications.
The hydraulic fan speed at cold engine startup will range
from 0 to 500 RPM’s until the engine coolant and the
hydraulic fluid reach basic operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 to 3500 RPM’s.

803 of 928
ENGINE COOLING SYSTEM (CONT’D) Remove the hydraulic fluid reservoir. (See Removing And
Blower Housing Removal And Installation (S/N
A3L529999 & Below) Figure 70-50-9
2 4
DANGER
P-67080
1
P-90328
AVOID DEATH 3
File has expired.

• Disconnecting or loosening any hydraulic P-67076

can cause lift arms to drop. Remove cable ties (Item 1) [Figure 70-50-9] attached to
• Keep out of this area when lift arms are raised blower housing.
Disconnect and plug the heater hoses (Item 2) [Figure

70-50-9].
D-1009-0409
Use updated files from Bobcat Disconnect the cab harness connector (Item 3) [Figure
70-50-9].
Remove the sealant between the blower housing and the

WARNING
Publications. loader frame (Item 4) [Figure 70-50-9].
Figure 70-50-10
W-2059-0598
2
IMPORTANT
parts clean. Always use caps and plugs on hoses, 3 P-67078
damage the system. Remove the fan motor inlet hose (Item 1) and outlet hose
I-2003-0888
(Item 2) [Figure 70-50-10].
Raise the lift arms and install an approved lift arm Remove the fan motor case drain hose (Item 3) [Figure
support device. (See Installing on Page 10-20-1.) 70-50-10].
Raise the operator cab.(See Raising on Page 10-30-1.) 50-10].
Remove the fan motor/charge pump filter housing. (See
Charge Filter Housing Removal And Installation on Page
20-80-3.)

804 of 928
ENGINE COOLING SYSTEM (CONT’D) Reverse the removal procedure to install the blower
housing.
Blower Housing Removal And Installation (Cont’d)
(S/N A3L529999 & Below) Figure 70-50-13
Figure 70-50-11
1 2
2
File has expired.

2 P-76698
P-76697
After the blower housing is installed, apply a bead of
polyurethane caulk sealant (P/N 6633583) between the
NOTE: Remove the two rear mounting bolts first. front edge (Item 1) of the crossmember and blower

housing (Item 2) [Figure 70-50-13] directly in front of the
Remove the four mounting bolts (Item 1 and Item 2) and inlet opening only.
spacer tubes. The only visible spacer tubes are on the
outside of the blower housing using mounting bolts (Item
2) [Figure 70-50-11].
Publications.
Figure 70-50-12
P-66649
NOTE: The picture shows the blower housing and fan

assembly removed from the loader. Two of
the mounting bolts (Item 1) [Figure 70-50-11]
have clips (Item 1) [Figure 70-50-12] to hold
the bolts from falling out during factory
installation of the blower housing and fan
together. The clips will fall during the removal
of the fan motor assembly bolts.
Remove the blower housing from the loader.

805 of 928
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Removal And Installation (S/N
A3L529999 & Below)
Fan Removal And Installation (S/N A3L529999 &
Below) Figure 70-50-16
Figure 70-50-14
1 1
File has expired.

P-54421A
P-54418
Remove bolts (Item 1) [Figure 70-50-16] and discard.
Remove the lock nut and spacer (Item 1) [Figure 70-50- Reverse removal procedure for installation.

14].
Installation: Torque fan motor mounting bolts and nuts
N•m) torque. Use updated files from Bobcat

Installation: Tighten the nut to 45 - 55 ft.-lb. (61 - 75 (Item 1) to 25 - 28 ft.-lb. (34 - 38 N•m).
Figure 70-50-15
Publications.
2
1
P-54419
Use the following procedure to remove the fan from the

shaft:
Install the nut (Item 1) [Figure 70-50-15] on the tapered
shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-50-15].
As the center bolt (Item 2) [Figure 70-50-15] is tightened,
periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-
15].

806 of 928
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly (S/N
A3L530001 & Above)
Hydraulic Fan Description (S/N A3L530001 & Above)
Figure 70-50-17
The proportioning valve meters the flow through the fan
motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors. 4
The hydraulic fan is used to cool the engine and

hydraulic / hydrostatic systems. The hydraulic fan 3
consists of a fan and hydraulic motor that is controlled by
a proportioning valve.
NOTE: The proportioning valve is factory set and can 2

not be adjusted accurately in the field due to
the adjustment being tamper proof.
The fan speed is determined by the engine coolant 1
File has expired.

P-76714A
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (RPM’s)
can range from 0 to 4000 RPM’s. NOTE: The mounting gasket (Item 1), proportioning
valve, and proportioning valve O-rings, back
The hydraulic fan speed at cold engine startup will range up washer and coil mounting nut (Item 2) are

from 0 to 500 RPM’s until the engine coolant and the available from Bobcat Parts. The fan motor
hydraulic fluid reach normal operating temperatures. (Item 3) [Figure 70-50-17] must be replaced as
During normal operating temperatures the fan speed may
range from approximately 1900 to 3500 RPM’s.
an assembly if damaged.
Remove the filter cover (Item 4) [Figure 70-50-17].
Publications. Installation: Tighten filter cover (Item 4) [Figure 70-50-

17] to 35 - 40 ft.-lb. (47,5 - 54 N•m) torque.
Figure 70-50-18
P-76715A

807 of 928
ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-21
Hydraulic Fan Disassembly And Assembly (S/N

A3L530001 & Above) (Cont’d)
Figure 70-50-19
4 1
P-76717
2
1 Remove the pressure transducer (Item 1) [Figure 70-50-
File has expired.

P-76716A
21].
Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-21] to 7.4 - 8.1 ft.-lb. (10 - 10,9 N•m)
Remove coil mounting nut (Item 1), the coil (Item 2), and torque.

the coil valve stem (Item 3) [Figure 70-50-19].
Figure 70-50-22
NOTE: Coil mounting nut must be replaced each time
it is removed. Coil mounting nuts are
available from Bobcat Parts.
Publications.
Installation: Install coil mounting nut with the
counterbored space (Item 4) [Figure 70-50-19] facing
towards the coil and tighten securely by hand.
Installation: Tighten coil valve stem (Item 3) [Figure 70-

50-19] to 21 - 25 ft.-lb. (28 - 34 N•m) torque.
1
Figure 70-50-20
1 P-76726
Inspect and replace the O-ring (Item 1) [Figure 70-50-

22] if necessary.
P-76637
Inspect and replace O-rings (Item 1) and back up washer

(Item 2) [Figure 70-50-20] if necessary.

808 of 928
ENGINE COOLING SYSTEM (CONT’D) Remove the fan motor/charge pump filter housing. (See
Charge Filter Housing Removal And Installation on Page
Blower Housing Removal And Installation (S/N 20-80-3.)
A3L530001 & Above)
Remove the hydraulic fluid reservoir. (See Removing And
DANGER Figure 70-50-23
2 4
P-67080
1
P-90328
AVOID DEATH
•
File has expired.
3
unless supported by an approved lift arm P-67076

D-1009-0409 Remove cable ties (Item 1) [Figure 70-50-23] attached
Use updated files from Bobcat to blower housing.
Disconnect and plug the heater hoses (Item 2) [Figure
70-50-23].
WARNING
Publications. Disconnect the cab harness connector (Item 3) [Figure
70-50-23].
Never work on a machine with the lift arms up unless Remove the sealant between the blower housing and the
the lift arms are secured by an approved lift arm loader frame (Item 4) [Figure 70-50-23].
support device can allow the lift arms or attachment Figure 70-50-24
W-2059-0598
4
IMPORTANT 3
1
parts clean. Always use caps and plugs on hoses, 1
5
damage the system.
I-2003-0888
2 P-82656

support device. (See Installing on Page 10-20-1.) Disconnect the two electrical connectors (Item 1) [Figure
70-50-24].
Raise the operator cab.(See Raising on Page 10-30-1.) Remove and cap the case drain hose (Item 2) and fan
inlet hose (Item 3) [Figure 70-50-24].
Remove and cap the fan outlet hose (Item 4) and the pilot
pressure hose (Item 5) [Figure 70-50-24].

809 of 928
ENGINE COOLING SYSTEM (CONT’D) Reverse the removal procedure to install the blower
housing.
Blower Housing Removal And Installation (Cont’d)
(S/N A3L530001 & Above) Figure 70-50-27
Figure 70-50-25
1 2
2 1
1
2
File has expired.

P-76698
P-85630B
After the blower housing is installed, apply a bead of
polyurethane caulk sealant (P/N 6633583) between the
NOTE: Remove the two rear mounting bolts first. front edge (Item 1) of the crossmember and blower

housing (Item 2) [Figure 70-50-27] directly in front of the
Remove the four mounting bolts (Item 1 and Item 2) and inlet opening only.
spacer tubes. The only visible spacer tubes are on the
outside of the blower housing using mounting bolts (Item
2) [Figure 70-50-25].
P-66649
NOTE: The picture shows the blower housing and fan

assembly removed from the loader. Two of
the mounting bolts (Item 1) [Figure 70-50-25]
have clips (Item 1) [Figure 70-50-26] to hold
the bolts from falling out during factory
installation of the blower housing and fan
together. The clips will fall during the removal
of the fan motor assembly bolts.
Remove the blower housing from the loader.

810 of 928
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Removal And Installation (S/N
A3L530001 & Above)
Fan Removal And Installation (S/N A3L530001 &
Above) Figure 70-50-30
Figure 70-50-28
1 1
1
File has expired.

P-82657
P-54418
Remove bolts (Item 1) [Figure 70-50-30] nuts, washers,
cotter pins and rubber gasket and discard.
Remove the lock nut (Item 1) and spacer (Item 2) [Figure

70-50-28]. Reverse removal procedure for installation.

N•m) torque.
Figure 70-50-31
Publications.
Figure 70-50-29
5
1
5
2 3
4 4
2
2
P-76699
1
P-54419 Installation: Always install new hydraulic fan rubber
mounting gasket (Item 1), bolts (Item 2), nuts (Item 3),
Use the following procedure to remove the fan from the thick washers (Item 4) and cotter pins (Item 5). Torque
shaft: fan motor mounting bolts and nuts to 5 - 9 ft.-lb. (6,78 -
12,20 N•m). Install cotter pins (Item 5) [Figure 70-50-31]
Install the nut (Item 1) [Figure 70-50-29] on the tapered and spread cotter pin ends.
shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-50-29].
As the center bolt (Item 2) [Figure 70-50-29] is tightened,
periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-
29].

811 of 928
ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-33
Drain the cooling system.

2
Remove the alternator belt.
1
Remove the water pump bolts.
3
Figure 70-50-32 4
B-14424
File has expired. Remove the flange (Item 1) [Figure 70-50-33].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-33] out the impeller side of the water pump.

Remove the impeller (Item 3) [Figure 70-50-33] from the
Remove the water pump [Figure 70-50-32].
B-5318
shaft.
Remove the seal (Item 4) [Figure 70-50-33].
the water pump.

Publications.
Installation: Always use a new gasket when installing Install a new seal (Item 4) [Figure 70-50-33] when
assembling the water pump.

812 of 928
ENGINE COOLING SYSTEM (CONT’D)
Thermostat Housing Removal And Installation
Figure 70-50-34
1 2 1
6 4
5 7
5
File has expired.

9

8
Publications. 9
10
7 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-34].
Remove clamps (Item 5) and hose (Item 6) [Figure 70-

50-34].
Remove bolts (Item 7), nut (Item 8), top and bottom
housing (Item 9), and gasket (Item 10) from the cylinder
head [Figure 70-50-34].

813 of 928
ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Checking
Figure 70-50-35
File has expired.

P-37172
Push down the thermostat valve and insert a string

between the valve and the valve seat.

Place the thermostat and a thermometer in a container

with water and gradually heat the water [Figure 70-50-
35].
Publications.
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 0.315 in. (8 mm).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory 74.5° - 78.5° C

opening spec. 166.1° - 173.3° F
temperature
Temperature at Factory 90° C
which thermostat spec. 194° F
completely opens

814 of 928
LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Remove the engine and hydrostatic pump assembly from 100-1.)
the loader. (See Engine Removal And Installation on
Page 70-10-9.) Remove the crankshaft gear.
The engine will have to be on an engine stand or Figure 70-60-3

suspended in the air safely to remove the oil pan.
Figure 70-60-1 1
2
2
File has expired.

B-3658

1
Use updated files from Bobcat P-66843 Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-60-3].
Publications.
Remove oil pan bolts securing oil pan (Item 1) [Figure
70-60-2]. Slightly tapping on the oil pan with a soft mallet
will break loose the oil pan from the engine block.
Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [Figure 70-60-3].
Installation: Tighten the oil pump mounting bolts to 60 -

Installation: Use a liquid gasket adhesive to the oil pan 72 in.-lb. (6,9 - 8,1 N•m) torque.
side of the oil pan gasket. Tighten oil pan bolts to 29 - 33
Figure 70-60-2
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.

815 of 928
LUBRICATION SYSTEM (CONT’D) If the clearance exceeds the allowable limit, replace the
oil pump.
Oil Pump Inspection
Figure 70-60-6
Figure 70-60-4
File has expired.

PI-10009
B-3616
Put a piece of press gauge on the rotor face [Figure 70-

Measure the clearance between the lobes of the inner 60-6].
rotor and outer rotor [Figure 70-60-4].

Install the cover and tighten the bolts.
Clearance 0.0012 - 0.0055 in.
Outer Rotor Use updated files from Bobcat

Between Inner & (0,03 - 0,14 mm) Remove the cover carefully. Measure the width of the
press gauge [Figure 70-60-6].
oil pump. Publications.

If the clearance exceeds the allowable limit, replace the If the clearance exceeds the allowable limit replace the
oil pump.
Figure 70-60-5 End Clearance 0.0041 - 0.0059 in. (0,11 - 0,15 mm)
A-2732
Measure the clearance between the outer rotor and

pump body [Figure 70-60-5].
Clearance 0.0043 - 0.0075 in.

Between Outer (0,11 - 0,19 mm)
Rotor & Body

816 of 928
LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-7
File has expired. PI-10010

Install a pressure gauge [Figure 70-60-7].

Start the engine and run until it is at operating
temperature.
Publications.
If the oil pressure is less than the allowable limit, check
the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed 7 PSI

Allowable Limit (0,48 bar)
At Rated Speed 42 - 64 PSI
(2,94 - 4,4 bar)
Allowable Limit 36 PSI
(2,5 bar)

817 of 928
File has expired.

Publications.

818 of 928
FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Checking Figure 70-70-3
Figure 70-70-1
1
1
P-48586

Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].

Disconnect the connector (Item 1) [Figure 70-70-1] from Figure 70-70-4
the fuel shutoff solenoid.

Use an ohm meter to check the fuel shutoff solenoid.
Figure 70-70-2
Publications. 2
P-51943
Remove the mounting nuts (Item 1) [Figure 70-70-4] that

secure the fuel shutoff solenoid.
P-51941
NOTE: There is a ground strap (Item 1) [Figure 70-70-
4] that is needed for the fuel shutoff solenoid
The reading between electrical connector terminal C and to function correctly. A good ground is
terminal A must be between approximately 15.6 ohm essential for correct operation of the fuel
[Figure 70-70-2]. shutoff solenoid.
The reading between electrical connector terminal C and Reverse the above procedure to install the fuel shutoff
terminal B must be between approximately 0.35 - 0.4 solenoid.
ohm.

819 of 928
FUEL SYSTEM (CONT’D) Move the speed control lever to the high engine idle
position.
Fuel Injection Pump - Checking
Turn the flywheel to increase the pressure. If the
The injection pump contains parts which have a very pressure can not reach the allowable limit, replace the
close tolerance and its operation has a direct effect on injection pump assembly.
the performance of the engine.
Fuel Tightness of Pump 2702 - 2916 PSI
Element Allowable Limit (186 - 201 bar)
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 2702 -
2916 PSI (186 - 201 bar).
Diesel fuel or hydraulic fluid under pressure can Turn the flywheel back approximately one-half turn. Keep
penetrate skin or eyes, causing serious injury or the flywheel at this position, and measure the time it
death. Fluid leaks under pressure may not be visible. takes the pressure to decrease from 1850 PSI (127.5
Use a piece of cardboard or wood to find leaks. Do bar).
File has expired.

W-2072-0807
Fuel Tightness of Delivery
Valve Allowable Limit
5 Seconds

procedure:

MEL 1237 - Adapter Fuel Line
MEL 1173-1 Pressure Gauge
Publications.
To check the discharge pressure at the fuel injection
pump, use the following procedure:
Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 70-70-5
B-8235
Connect the adapter fuel line (Item 1) to the fitting and

connect the pressure gauge (Item 2) [Figure 70-70-5].

820 of 928
FUEL SYSTEM (CONT’D) Remove the four oil fill tube bolts (Item 3) [Figure 70-70-
7].
Fuel Injection Pump Removal And Installation
Figure 70-70-8
Figure 70-70-6
1
1
1
File has expired.

P-76728
P-51933
Clean the area around the injection pump thoroughly. Remove the high pressure fuel lines (Item 1) [Figure 70-
Disconnect the high pressure fuel lines (Item 1) [Figure 70-8] from the injection pump.
70-70-6] from the fuel injectors.

Note: Do not loosen the clamp screws (Item 2)
[Figure 70-70-8] on the injection pump. This is
IMPORTANT
to be done only when the entire injection
pump is sent out to be serviced.
Publications.
Do not bend the high pressure fuel injection tubes
when removing or installing them.
Figure 70-70-9
I-2029-0289
2
Figure 70-70-7
1
2
3
P-48820
Remove the mounting bolts (Item 1) from the intake

manifold (Item 2) [Figure 70-70-9].
3 P-51944
Remove the intake manifold from the engine.
Disconnect the fuel inlet hose (Item 1) and the fuel return Installation: Tighten the mounting bolts to 16 - 20 ft.-lb.
hose (Item 2) from the injection pump vent [Figure 70- (22 - 27 N•m) torque.
70-7].
NOTE: Replace the manifold gasket if it is worn or
Cap the inlets on the injection pump vent where the
damaged.
hoses were removed [Figure 70-70-7].

821 of 928

1
(Cont’d)
Figure 70-70-10
P-51951
1
Remove the cover plate bolts (Item 1) and nuts (Item 2)
File has expired.

P-51942
[Figure 70-70-12].
Remove the cover plate (Item 3) [Figure 70-70-12].
Remove the fuel shutoff solenoid (Item 1) [Figure 70-70- Figure 70-70-13

10]. (See Fuel Shutoff Solenoid Removal And Installation
on Page 70-70-1.)

Figure 70-70-11
P-51953
1
Remove the stop solenoid guide (Item 1) [Figure 70-70-
P-51683 13].
Remove the high-idling body (Item 1) [Figure 70-70-11]

from the engine block.
Installation: Tighten the high idle body to 33 - 36 ft.-lb.

(44 - 49 N•m) torque.

822 of 928
FUEL SYSTEM (CONT’D) NOTE: Make sure the same number of shims with the
same thickness are installed under the
Fuel Injection Pump Removal And Installation injection pump. The shims are used for
(Cont’d) engine timing.
Figure 70-70-14 NOTE: The pin (Item 2) [Figure 70-70-15] located on

the control rack, needs to be installed
correctly during installation. See above for
correct installation.
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 2

Figure 70-70-16
Remove the four mounting bolts (Item 1) and two nuts

(Item 2) [Figure 70-70-14] from the injection pump.
1

(22 - 27 N•m) torque.
Publications.
Figure 70-70-15
P-4364
2
Install the shim(s) (Item 1) [Figure 70-70-16] on the

injection pump mounting surface. For information on the
number of shims used. (See Fuel Injection Pump -
1 Timing on Page 70-70-8.)
NOTE: Make sure the same number of shims with the

P-4359
same thickness are installed under the
injection pump. The shims are used for
engine timing.
Remove the injection pump (Item 1) [Figure 70-70-15]
and shim(s) from the engine.
Installation: When the injection pump is installed, the

rack pin (Item 1) [Figure 70-70-15] must be aligned with
the slot in the engine block and positioned on the left side
of the fork lever.
If the rack pin is not installed correctly engine damage

can result.

823 of 928
FUEL SYSTEM (CONT’D)

(Cont’d)
Figure 70-70-17
File has expired.

P-64218
Install the injection pump in the engine.

Ensure the control rack pin (Item 1) is to the left side of

the fork lever (Item 2) [Figure 70-70-17].
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

824 of 928
Governor Disassembly And Assembly
The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the
engine according to changes in the engine load.
Figure 70-70-18
File has expired.

1. Start Spring
2. Governor Spring
3. Governor Spring
Publications.
4. Fork Lever
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball PI-10008
Disassemble and assemble the governor and fuel

camshaft as shown in figure [Figure 70-70-18].
Check all the parts for wear or damage and replace as

needed.

825 of 928
FUEL SYSTEM (CONT’D) Fuel Injection Pump - Timing
Fuel Camshaft Removal And Installation Timing the injection pump is done by changing the
number of shims between the injection pump and the
Remove the timing gearcase cover.(See Timing injection pump mounting surface.
100-1.) Disconnect the number one (closest to water pump)
cylinder high pressure line from the injection pump.
Remove the idler gear. (See Idler Gear And Camshaft
Removal And Installation on Page 70-100-4.) Figure 70-70-21
Figure 70-70-19
File has expired. 1

P-54133
1 1

Turn the fuel supply lever (Item 1) [Figure 70-70-21] to
the ON position.
Publications.
Remove the three bolts (Item 1) [Figure 70-70-19].
Remove the two bolts and fuel camshaft retainer plate

Figure 70-70-22
(Item 2) [Figure 70-70-19].
Figure 70-70-20
1
P-4361
Install a short plastic tube (Item 1) [Figure 70-70-22] in

P-47266 the number one cylinder port of the injection pump. The
tube should fit securely in the port and point upward.
Remove the fuel camshaft and fork lever assembly at the

same time [Figure 70-70-20].

826 of 928
Injection Pump - Timing (Cont’d)
Figure 70-70-23
Rotation
Direction
1 P-48779
The correct engine timing is 5 degree B.T.D.C. (0,087
File has expired. P-48823 rad) Add or subtract shims (Item 1) [Figure 70-70-25] to
time the engine to 5 degree B.T.D.C. (0,087 rad) The
engine is correctly timed when the correct mark on the
Rotate the engine in the direction shown [Figure 70-70- flywheel is aligned with the notch in the timing hole.
23].

The size of shims are identified by a symbol on the
Continue rotation until flywheel timing mark just appears shims.
in the window (Item 1) [Figure 70-70-23].
Rotate slowly until fuel just starts to flow upward into the
(1) Two holes means 0.008 in (0,20 mm) shim.
Publications.
plastic tube as shown in [Figure 70-70-22].
Figure 70-70-24
(2) One hole means 0.010 in (0,25 mm) shim.
(3) Without hole means 0.012 in (0,30 mm) shim.
(4) Three holes means 0.014 in (0,35 mm) shim.
P-4364
Add or subtract shim(s) (Item 1) [Figure 70-70-24] as

needed to adjust the fuel delivery timing.
NOTE: Adding or removing one shim will vary the

timing by 0.5 degree. Adding shims retards
timing.

827 of 928
Fuel Injector Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes
WARNING when removing or installing them.
I-2029-0289

Diesel fuel or hydraulic fluid under pressure can Figure 70-70-27
enters skin or eyes, get immediate medical attention 1
W-2072-0807
Figure 70-70-26
File has expired.
2
1

2 P-48727A
Use updated files from Bobcat Remove the four retainer bolts from the top of the fuel
1
Publications. injectors (Item 1) [Figure 70-70-27].
Remove the fuel return tube (Item 2) [Figure 70-70-27]

from the fuel injectors.
Installation: Tighten retainers and fuel return tubes to

P-51949 7.25 - 8.25 ft.-lb. (10 - 11 N•m).
The following are some problems caused by faulty

injectors:
-Engine is hard to start or will not start

-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke
Disconnect the fuel return hoses (Item 1) [Figure 70-70-

26] from the injectors.
Disconnect the high pressure fuel lines (Item 2) [Figure

70-70-26] from the fuel injectors and from the injection
pump.
Remove the high pressure fuel lines from the engine.

828 of 928
FUEL SYSTEM (CONT’D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 70-70-28
OEM1064 - Injector Nozzle Tester
Figure 70-70-30
1
Remove the injector nozzle holder bolt (Item 1) [Figure

P-76960
70-70-28] from the cylinder head.

Pull on the injector nozzle to remove the injector nozzle Set the injection nozzle to the nozzle tester [Figure 70-
from the cylinder head.
Installation: Tighten the nozzle holder bolt to 19 - 21 ft.-

70-30].
Slowly move the tester handle to measure the pressure
Publications.
Figure 70-70-29
at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

specifications, replace or repair the injection nozzle
assembly.
Fuel Injection Pressure 2702 - 2916 PSI

(186 - 201 bar)
1
2
NOTE: Injection nozzle gasket must be replaced
when the injection nozzle is removed for
checking.
P-37583
[Figure 70-70-29] shows the injector nozzle removed

from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) [Figure 70-70-29] before
installing new or used injectors.

829 of 928
FUEL SYSTEM (CONT’D) Valve Seat Tightness
Nozzle Spray Condition The tool listed will be needed to do the following
procedure:
procedure: OEM1064 - Injector Nozzle Tester
OEM1064 - Injector Nozzle Tester Figure 70-70-32
Figure 70-70-31
Correct Incorrect
File has expired.

P-76962

P-76961
Set the injection nozzle to a nozzle tester.
Set the injection nozzle to a nozzle tester, and check the
nozzle spraying condition [Figure 70-70-31].
Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
cm², 2418 PSI) for 10 seconds.
Publications.
If the spraying condition is defective, replace or repair the
injection nozzle assembly.
If any fuel leak is found, replace or repair the injection
nozzle assembly.
Valve seat Factory No fuel leak at 16.67 MPa

tightness spec. 170 kgf/cm²
2418 PSI

830 of 928
CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-2
Figure 70-80-1
2 3
P-51933

Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-80-2] from the top of
each glow plug.

Use an ohm meter to check the glow plugs. Touch one
probe to the end of the glow plug and the other probe to Disconnect the engine harness wire (Item 2) [Figure 70-
the body of glow plug (Item 1) [Figure 70-80-1].
The resistance should be approximately one ohm. If the

80-2] from the glow plug.
Remove the glow plug connecting strap (Item 3) [Figure
Publications.
resistance is infinite, the coil of the glow plug is broken.
Repeat the procedure for each glow plug.

70-80-2].
Figure 70-80-3
P-51935
Loosen and remove the glow plug (Item 1) [Figure 70-

80-3].
Installation: Tighten the glow plug to 14.5 - 18.1 ft.-lb.

(19,6 - 24,5 N•m) torque.

831 of 928
CYLINDER HEAD (CONT'D) Figure 70-80-6
Glow Plugs Removal And Installation (Cont’d)
Figure 70-80-4
B-11621
Adjust the valve clearance as follows:
File has expired.

P-48708
Loosen the lock nut (Item 1) [Figure 70-80-6].
Photo [Figure 70-80-4] shows the glow plug removed Put the correct size feeler gauge between the rocker arm
from the engine. Inspect the glow plugs and replace and valve stem. Turn the adjustment bolt until the

when necessary. clearance is correct and tighten lock nut [Figure 70-80-
6].
Valve Clearance Adjustment
Adjust the valve clearance with the engine stopped and

cold.
Figure 70-80-5
Publications.
0.007-0.009 in.
(0,18-0,22 mm)
MC-1368
The correct valve clearance is 0.007 - 0.009 in. (0,18 -

0,22 mm) [Figure 70-80-5].
Make sure the piston is at T.D.C. when making the

adjustment for the valves of the particular cylinder.
NOTE: The clearance is measured between the

rocker arm and valve stem tip [Figure 70-80-
5].

832 of 928
CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7
4
3
1 2 3 4 5 6 7 8 1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
Figure 70-80-8
Remove the engine. (See Engine Removal And


Cylinder Number 1 2 3 4
Remove the timing gearcase cover. (See Timing
Valve Number 1 2 3 4 5 6 7 8
100-1.)
Publications. Make sure the timing marks are in correct alignment

[Figure 70-80-9].
Valve
I = Intake I E I E I E I E
E = Exhaust
Adjust the valve clearance as follows:

0.0071 - 0.0087 in. (0,18 - 0,22 mm) Intake And
Exhaust
Use the following sequence to set the valves [Figure 70-
80-7] and [Figure 70-80-8]:
1. With the rocker arm rocking (valves 7 and 8) on No. 4
cylinder set clearance at No. 1 cylinder (valves 1 and
2).
6).
8).
4).

833 of 928
Cylinder Head Removal And Installation
Figure 70-80-10
2 4 1
2
3
P-47243
Remove the glow plugs (Item 1) and fuel injector holder
File has expired.

P-47241 assemblies (Item 2) [Figure 70-80-12].
Installation: Tighten the glow plugs to 11 - 14 ft.-lb. (15 -

Remove the glow plug lead (Item 1), breather hose (Item 20 N•m) torque.
2), and valve cover bolts (Item 3) [Figure 70-80-10].

Tighten the injector holders to 19 - 22 ft.-lb. (26 - 29 N•m)
Remove the valve cover (Item 4) [Figure 70-80-10] and torque.
gasket.
Installation: Gradually tighten the valve cover bolts to 5 -
Figure 70-80-13
Publications.
8 ft.-lb. (7 - 11 N•m). Tighten center bolts first, then work
your way to the front and back of the valve cover.
1
Figure 70-80-11
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-80-13].
P-47242
N•m) torque.
Loosen the bolts on the clamps (Item 1) and remove the
injection tubes (Item 2) [Figure 70-80-11]. Remove the pushrods (Item 2) [Figure 70-80-13].
Remove the overflow tube assembly.

834 of 928
Cylinder Head Removal And Installation (Cont'd) 14 6 3 11

18 10 2 7 15
Figure 70-80-14
2
17 9 1 8 16
13 5 4 12
P-47247
Remove the cylinder head bolts in order of #18 to #1
NOTE: (A) is the gear case side, (B) is the flywheel

Installation: The push rod (Item 1) must be seated in the side.
tappet (Item 2) [Figure 70-80-14] correctly or the push

rods will be damaged. Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence in order of #1-#18 to 68 - 72 ft.-
After installing the rocker arm assembly and push rods,
the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 70-80-2.)
lb. (93 - 98 N•m).
NOTE: Re-tighten the cylinder head bolts in the
Publications.
NOTE: Remove intake manifold (See Fuel Injection
Pump Removal and Installation on page 70-
correct sequence after the engine has been
run for 30 minutes.
70-6) Figure 70-80-17
Figure 70-80-15
2
1
1 2
P-47248
P-47246
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-17].
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 70-80-15] from the thermostat housing. NOTE: Remove thermostat housing (See Thermostat
Housing Removal and Installation on page 70-
50-8)

835 of 928
Cylinder Head Removal And Installation (Cont'd) Gasket Size

Piston Protrusion
(Number)
Figure 70-80-18 0,475 - 0,525 mm
15
0.0187 - 0.0207 in.
0,525 - 0,575 mm
20
0.0207 - 0.0226 in.
25 0,575 - 0,625 mm
0.0226 - 0.0246 in.
0,625 - 0,067 mm
30
0.0246 - 0.0266 in.
35 0,675 - 0,725 mm
0.0266 - 0.0285 in.
Select the correct gasket size (thickness) from the chart

1
File has expired.
P-47249A
[Figure 70-80-20].
Find the measurement of the highest piston protrusion

When replacing just the gasket, use a new gasket that and the lowest piston protrusion (recorded earlier) for
has the same mark (Item 1) [Figure 70-80-18] as the each piston.

original gasket.
If the highest measurement exceeds the piston

When replacing the gasket after an engine rebuild, the
piston protrusion must be measured.
protrusion of the selected gasket, use the gasket which is
one size larger. If the measurement exceeds gasket size
35, the engine must be disassembled, clearances
Publications.
(See Cylinder Head Top Clearance on Page 70-80-8.)
Figure 70-80-19
checked, and reassembled.
If the measurement is two sizes smaller than the selected

gasket or smaller than gasket size 15, the engine must
be disassembled, clearances checked, and
reassembled.
1
After the gasket and cylinder head have been installed,
turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
P-47252
Measure and record the protrusion of each piston in the

four places shown (Item 1) [Figure 70-80-19]. Find the
average of each piston, then find the combined average
of the four pistons.

836 of 928
CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-21 Figure 70-80-23
File has expired.

PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-23] on the
spring [Figure 70-80-21]. cylinder head.

Figure 70-80-22 NOTE: Do not put the straight edge across
Use updated files from Bobcat combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-23] between
Publications. the straight edge and the surface of the cylinder head.
Figure 70-80-24
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 70-80-21] and [Figure 70-80-22].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-21] and [Figure 70-80-22].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-21] and [Figure 70-80-22]. and two diagonal as shown in figure [Figure 70-80-24].
The maximum distortion of the head surface is ± 0.002 in.

(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

837 of 928
CYLINDER HEAD (CONT'D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
Figure 70-80-25 70-80-7.)
Remove the carbon from the valve guide.
2 Figure 70-80-26
1 3
File has expired.

PI9989
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-25] being checked at T.D.C.
B-14335

Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)

[Figure 70-80-25] on the top of the piston. Use grease to
hold them in position.
Measure the valve stem O.D. [Figure 70-80-26].
Measure the valve guide I.D. [Figure 70-80-26].
the valves. Publications.

NOTE: Put the solder in position so they do not touch
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Turn the piston to bottom dead center.
Valve Guide I.D. 0.3156 - 0.3161 in.
Install the cylinder head and tighten to the correct torque (8,015 - 8,03 mm)
in the correct sequence. (See Cylinder Head Removal
Valve Stem O.D. 0.3134 - 0.3140 in.
(7,96 - 7,98 mm)
Clearance Between 0.0016 - 0.0028 in.
Turn the crankshaft until the piston exceeds T.D.C.
Valve Stem and Guide (0,04 - 0,07 mm)
Remove the cylinder head.
Allowable Limit 0.004 in.
Remove the solder wire (Item 3) [Figure 70-80-25] and (0,1 mm)
measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0236 - 0.0276 in. (0,6 - 0,7 mm)

838 of 928
CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide Removal And Installation Figure 70-80-29
Figure 70-80-27
8.86” (225 mm)
0.787” 2.76” (70mm) 1.77”

(20 mm) (45 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
0.263-0.275” 0.98” P-51632

0.490-0.50”
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm)

Install the valve into the guide. Measure the valve
recessing or protrusion with a depth gauge [Figure 70-
To remove and replace the valve guide, make the driver 80-29].
tool as shown in figure [Figure 70-80-27].

Figure 70-80-30
Figure 70-80-28

Publications.
1
1. Cylinder Head
Surface
2 2. Recessing
3. Protrusion
PI-9990
PI-9992
If the measurement exceeds the allowable limit, replace

Press the used valve guide out of the cylinder head using the valve or cylinder head [Figure 70-80-30].
the special driver tool [Figure 70-80-28].
Protrusion 0.002 in. (0,5 mm)
Put oil on the outside diameter of the new valve guide. Recessing 0.006 in. (0,15 mm)
Press the new valve guide into the cylinder head from the Allowable Limit (Recessing) 0.016 in. (0,4 mm)
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-28], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

839 of 928
Reconditioning The Valve And Valve Seat (Cont’d) 1 2

15° Exhaust
Figure 70-80-31 30° Intake
PI-9995
Check the seat surface and valve face (Item 1) [Figure
File has expired.

PI-9993 70-80-33].
(a) identical dimensions above and below the valve seat

Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-31]. 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
Clean the valve seat and combustion chamber. exhaust to get the correct width (Item 3) [Figure 70-80-
Figure 70-80-32 Use updated files from Bobcat 33].
Valve Seat Width
Publications. Intake
Exhaust
0.0835 in. (2,12 mm)
0.0835 in. (2,12 mm)
Valve Seat And Face Angle
45° Exhaust Intake 45 degrees

15° Exhaust 45° Intake Exhaust 45 degrees
30° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-32].

840 of 928
CYLINDER HEAD (CONT'D) Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the
Valve Spring spring.
Figure 70-80-34 Setting Length 1.378 in. (35,0 mm)

Setting Load 26.4 lb. (117,6 N)
Allowable Limit 22.5 lb. (100,0 N)
Measure the length of the valve spring. If the

measurement is less than the allowable limit, replace the

spring [Figure 70-80-34].

Free Length
Allowable Limit
1.6417-1.6614 in. (41,7-42,2 mm)
1.622 in. (41,2 mm)
Publications.
Put the spring on a flat surface, place a square on the
side of the spring [Figure 70-80-34].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 0.039 in. (1,0 mm)
Figure 70-80-35
A-2759
Put the spring on a tester and compress to specified

length [Figure 70-80-35].

841 of 928
CYLINDER HEAD (CONT'D) Rocker Arm And Shaft - Checking
Valve Tappets Figure 70-80-38
Figure 70-80-36
1
2
B-3697
File has expired.

P-47267
Measure the rocker arm I.D. (Item 1) [Figure 70-80-38]
with an inside micrometer.
Remove the valve tappets (Item 1) [Figure 70-80-36].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-

Figure 70-80-37 80-38] with an outside micrometer.
Use updated files from Bobcat If the clearance exceeds the allowable limit, replace the
bushing.
Publications. If the clearance still exceeds the allowable limit after the
bushing is replace, replace the rocker arm shaft.
Oil Clearance 0.0006 - 0.0018 in.

Between Rocker Arm& (0,02 - 0,05 mm)
Shaft
(0,10 mm)
Rocker Arm Shaft O.D. 0.5501 - 0.5506 in.
(13,97 - 13,98 mm)
P-47268
Rocker Arm I.D. 0.5512 - 0.5519 in.
(14,0 - 14,02 mm)
Measure the O.D. of the tappet [Figure 70-80-37].
Measure the ID of the tappet bore [Figure 70-80-37].
If the clearance exceeds the allowable limit, replace the

tappets.
Tappet OD 0.943 - 0.944 in. (23,96 - 23,98 mm)

Tappet Bore ID 0.945 - 0.9457 in. (24 - 24,02 mm)
Clearance
Between Tappet
and Tappet Bore 0.0008 - 0.0024 in. (0,02 - 0,06 mm)
Allowable limit 0.0028 in. (0,07 mm)

842 of 928
CYLINDER HEAD (CONT'D)
Push Rod Alignment - Checking
Figure 70-80-39
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.
Publications.
Push rod alignment Allowable limit 0.0098 in.
(0,25 mm)

843 of 928
File has expired.

Publications.

844 of 928
CRANKSHAFT AND PISTONS Figure 70-90-2
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
1
Remove the oil pan (See Oil Pan Removal and
Installation on page 70-60-1)
Remove the oil pump strainer (See Oil Pan Removal and
Installation on page 70-60-01). A-2903
Figure 70-90-1
Installation: Make sure the marks on the connecting rod
File has expired. and bearing are aligned when installing the bearing cap
(Item 1) [Figure 70-90-2].
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

Figure 70-90-3
Publications. 1 3
P-51633A
2
1
Turn the flywheel and put a pair of connecting rods at
bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 33 - 36 P-47270

Remove the rod cap and bearing [Figure 70-90-1]. Remove the piston rings [Figure 70-90-4].
Use a hammer handle and push the piston/connecting Remove the snap ring (Item 1) and piston pin (Item 2)
rod assembly out of the cylinder bore [Figure 70-90-1]. [Figure 70-90-4].
NOTE: Make sure the pistons are marked so they will Separate the piston (Item 3) from the connecting rod
be returned to the same cylinder bore and (Item 4) [Figure 70-90-4].
direction.
NOTE: Mark the piston (Item 3) [Figure 70-90-4] and
connecting rod (Item 4) [Figure 70-90-4] with
the same number to ensure correct
installation and proper cylinder placement.

845 of 928
CRANKSHAFT AND PISTONS (CONT’D) NOTE: Assemble the piston to the connecting rod
with the FW mark (Item 6) [Figure 70-90-5] is
Piston And Connecting Rod Removal And facing the flywheel side and the connecting
Installation (Cont’d) rod mark (Item 1) [Figure 70-90-5] facing the
injection pump side.
Figure 70-90-4
Piston And Connecting Rod - Servicing
Figure 70-90-6
2
1
3
File has expired.

PI-10015
Installation: When installing new rings, assemble the

P-47272

ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander

joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 70-90-4].
Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-90-6].
Figure 70-90-5
Publications. If the measurement exceeds the allowable limit, replace
the piston.
3
1 Piston Bore I.D. 0.984 - 0.985 in.
2 (25,0 - 25,013 mm)
(25,05 mm)
5
6 4
P-47271
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in clean engine oil to 176° F (80° C) and tap the
piston pin into position. Place the piston rings so that
there are gaps every 120 degrees (Items 3, 4 and 5)
[Figure 70-90-5] with no gap facing the piston pin in the
cylinder.

846 of 928
CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-8
Piston And Connecting Rod - Servicing (Cont’d) 1.38” (35 mm)

1.063” (27 mm)
Figure 70-90-7
6.38” (162 mm)
1 1.378”
(35 mm)
1.098-1.1004”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
To replace the connecting rod small end bushing, make a
File has expired. P-47273 driver tool as shown in figure [Figure 70-90-8].
Figure 70-90-9
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-7].

Measure the I.D. of the connecting rod small end (Item 2)

[Figure 70-90-7].
Calculate the oil clearance. If the clearance exceeds the
Publications.
allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.9843 - 0.9847 in.

(25,0 - 25,11 mm)
Bushing I.D. 0.9852 - 0.9858 in.
(25,3 - 25,04 mm)
Oil Clearance Between 0.0006 - 0.0015 in. PI-10016
Piston Pin & Bushing (0,014 - 0,038 mm)
Allowable Limit 0.006 in. Use a press and special driver tool to remove the small
(0,15 mm) end bushing [Figure 70-90-9].
Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-9].

847 of 928
CRANKSHAFT AND PISTONS (CONT’D) If the clearance exceeds the allowable limit, replace the
ring. If the clearance still exceeds the allowable limit,
Piston And Connecting Rod - Servicing (Cont’d) replace the piston.
Figure 70-90-10 Top Ring 0.0020 - 0.0035 in.

(0,05 - 0,09 mm)
Allowable Limit 0.008 in (0,2 mm)
Second ring 0.00307- 0.0043 in.
(0.080 - 0.110 mm)
Allowable Limit 0.008 in. (0,2 mm)
Oil Ring 0.0012 - 0.0028 in.
(0,03 - 0,07 mm)
File has expired.

B-3622
Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure

70-90-10].

If the gap exceeds the allowable limit, replace the ring.
Top Ring Gap 0.008 - 0.013 in.
Oil Ring Gap Publications. (0,2 - 0,35 mm)

0.008 - 0.015 in.
(0,20 - 0,40 mm)
(1,25 mm)
Second Ring Gap 0.012 - 0.017 in.
(0,30 - 0,45 mm)
Figure 70-90-11
PI-10017
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler
gauge [Figure 70-90-11].

848 of 928
CRANKSHAFT AND PISTONS (CONT’D) Install the connecting rod on an alignment tool.
Cylinder Bore - Checking Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-12
Figure 70-90-14
B-4067
Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-90-12]. If the gauge does not fit squarely against the face plate,

measure the space between the gauge and face plate
Figure 70-90-13 [Figure 70-90-14].
Use updated files from Bobcat If the measurement exceeds the allowable limit, replace
the connecting rod.
Publications. Rod Alignment 0.002 in. (0,05 mm)
A-2717
Measure the six points as shown in figure [Figure 70-90-

13] to find the maximum wear.
The factory specification is:
3.425 - 3.426 in. (87,0 - 87,022 mm)
The allowable limit is: 3.4319 in. (87,170 mm)
Connecting Rod Alignment
NOTE: The small end bushing is the basis of this

check, check the bushing for wear before
doing this check.
Install the piston pin into the connecting rod.

849 of 928
CRANKSHAFT AND PISTONS (CONT’D) Mark and remove the inside screws (Item 1) first, then
remove the outside screws (Item 2) [Figure 70-90-16].
Crankshaft Gear Removal And Installation
NOTE: The inside bolts are different length than the
Remove the timing gearcase cover. (See Timing outside bolts.
100-1.) Install two screws in the bearing case cover and remove
the cover (Item 3) [Figure 70-90-16].
Remove the idler gear. (See Idler Gear And Shaft -
Servicing on Page 70-100-6.) Remove the two gaskets (Item 4) and oil seal (Item 5)
[Figure 70-90-16] from the cover.
Figure 70-90-15
Figure 70-90-17
File has expired.

1

2
Use updated files from Bobcat B-3686
P-47275
15]. Publications.
Remove the crankshaft gear with a puller [Figure 70-90-
Installation: Install the gaskets (Item 1) and (Item 2)
[Figure 70-90-17] as shown.
Remove the crankshaft key.
Crankshaft And Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See

Piston And Connecting Rod Removal And Installation on
Page 70-90-1.)
Figure 70-90-16
2 5
P-47274

850 of 928
CRANKSHAFT AND PISTONS (CONT’D) Allowable Limit 0.020 in.
(0,5 mm)
Crankshaft And Bearings Removal And Installation
(Cont’d) Figure 70-90-20
Figure 70-90-18
2
1
2
1

P-47278
Remove the main bearing case bolt (Item 1) [Figure 70-

90-20].
Install the bearing case cover (Item 1) [Figure 70-90-18]

with the casting mark (Item 2) [Figure 70-90-18] in the Installation: Align the bearing case hole (Item 2) [Figure
upward position. Tighten the bolts to 17 - 20 ft.-lb. (24 - 70-90-20] with the hole in the block. Put oil on the bolt
28 N•m) torque.
Figure 70-90-19
threads and tighten to 51 - 54 ft.-lb. (69 - 73 N•m) torque.
Figure 70-90-21
Publications.
1
P-47277
P-47279
Before removing the crankshaft/main bearings, check the Remove the crankshaft/main bearing assembly from the
end play. Install a dial indicator. Move the crankshaft engine block [Figure 70-90-21].
[Figure 70-90-19] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft NOTE: Turn the crankshaft as needed to allow the
toward the gear case side. crank pin journals to pass through the cut out
(Item 1) [Figure 70-90-21] of the engine block.
If the measurement exceeds the allowable limit, replace
the thrust washers [Figure 70-90-19]. Mark the bearing case halves for correct installation.
End Play 0.006 - 0.014 in.

(0,15-0,35 mm)

851 of 928
CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Removal And Installation Figure 70-90-24

(Cont’d)
Figure 70-90-22
A-2763
File has expired.

B-4092 Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 70-90-24].
Remove the two bearing case bolts [Figure 70-90-22]. Turn the crankshaft at a slow rate to obtain the

misalignment (one half of the alignment measurement).
Remove the bearing case and bearing.

Installation: Tighten the bearing case bolts to 34 - 38 ft.-
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Figure 70-90-23 Publications. Alignment 0.0008 in. (0,02 mm)
Tighten the connecting rod bolts to 33 - 36 ft.-lb. (45 - 49

N•m) torque.
Figure 70-90-25
120
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
A-2727
side of the engine block [Figure 70-90-23]. The thrust
washers oil grooves must face outward.
Measure the crankpin bearing I.D. [Figure 70-90-25].

852 of 928
CRANKSHAFT AND PISTONS (CONT’D) If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Crankshaft And Bearings - Servicing (Cont’d)
Wear of Sleeve 0.004 in. (0,1 mm)
Figure 70-90-26
The special tool set will be needed to replace the
crankshaft sleeve.
Remove the sleeve.
File has expired. A-2716
Measure the crankpin O.D. [Figure 70-90-26].

Calculate the oil clearance.

Crankpin Bearing I.D.
Crankpin O.D.
1.850 - 1.852 in.
(47,0 - 47,05 mm)
1.8488 - 1.8494 in.
Publications.
Oil Clearance
(46,96 - 46,98 mm)
0.0010 - 0.0034 in.
(0,025 - 0,087 mm)
Allowable limit 0.008 in. (0,2 mm)
Figure 70-90-27
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure

70-90-27].

853 of 928
Figure 70-90-28
2 2
1 3
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-
File has expired.

PI-10023 90-30].
Calculate the oil clearance.

Install the sleeve guide (Item 1) and stop (Item 2) [Figure
70-90-28]. If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Heat the sleeve to approximately 302° - 392° F (150° -

200° C). Install the sleeve on the crankshaft using the
special driver tool (Item 3) [Figure 70-90-28].
Bearing 1:
Bearing I.D. 2.0362 - 2.0364 in. (59,98 - 60,04
Publications.
NOTE: The sleeve is installed with the larger
chamfered surface to the front of the
crankshaft (Item 1) [Figure 70-90-27 on Page
Journal O.D.
mm)
2.3591 - 2.3598 in. (59,92 - 59,94
mm)
9].
Oil Clearance 0.016 - 0.0046 in. (0,04 - 0,12 mm)
Figure 70-90-29 Allowable Limit 0.008 in. (0,2 mm)
NOTE: Make sure you use the correct size bearing

when installing. Oversize bearings are
generally marked.
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

70-90-29].

854 of 928

1. Seam 4
Figure 70-90-31 2. Bearing
3. Engine Block
Removal Tool 4. Bearing Recession
3
5.31” (135 mm)
0.8”
(20 mm)
2.354-2.358”
(59,8-59.9 mm)
2.83”
(72 mm) 2 1 2
P-48778
0.8” (20 mm)
2.551-2.555
1.57” 0.4” (64,8-64,9 mm) Remove the front bearing with the special removal tool
(40 mm)
File has expired.
(10 mm) MC-1367 [Figure 70-90-31].
Installation: Clean the new bearing (Item 2) and bore,

To remove the front bearing make the tool as shown in apply oil to the bearing and bore. Install the new bearing
figure [Figure 70-90-31]. with the seam (Item 1) [Figure 70-90-33] towards the

exhaust manifold side, using the installation driver tool.
Figure 70-90-32

Installation Tool
5.12” (130 mm)
Check the depth (Item 4) of the bearing (Item 2) from the
face of the engine block (Item 3) [Figure 70-90-33]. This
will ensure proper bearing alignment with the crankshaft.
Publications. 0.16”
(4 mm)
0.8”
(20 mm)
2.551-2.555”
Bearing Number 1
Recession
0.1654 - 0.1772 in.
(4,2 - 4,5 mm)
2.83” (64,8-64.9 mm)

Clean the crankshaft journal and bearing. Put a strip of
(72 mm) press gauge on the center journal.
2.68”
(68 mm) Install the main bearing case halves and tighten the bolts.
0.8” (20 mm) Remove the bearing case halves.
1.57” 2.354-2.358”
0.4” (59,8-59,9 mm) NOTE: DO NOT turn the crankshaft with the press
(40 mm) (9mm) MC-1365 gauge installed. Incorrect measurements will
be obtained.
To install the front bearing make the tool as shown in
figure [Figure 70-90-32].

855 of 928
CRANKSHAFT AND PISTONS (CONT’D)
Figure 70-90-34
File has expired.

PI-10025
Measure the flattened press gauge [Figure 70-90-34].

No. 2 crankshaft bearing.

Crankshaft Journal O.D. 2.3591 - 2.3598 in.
(59,92 - 59,94 mm)
Bearing I.D.
Oil Clearance
Publications.
2.3615 - 2.3631 in.
(59,98 - 60,02 mm)
0.0016 - 0.0041 in.
(0,04 - 0,12 mm)

856 of 928
CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation
Figure 70-100-1
7.87” (200 mm)
P-47256
Remove the speed control plate (Item 1) [Figure 70-100-
Figure 70-100-4
Bend a hook on the end of a 7.87 in (200 mm) long,
0.050 in (1,2 mm) diameter hard wire [Figure 70-100-1].

Figure 70-100-2

Publications. 1
P-47257
Remove the wire (Item 1) [Figure 70-100-4] from the

P-47255 springs.
Installation: Do not drop the governor springs into the

Disconnect the two governor springs (Item 1) [Figure 70- gear case.
100-2].
Remove the crankshaft pulley nut.

N•m) torque.

857 of 928
CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-7
Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 70-100-5
P-47259
Remove the timing gearcase cover [Figure 70-100-7].
File has expired.

P-47258 Figure 70-100-8
Use a puller and remove the crankshaft pulley. [Figure

70-100-5].
3

Figure 70-100-6
2
Publications.
1
1
2
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

and oil slinger (Item 3) [Figure 70-100-8].
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 70-100-6].
Remove the bolts from the timing gearcase cover.

N•m) torque.

858 of 928
CAMSHAFT AND TIMING GEARS (CONT’D) Timing Gears Backlash - Checking
Timing Gearcase Cover Removal And Installation When the gears are installed, check the backlash of the
(Cont'd) gears.
Figure 70-100-9 Figure 70-100-10
Oil Seal O-rings
File has expired. B-3617B P-47264
Installation: Install new O-rings and oil seal into the Install a dial indicator [Figure 70-100-10].

timing gearcase cover [Figure 70-100-9].
Hold one gear while turning the other gear [Figure 70-
Use updated files from Bobcat 100-10].
If the backlash exceeds the allowable limit, check the oil
Publications. clearance of the shaft and gear. If the oil clearance is

correct, replace the gear.
Crank Gear & Idler Gear 0.0016 - 0.0044 in

(0,042 - 0,112 mm)
Cam Gear & Idler Gear 0.0016 - 0.0045 in
(0,042 - 0,115 mm)
Allowable Limit 0.006 in (0,15mm)
Injection Pump Gear 0.0016 - 0.0045 in
& Idler Gear (0,042 - 0,115 mm)
Oil Pump Gear & Crankgear 0.0016 - 0.0043 in
(0,042 - 0,109 mm)

859 of 928
Idler Gear And Camshaft Removal And Installation
Remove the timing gearcase cover. (See Timing 2

100-1.)
Figure 70-100-11
1
2
1
P-47262
Align the holes (Item 1) on the camshaft gear with the
File has expired. camshaft retainer plate bolts (Item 2) [Figure 70-100-13].
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to 18 -

P-47260 20 ft.-lb. (24 - 27 N•m) torque.

Remove the camshaft from the engine block.
Remove the snap ring (Item 1) and collar from the idler
gear shaft (Item 2) [Figure 70-100-11].
Figure 70-100-14
Installation: Make sure the timing marks are in correct
Publications.
alignment when installing the timing gears [Figure 70-
100-11].
Figure 70-100-12
PI-10002
Installation: Check the camshaft end play. If clearance

exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-14].
B-3699
Camshaft End Play 0.003 - 0.009 in

Remove the idler gear (Item 1) [Figure 70-100-12]. (0,07 - 0,22 mm)
Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
collar.
Idler Gear End Play 0.005 - 0.0189 (0,12 - 0,48mm)


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Camshaft - Servicing
Figure 70-100-15
B-5001
Measure the cam lobes at their highest point [Figure 70-
File has expired. P-47263 100-17].
If the measurement is less than the allowable limit,

Measure the cylinder block bore in the engine block replace the camshaft.
[Figure 70-100-15].

Cam Lobe Height 1.3346 in (33,9 mm)
Figure 70-100-16
Use updated files from Bobcat Allowable Limit
Figure 70-100-18
1.3327 in (33,85 mm)
Publications.
A-2761
Measure the camshaft journal [Figure 70-100-16]. A-2760
Calculate the oil clearance. If the clearance exceeds the

Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft.
[Figure 70-100-18].
Cylinder Block Bore I.D. 1.575 - 1.576in Turn the camshaft at a slow rate. If the misalignment
(40,0 - 40,025 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.572 - 1.573 in
(39,93 - 39,95 mm) Camshaft Alignment Allowable Limit 0.0004in
Oil Clearance of Cam- 0.002 - 0.0035 in (0,01 mm)
shaft Journal (0,05 - 0,091 mm)

861 of 928
Idler Gear And Shaft - Servicing

1.49” (38 mm)
Figure 70-100-19
6.89” (175 mm)
1.77” 1.575”
(45 mm) (40 mm)
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
To replace the idler gear bushing, make a driver tool as
File has expired.

PI-10003 shown in figure [Figure 70-100-20].
Figure 70-100-21
Measure the O.D. of the idler gear shaft [Figure 70-100-
19].

Measure the I.D. of the idler gear bushing [Figure 70-
100-19].
bushing.
Publications.
Idler Gear Shaft O.D. 1.494 - 1.495 in
(37,96 - 37,98 mm)
Idler Gear Bushing I.D. 1.496 - 1.497 in
(38,0 - 38,03 mm)
Clearance Between Idler 0.001-0.0026 in
Shaft & Gear Bushing (0,025-0,07 mm) PI-10004

Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 70-100-21].

862 of 928
FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-110-2
Remove the drive belt shield. (See Shield Removal And

Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Figure 70-110-1
1
P-48850
File has expired. The ring gear (Item 1) [Figure 70-110-2] on the flywheel
is an interference fit. Heat the ring gear enough to
1 expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.

Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Clean the new ring gear and heat it to a temperature of

P-48649
Publications.
Remove the six mounting bolts (Item 1) from the engine
450° - 500° F (232° - 260° C)
Fit the ring on the flywheel and be sure the gear is seated
flywheel (Item 2) [Figure 70-110-1]. correctly.
Installation: Apply engine oil to the threads and seats

before tightening. Tighten to 72 - 80 ft.-lb. (98 - 108 N•m)
torque.
Remove the flywheel from the engine.
Installation: Be sure to align the hole in the flywheel with

the pin located on the crankshaft.
Reverse the removal procedure to install the flywheel.

863 of 928
FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-4
Remove the drive belt shield. (See Shield Removal And

Remove the engine/hydrostatic pump package from the

70-10-9.)
Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.) P-48651C
Remove the starter. (See Removal And Installation on

Page 60-40-2.) Install a puller in the drive pulley and remove the pulley
File has expired.

Remove the flywheel. (See Flywheel Removal And
from the hydrostatic pump shaft [Figure 70-110-4].
Installation: Install the pulley key in the shaft before

installing the drive pulley.
Figure 70-110-3

Publications.
1
P-48651B
Remove the hydrostatic pump drive pulley mounting nut

(Item 1) [Figure 70-110-3] and washer.
Installation: Tighten the mounting nut to 175 - 200 ft.-lb.

(237 - 271 N•m) torque.

864 of 928
FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-7
Housing Removal And Installation (Cont’d)
Figure 70-110-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
File has expired. P-48650 110-7] which fasten the housing on the engine.

Remove the two mounting bolts (Item 1) [Figure 70-110- (48 - 54 N•m) torque.
5] from the drive belt housing which mount the

hydrostatic pump to the housing. Remove the 2 bolts (Item 2) [Figure 70-110-7] which
fasten the housing on the engine.
(88 - 95 N•m) torque. Installation: Tighten the mounting bolts to 60 - 65 ft.-lb.
(82 - 88 N•m) torque.
Publications.
Figure 70-110-6
Remove the housing.
Reverse the removal procedure to install the housing.
P-4231A
Remove the mounting bolt (Item 1) [Figure 70-110-6]

from engine coolant tubeline mounting bracket which is
attached to the flywheel housing.
Installation: Tighten the mounting bolt to 25 - 28 ft.-lb.

(34 - 38 N•m) torque.

865 of 928
File has expired.

Publications.

866 of 928
HEATER
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-4
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

File has expired.

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Publications.
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Operates Normally, But Air Flow Is Insufficient . .
80-30-1
80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . 80-30-6
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . 80-30-7
HEATER

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


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File has expired.

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HEATER SYSTEM Figure 80-10-3
Description
Figure 80-10-1 1
2 3
N-20876
Control Panel: The panel (Item 1) [Figure 80-10-3] has
File has expired. P-67081 two separate components.
Fan Switch: This is a four position rotary switch (Item 2)

Heater Unit: The heater (Item 1) [Figure 80-10-1] is [Figure 80-10-3]. When the fan switch is in the off
located behind the loader cab. The unit delivers the warm position the heat valve will operate, as it is controlled by

air for heat into the cab. The unit contains the blower and the ignition power.
heater coil.

Figure 80-10-2
Potentiometer: The potentiometer (Item 3) [Figure 80-
10-3] controls the Heater Valve (Item 1) [Figure 80-10-4]
from fully Off to fully On. This can be used for defrost of
Publications. the windows and temperature control.
2
1
N-22092
Heater Coil: The heater coil (Item 1) [Figure 80-10-2]

supplies the warm air into the cab by passing air through
the coil.
Heater Blower: The blower (Item 2) [Figure 80-10-2] is

used to push air through the heater and into the cab.

869 of 928
HEATER SYSTEM (CONT’D)
Description (Cont'd)
Figure 80-10-4
File has expired.

P-66921
Heater Valve: The heater valve (Item 1) [Figure 80-10-4]

is used to control the amount of engine coolant that flows

to the heater coil.

Publications.

870 of 928
REGULAR MAINTENANCE Heater Coil
Filters Raise the operator cab. (See Raising on Page 10-30-1.)
1
1
P-48012
P-76565
The Fresh Air Filter (Item 1) [Figure 80-20-1] is located
File has expired.

below the rear window outside the cab. Remove the
clamping knobs, filter cover and filter. Remove the cover screws (Item 1) [Figure 80-20-3] and
remove the cover.
Shake the filter or use low pressure air to remove dirt.
This can be done several times before replacement is Figure 80-20-4

required. Install the filter, filter cover and clamping knobs.
1
Figure 80-20-2
Publications.
P-43852A
Use low pressure air or water to remove debris from the

1
heater coil (Item 1) [Figure 80-20-4].
P-48005
Install the cover and lower the operator cab. (See
Lowering on Page 10-30-2.)
The Recirculation Filter (Item 1) [Figure 80-20-2] is
located in front of the rear window inside the cab.
Remove the clamping knobs, filter cover, and filter.
Shake the filter or use a vacuum to clean. This can be

done several times before replacement is required. Install
the filter with the arrows pointing forward (Inset) [Figure
80-20-2], install the filter cover and clamping knobs.

871 of 928
File has expired.

Publications.

872 of 928
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
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Motor.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient
POSSIBLE CAUSE
1. Air leak. File has expired. INSPECTION
Check to make sure air hoses are properly hooked to
Louvers, and air ducts.
SOLUTION
Repair or adjust.
2. Plugged cab filters. Check cab filter condition. Clean or replace filters.

Publications.

873 of 928
TROUBLESHOOTING (CONT’D) Figure 80-30-3
Electrical System
NOTE: The key must be put in the ON position when

checking for power in circuits.
Figure 80-30-1
1 1
P-68444
Check the loader harness (Item 1) [Figure 80-30-3] for
File has expired. voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

P-66829 harness for broken wires or blown fuse.

If there is voltage at the wiring harness, check the
Remove the access cover (Item 1) [Figure 80-30-1] from resistance to the blower fan at the blower fan wiring
the operator cab.
Figure 80-30-2
connector (Item 2) [Figure 80-30-3].
If there is no resistance value replace the blower fan.
Publications. (See Removal And Installation on Page 80-60-1.)
If there is a resistance value check the climate controls at

the control panel inside the loader cab.
P-68118
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-30-2] from the loader wiring harness.

874 of 928
Electrical System (Cont'd)
Figure 80-30-4 1
P-28918
1
Disconnect the loader wiring harness (Item 1) [Figure
File has expired.

N-20876 80-30-6] from the blower switch.
Check the loader harness for voltage. The voltage should

Remove the three mount screws (Item 1) [Figure 80-30- be 12 volts.
4] from the cab control panel.

If there is no voltage at the wiring harness, check the
Figure 80-30-5 harness for broken wires or blown fuse.
Publications.
P-28920
Remove the control panel and wiring harness from the

cab [Figure 80-30-5].

875 of 928
Figure 80-30-7
C
H
B
M
L P-28920
The potentiometer will affect the operation of the heater.
File has expired.

N-22288
If heater valve does not open, or close, check the
potentiometer.
If there is voltage at the wiring harness, check the blower
switch [Figure 80-30-7] for resistance. At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-8] from the potentiometer.
With the switch in the OFF position, there should be zero

resistance between all terminals.
With the switch in the 1 position, there should be

Figure 80-30-9
Publications.
resistance between C terminal and the B terminal,
between the C terminal and the L terminal and also
between the B terminal and the L terminal frame [Figure
80-30-7].

resistance between C terminal and the B terminal,
between the C terminal and the M terminal and also 1
between the B and the M terminal frame [Figure 80-30-
7].

resistance between C terminal and the B terminal, P-28919
between the C terminal and the H terminal and also
between the B terminal and the H terminal frame [Figure
80-30-7]. Check the loader harness (Item 1) [Figure 80-30-9] for
voltage. The voltage should be 12 volts.
If any of the above resistance tests fail, replace the
blower switch. If there is no voltage at the wiring harness, check the
harness for broken wires or blown fuse.
If the above resistance tests are good, check the
potentiometer.

876 of 928
Figure 80-30-10
A C
1
N-22175
B
To check the resistance of the white wire, turn the
File has expired.N-22290 potentiometer control (Item 1) [Figure 80-30-12] to the

full A/C position.
If there is voltage at the wiring harness, check the Figure 80-30-13

potentiometer [Figure 80-30-10] for resistance.

The resistance should be 10 K ohm between wire

terminal A and wire terminal C frame [Figure 80-30-10].
If no resistance is found replace the potentiometer.
Publications.
Figure 80-30-11
A C
N-22290
The resistance between the wire terminal A and wire

1 terminal B frame [Figure 80-30-13] should be
approximately 49 K ohm.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-30-13] should be
approximately 39 K ohm.
The white wire B, (Item 1) [Figure 80-30-11], on the

potentiometer, is a resistor wire.

877 of 928
TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Figure 80-30-16
Figure 80-30-14
N-20876
File has expired.

N-22175
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-30-14] to the Turn the fan switch (Item 1) [Figure 80-30-16] to the

full Heater position. High Speed position, with the loader ignition switch OFF.

Figure 80-30-15 Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 80-30-17
Publications.
A C
N-22290
P-68119
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-15] should be
approximately 39 K ohm. Connect the remote start tool to the loader. (See
Check the resistance between the wire terminal C and 1.)
wire terminal B frame [Figure 80-30-15] should be
approximately 49 K ohm. Start the loader and run at high idle, for ten minutes.
If the resistance is not found replace the potentiometer. Check the heater hose (Item 1) [Figure 80-30-17] for
temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replaced.

878 of 928
TROUBLESHOOTING (CONT’D) Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Heater Valve Not Opening Or Closing
Lower operator cab.
Figure 80-30-18
Turn the temperature control (Item 2) [Figure 80-30-18]
to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-19], as the key of
2 the remote start is turned to the ON position without
1 starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-2.)

Replace the heater valve. (See Removal And Installation
on Page 80-70-1.)

Turn the fan switch (Item 1) to position 1. Turn the

temperature control (Item 2) [Figure 80-30-18] to the
High cold position, with the loader ignition switch OFF.
Publications.

1.)
Figure 80-30-19
P-68117
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 80-30-19], as the key of
the remote start tool is turned to the ON position without
starting the loader. The heater valve should rotate. Place
a mark on the heater valve shaft.

879 of 928
File has expired.

Publications.

880 of 928
HEATER UNIT Figure 80-40-3

Figure 80-40-1
1 P-68840
Remove the two mounting nuts (Item 1) [Figure 80-40-3]
File has expired. at the right side.
Figure 80-40-4

P-66829

Remove the access cover (Item 2) [Figure 80-40-1] from
the operator cab.
1
P-68841
1
Remove the two mounting nuts (Item 1) [Figure 80-40-4]
at the left side.
P-68118
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-40-2] from the loader wiring harness.

881 of 928
HEATER UNIT (CONT’D)
Figure 80-40-5
File has expired.

P-66921
Remove the heater hoses (Item 1) [Figure 80-40-5] from

the heater coil.

Remove the heater unit from the loader.

Reverse the removal procedure to install the heater unit.
Publications.

882 of 928
HEATER COIL Figure 80-50-2
Figure 80-50-1
1
1
2
N-22093
Remove the three mount bolts (Item 1) [Figure 80-50-2]
File has expired. P-66921 and remove the mount plate from the end of the unit.
Figure 80-50-3


Remove the heater unit from the back of the cab. (See
Publications.
Remove the heater valve (Item 1) [Figure 80-50-1]. (See
1
Mark the heater hoses (Item 2) [Figure 80-50-1] for

proper installation.
Cap the hoses and the heater coil with hydraulic caps N-22094
and plugs to prevent oil loss from the system.
Remove the rear cover from the heater unit. (See Heater Remove the two mount bolts (Item 1) [Figure 80-50-3]
Coil on Page 80-20-1.) from the heater coil.
Remove the heater coil from the unit.
Reverse the removal procedure to install the heater coil.

883 of 928
File has expired.

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BLOWER FAN Figure 80-60-3
Raise the lift arms and install an approved lift arm 1

NOTE: The blower fan assembly can be removed

from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is remove here for photo clarity.
Figure 80-60-1
P-39553
Remove the two flange mount bolts (Item 1) [Figure 80-

1
File has expired. 60-3] from the evaporator/heater unit.
Figure 80-60-4

1
Remove the cover (Item 1) [Figure 80-60-1] from the
evaporator/heater unit.
Figure 80-60-2
P-39554
1 Remove the flange and attached foam (Item 1) [Figure

80-60-4] from the unit.
P-68120
Remove the two flange mount bolts (Item 1) [Figure 80-

60-2] from the evaporator/heater unit.

885 of 928
BLOWER FAN (CONT'D) Disassembly And Assembly
Figure 80-60-5
1 1
2 N-22102
File has expired.

P-68120A
Remove the eight mount bolts (Item 1) [Figure 80-60-7]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-60-5] from the unit. Remove the blower wheel cover from the housings.

Figure 80-60-6 Remove the four mount bolts (Item 2) [Figure 80-60-7]
1
from the blower motor mount.
Remove the blower motor mount.
Publications. Remove the blower motor assembly from the housing.
Figure 80-60-8
P-39556
Remove the three mount bolts (Item 1) [Figure 80-60-6] 1

from the blower fan housing.
2
Remove the blower fan housing from the evaporator/
heater unit.
N-22107
Check the blower housing (Item 1) and blower motor

mount (Item 2) [Figure 80-60-8] for wear and replace as
needed.

886 of 928
BLOWER FAN (CONT'D) Figure 80-60-11
Figure 80-60-9
N-22110
2 Figure 80-60-12
Remove the outside rings (Item 1) and blower wheel

covers (Item 2) [Figure 80-60-9] from the blower motor

and blower wheels.

Figure 80-60-10
Publications. 1
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-60-11] and [Figure 80-60-12] from the blower wheel.
N-22109
Inspect the end rings and blower wheel covers for wear
and replace as needed [Figure 80-60-10].

887 of 928
BLOWER FAN (CONT'D) Connector Identification
Disassembly And Assembly (Cont'd) Figure 80-60-15
Figure 80-60-13
P-68118
File has expired.

N-22111
The wiring code for the blower fan connector [Figure 80-
60-15] is:
Remove the inside blower wheel clamp (Item 1) [Figure
80-60-13] from the blower wheel. Number on Connector Wire Color

A Orange
Figure 80-60-14
Use updated files from Bobcat B

C
D
Red
Yellow
Black
Publications. 1
N-22116
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-60-14] from the blower motor shaft.
Repeat the procedure for the other blower wheel.

888 of 928
HEATER VALVE Figure 80-70-2

Remove the Heater Unit from under the cab and place it
across the mainframe supported by blocks (See Removal
Remove any tie-straps that hold the heater hoses. 1
Figure 80-70-1 P-66922
Disconnect the loader wiring harness (Item 1) [Figure
File has expired. 80-70-2] from the heater valve.

1 2
3

Remove the mount bolts (Item 1) [Figure 80-70-1] from

the heater valve mount.
Remove the heater hose clamps (Item 2) and (Item 3)

[Figure 80-70-1].
Remove the heater hoses from the heater valve.
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.

889 of 928
HEATER VALVE (CONT'D) Figure 80-70-5
Figure 80-70-3 1
P-66925
Remove the three mounting bolts (Item 1) [Figure 80-70-
File has expired.

P-66923 5] from the heater valve mount plate.
Remove the mount plate (Item 2) [Figure 80-70-5] from

Remove the three mount bolts (Item 1) [Figure 80-70-3] the heater valve bracket.
from the heater valve actuator.

Figure 80-70-6
Figure 80-70-4

Publications. 1
1 1
2
2
P-66926
P-66924

Remove the actuator (Item 1) and the three mounting 6] from the heater valve.
spacers (Item 2) [Figure 80-70-4] from the heater valve
mount plate.

890 of 928
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalent Chart. . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . SPEC-50-1 SAFETY &
MAINTENANCE
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-30-1
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-30-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-30-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3 DRIVE
SYSTEM
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS SPEC-40-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
File has expired.

(S175) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-10-1
SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

ELECTRICAL
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 SYSTEM &
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-10-4
SPEC-10-2
ANALYSIS
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Publications.
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-10-2
SPEC-10-4
ENGINE
SERVICE
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-20-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-20-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-20-1 SPECIFICATIONS

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

SPEC-01 S175 Service Manual

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File has expired.

Publications.
SPEC-02 S175 Service Manual

892 of 928
(S175) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 68 inch Construction And Industrial bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
95°
152.1 in.
(3862 mm)
42°
118.2 in.
29.6 in. (3002 mm)
File has expired. (753 mm)
76.3 in. 91 in.

(1938 mm) (2310 mm)

23°
7.5 in.
(190 mm)
40.6 in.
(1030 mm)
25°
101.9 in.
Publications. (2588 mm)

130.3 in.
(3309 mm) B-16431
68 in.
(1727 mm) 78.8 in.
(2001 mm)
56.4 in.
(1433 mm)
66 in.
(1676 mm) B-16432
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
SPEC-10-1 S175 Service Manual

893 of 928
(S175) LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity (ISO) 1750 lb. (794 kg)

with 200 Pound Frame Mounted 1900 lb. (862 kg)
Counterweight Kit
Tipping Load (ISO) 4126 lb. (1872 kg)
Operating Weight 6290 lb. (2853 kg)
Travel Speed
- Single Speed Loader 7.3 mph (11,8 km/hr.)
- Two-Speed Loader (Opt.) Low/High 7.5 mph (12,1 km/hr.) / 11.1 mph (17,9 km/hr.)
SAE Breakout Force - Lift 3600 lb. (1633 kg)
SAE Breakout Force - Tilt 3550 lb. (1610 kg)
Push Force 4300 lb. (1950 kg)
Engine
Make / Model
Fuel / Cooling
File has expired. Kubota / V2403-M-DI-E3B Interim Tier IV
Diesel / Liquid
Horsepower (SAE Net) 46.1 HP (34,4 kW) @ 2700 RPM
Torque (SAE Net) 109.6 ft.-lb. (148,6 N•m) @ 1600 RPM

Number of Cylinders 4
Displacement
Bore / Stroke
Use updated files from Bobcat 148.5 cu. in. (2,433 L)
3.425 in. / 4.03 in. (87 mm / 102,4 mm)
Lubrication Gear Pump Pressure system with Filter
Crankcase Ventilation
Air Cleaner
Publications. Closed Breathing
Dry replaceable paper cartridge with separate safety element.
Ignition Diesel Compression
Air Induction Naturally Aspirated
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Low Idle 1075 - 1225 RPM
High Idle 2760 - 2900 RPM
Drive System
Main Drive Hydrostatic 4-wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully
reversing hydrostatic motors.
Final Drive Chains Prestressed #80 HSOC endless roller chain (no master link) and sprockets
in sealed chaincase with oil lubrication (No adjustment need ed). Two
chains per side with no idler sprocket.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 in. (50,8 mm), heat treated
Wheel Bolts Eight 9/16 in Wheel Bolts fixed to axle hubs

894 of 928
Controls
Vehicle Steering Direction and speed controlled by two hand operated steering levers or
optional joystick(s)
Loader Hydraulics - Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System
(ACS) or optional Selectable Joystick Control (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or optional Right
Hand Selectable Joystick Control (SJC)
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or optional Left Hand
Selectable Joystick Control (SJC)
Auxiliary Pressure Release Pressure relieved through front quick couplers. Push couplers in, hold for 5
seconds.
Engine Hand lever speed control; key-type start switch or optional Deluxe
Instrumentation Panel and function error shutdown.
Service Brake Two independent hydrostatic systems controlled by two hand operated
steering levers or optional joystick(s)
Secondary Brake
File has expired.
One of the hydrostatic transmissions.
Parking Brake (Standard on Single Mechanical disc, manually operated switch on front instrument panel.
Speed and Two-Speed Loaders)

Hydraulic System
Pump Type
Pump Capacity - Standard
Engine driven gear type
16.9 GPM (64 L/min.) @ 2825 Engine RPM @ 91% efficiency
- High-Flow Option 26.4 GPM (100 L/min.) @ 2825 Engine RPM @ 91% efficiency
Filters
Publications.
System Relief at Quick Couplers 3250 - 3350 PSI (224 - 231 bar)
Full flow replaceable, 3-micron synthetic media element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 2.50 in. (63,5 mm)
Tilt Cylinder (2) 2.75 in. (69,8 mm)
Rod Diameter: Lift Cylinder (2) 1.50 in. (38,1 mm)
Tilt Cylinder (2) 1.375 in. (34,9 mm)
Stroke: Lift Cylinder (2) 23.67 in. (601 mm)
Tilt Cylinder (2) 13.19 in. (335 mm)
Control Valve 3 spool, open center type with float detent on lift and electrically controlled
auxiliary spool.
Fluid Type BOBCAT FLUID, Hydraulic/Hydrostatic
6903117 - (2.5 Gal.)
6903118 - (5 Gal.)
6903119 - (55 Gal.)
Fluid Lines SAE Standard tubelines, hoses and fittings
Hydraulic Function Time:
Raise Lift Arms 3.5 Seconds
Lower Lift Arms 2.5 Seconds
Bucket Dump 2.4 Seconds
Bucket Rollback 1.9 Seconds

895 of 928
Electrical
Alternator Belt driven, 90 amps ventilated

Battery 12 volts, 600 cold cranking amps @ 0° F (-18° C)
115 minute reserve capacity at 25 amps
Starter 12 volts, gear type, 3.62 HP (2,7 kW)
Instrumentation Gauges: Engine Coolant Temperature, Fuel Level.
Warning lights: Fuel Level, Seat Belt, Engine Coolant Temperature,
Engine Malfunction, Hydraulic Malfunction, General Warning.
Indicators: BICS Functions, Two-Speed, 3-Point Shoulder Belt, Turn
Signals, Engine Preheat.
Data Display: Operating Hours, Engine RPM, Speed Management
Setting, Maintenance Clock Countdown, Battery Voltage, Service Codes,
Engine Preheat Countdown, Steering Drift Compensation Setting.
Other: Audible Alarm, Lights, Option / Accessory Switches.
File has expired. Optional Deluxe Instrumentation Panel:

*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock,
Attachment Control Information, High-Flow / Two-Speed / Password

Lockouts, Multi-language Display, Help Screens, Diagnostic Capability and
Capacities
Use updated files from Bobcat Engine / Hydraulic Systems Shutdown Function.
Fuel Tank
Engine Oil with filter
Publications. 24 Gal. (90,8 L)
9.2 qt. (8,7 L)
Engine Cooling System Propylene Glycol / water mixture (53% PG / 47% water)
without heater 10.8 qt. (10,2 L)
with Heater 12 qt. (11,3 L)
Hydraulic / Hydrostatic Reservoir 4.8 Gal. (18,2 L)
Hydraulic / Hydrostatic System (including
Reservoir) 9 Gal. (34,1 L)
Chaincase Reservoir 8 Gal. (30,3 L)
Tires
Bobcat Standard Duty Bobcat Standard Duty 10-16.5 8 Ply Rating

Bobcat Severe Duty Bobcat Severe Duty 10-16.5 10 Ply Rating
Bulky Hulk Bobcat Super Float 31.5x13-16.5
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.

896 of 928
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE Grade 5 SAE Grade 8
Size
in.-lb. 0.250 80 - 90 110 - 120
(N•m) (9,0 - 10,2) (12,4 - 13,6)
0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27 - 1)
ft.-lb. 0.375 25 - 28 35 - 40
(N•m) (34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
(54 - 61) (81 - 88)
0.500 65 - 70 90 - 100
0.5625
File has expired.
(88 - 95)
90 - 100
(122 - 136)
125 - 140
(122 - 136) (170 - 190)
0.625 125 - 140 175 - 190
(170 - 190) (240 - 260)

0.750 220 - 245 300 - 330

0.875
(300 - 330)
330 - 360
(450 - 490)
(410 - 450)
475 - 525
(645 - 710)
Publications.
1.000
1.125
475 - 525
(645 - 710)
650 - 720
725 - 800
(985 - 1085)
1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 - 4750) (7450 - 8300)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)

897 of 928
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M 6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M 8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M 10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M 12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M 14 x 1.25 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
File has expired.

(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)

Publications.

898 of 928
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x ft.-lb.
IMPORTANT Diameter
1/4”
Thread Size
9/16” - 18
(N•m)
13 (18)
When repairing hydrostatic and hydraulic systems, 3/8” 11/16” - 16 22 (30)
clean the work area before disassembly and keep all 1/2” 13/16” - 16 40 (54)
5/8” 1” - 14 60 (81)
damage the system. 3/4” 1-3/16” - 12 84 (114)
I-2003-0888 7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-30-1
1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)

File has expired.

Publications. B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].

899 of 928
HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-30-4
Straight Thread O-ring Fitting
Figure SPEC-30-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
File has expired.

A-1852 Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until

of the connection (Item 1) [Figure SPEC-30-4]
the washer is tight against the surface [Figure SPEC-30-
3].
Tubelines And Hoses
Use the chart [Figure SPEC-30-5] to find the correct
tightness needed (Item 2) [Figure SPEC-30-4]. If the
fitting leaks after tightening, disconnect it and inspect the
Publications.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
seat area for damage.
Figure SPEC-30-5
heat.
Flare Fitting Tightening Torque
Replace hoses which show signs of wear, damage or Tubeline x TORQUE
weather cracked rubber. Outside x ft.-lb.
Diameter Thread Size (N•m)
Always use two wrenches when loosening and tightening 1/4” 7/16” - 20 13 (18)
hose or tubeline fittings.
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)

900 of 928
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-7
(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-30-6 x TORQUE
x ft.-lb.
Thread Size (N•m)
7/16” - 20 13 (18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
Nut Seals
To Fitting 1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
Nut Seals
File has expired.

To Port
1-5/8” - 12 163 (221)
Use the following procedure to tighten the port seal

fitting:

Secondary O-ring Seal P-13008 Port seal and nut, washer and O-ring (O-ring Boss)

The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
fittings use the same tightening torque valve chart.
If a torque wrench cannot be used, use the following

method.
Publications.
the connection [Figure SPEC-30-6].
The hex portion of the nut does not contact the surface of
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
the component when the nut is tight.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.

901 of 928
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Publications.

902 of 928
SPECIFICATIONS
Specifications WARNING
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0910
TEMPERATURE RANGE ANTICIPATED

File has expired.
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.)
Publications.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below zero degree F (-18° C) 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.

903 of 928
File has expired.

Publications.

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CONVERSIONS
Decimal And Millimeter Equivalent Chart
File has expired.

Publications.
U.S. To Metric Conversion Chart

905 of 928
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Publications.

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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: S175 - 1

Date: 2 May 2008
Product: Bobcat Loader
Model:
Manual No:
S175 File has expired.
6987035 (5-08)
The following Sections are a revision to the above Service Manual.

Replace Manual dated 4-08 with Manual dated 5-08
Publications.
Printed in U.S.A.
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Date: 14 August 2008
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6987035 (8-08)

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50-01
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50-10
50-130
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10-200
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20-01
20-40
20-41
50-01
50-130
60-01
ELECTRICAL SCHEMATICS
60-70
60-72
70-01
70-50
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FOREWORD
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30-21
30-30
30-31
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ALPHABETICAL INDEX
80-01
Publications.
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10-70
10-200
SPEC-01
SPEC-10
10-210 ADDED
20-01
30-01
40-01
50-01
60-01
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60-160
60-210
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MAINTENANCE SAFETY
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30-60
ELECTRICAL SCHEMATICS
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ALPHABETICAL INDEX ELECTRICAL SCHEMATICS
60-20
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10-50
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60-50
60-90
10-61 60-100
10-70 60-161
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SPEC-10
30-10
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ALPHABETICAL INDEX
FOREWARD
Publications.
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10-30
10-100
10-110
10-120
10-140
10-141
50-01
50-70
60-01
60-140
60-141
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70-80
SPEC-40
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20-60
20-61
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10-80
60-30
60-80
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10-120 70-10
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10-140
10-141 SPEC-40
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Service Manual

S175 Skid-Steer Loader

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CORRECT CORRECT CORRECT

P-90216 B-15535 B-15524

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Wear dust mask when grinding

B-15733 B-15523 B-6589

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ACCESS PANEL (INSIDE) ..................................... 50-01 ELECTRICAL SYSTEM INFORMATION.................60-01

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CALIBRATION ........................................................ 60-01 HEATER COIL .........................................................80-01

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INSTRUMENT PANELS ..........................................60-01

S175 Service Manual

LIFT ARMS ..........................................................50-01 THERMOSTAT ........................................................ 80-01

MAIN RELIEF VALVE ..............................................20-01 WINDOW (FRONT DOOR) ..................................... 50-01

PASSWORD SETUP (DELUXE INSTRUMENTATION File has expired.

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Use updated files from Bobcat

SEAT BAR ...............................................................50-01

S175 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

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HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

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SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER

I S175 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be

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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.

II S175 Service Manual

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22. Check for any field

III S175 Service Manual

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IV S175 Service Manual

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Use updated files from Bobcat

I-2019-0284 • The Service Manual and Parts Manual are available

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

V S175 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

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VI S175 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

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