Service Manual T650 Compact Track Loader: S/N A3P011001 & Above S/N A3P111001 & Above

Service Manual
T650 Compact Track Loader
S/N A3P011001 & Above

S/N A3P111001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6987172 (8-11) Printed in U.S.A. © Bobcat Company 2011

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 NA1711 NA1715

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
NA1714 NA1710 NA1712

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1722 NA1725 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.
MSW40-0609
1-1 T650 Service Manual

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

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

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

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

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

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

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

the work lights.
FW SSL-1008 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

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

FW SSL-1008 SM

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service. • An Operator’s Handbook fastened to the operator
Untrained operators and failure to follow instructions cab. It’s brief instructions are convenient to the
can cause injury or death. operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine

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

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

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

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-0511 SM

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

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

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

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-0511 SM

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

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

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

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

hot components can contact flammable material, Spark Arrester Exhaust System
explosive dust or gases. The spark arrester 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 arrester exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrester 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-0511 SM

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

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

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

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-0511 SM

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

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-90466
1
The engine serial number is located on the side of the
engine (Item 1) [Figure 3] behind the alternator.
P100008
The loader serial number plate (Item 1) [Figure 1] is

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

Combination P-90175
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 4
B-16315
The delivery report [Figure 4] must be completed by the

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

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
[1] BUCKET
STEP
BUCKET
STEPS
[2] OPERATOR CAB

LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
TAIL LIGHT NA1669
DOOR [3] TRACKS
NA1670
[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
[3] TRACKS - Optional tracks are available.

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

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

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

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

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

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

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

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

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

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

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4

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

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

External Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1


LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-85425
P-85423
Lift the rear of the loader and install jackstands in the

B-7023A notched area of the frame [Figure 10-10-2].
Figure 10-10-3
WARNING
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 when
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807 P-85424
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the struts [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tracks. Make sure the tracks clear the floor or
any obstacles.
NOTE: The lift arms are raised for photo clarity.

WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
10-10-1 T650 Service Manual

LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
WARNING 1
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

are missing. Using a damaged lift arm support or P-85463A P100009
with missing parts can cause lift arms to drop

causing injury or death. Put jackstands under the rear corners of the loader frame
W-2572-0407
(Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.
DANGER The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-90328
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 BOB-TACH

(HAND LEVER) on Page 50-40-1.) OR (See BOB-TACH P-90567
(POWER) on Page 50-41-1.)
Have a second person install the lift arm support device

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

cylinder rod.

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

device.
Lower the lift arms all the way and stop the engine.
Return the lift arm support device to the storage position

and secure with clamping knobs.
Remove the jackstands.
P100005
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure
10-20-3]. The tabs of the lift arm support device must go
past the end of the cylinder (Inset) [Figure 10-20-3].

OPERATOR CAB
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 all parts.
ROPS / FOPS - Roll Over Protective Structure per ISO

3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
Level I
Protection from falling bricks, small concrete blocks,

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

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

OPERATOR CAB (CONT’D)
Raising WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See LIFT ARM • STOP ENGINE before raising or lowering cab.
SUPPORT DEVICE on Page 10-20-1.) W-2758-0908
Figure 10-30-1
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.
Figure 10-30-3
P-85463A
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
Hardware Installed Hardware Removed P-90564A
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P-90512A P-90511A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONT’D) Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-4]. Remove your hand
Lowering from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Always stop the engine before raising or lowering the all the way down.
operator cab.
NOTE: Always use the grab handles to lower the

operator cab. WARNING
Figure 10-30-4
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
Hardware Removed Hardware Installed
N-20120 P-90565A
Pull down on the bottom of the operator cab until it stops

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

when equipped with options and accessories P-90511A P-90512A
such as cab door, heater, air conditioning,

etc. In these cases, the operator cab may need Install the washers and nuts (both sides) [Figure 10-30-
to be raised slightly from the latch to be able 5].
to release the latch.
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
WARNING
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.

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
openings. Install the Special Applications Kit to
3 provide added operator protection in these
applications.
S3999A W-2737-0508
Figure 10-30-8
1
2
P-68116
P-68115
The cab door has a sensor (Item 1) [Figure 10-30-6]

installed which deactivates the lift and tilt valves when the
door is open.
A decal is located on the latch mechanism (Item 2) NA1026
[Figure 10-30-6].
Available for special applications to restrict material from
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]
entering cab openings. Kit includes 12,7 mm (0.50 in)
will be OFF when the door is closed, the key switch is
thick polycarbonate front door and polycarbonate rear
turned to RUN or the RUN button is pressed, the seat bar
window [Figure 10-30-8].
is lowered and the PRESS TO OPERATE LOADER
button is pressed.
Polycarbonate top window (standard item) must be
installed for special applications to restrict material from
Figure 10-30-7
entering cab openings.
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.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] • Do not clean with metal blades or scrapers.
will be ON when the door is open, the key switch is
turned to RUN or the RUN 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].

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

Rear Tie Down Front Tie Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P-85616A
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1
P-90559C
Alternate Rear Tie Down Alternate Front Tie Down
1
P-90558C
P-85466
P-85717A P-85599A
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie down

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

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

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

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

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

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

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

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

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
2
2
1
1
P-85728
Loaders equipped with an attachment harness (Item 1)

P16114 must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Remove the service tool harness (Item 1) from the cover Connect the service tool harness to the ACD connector
(Item 2) [Figure 10-60-3]. and the loader harness connector.
Figure 10-60-4 NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.
P-85729
Remove the cap (Item 1) [Figure 10-60-4] from the

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

harness connector.

REMOTE START TOOL-MEL1563 (CONT'D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The service tool harness communicator (Item 1) is P16115

required to connect remote start tool to the Service PC
(Item 2) [Figure 10-60-6].
The remote start tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
1
P-85728
Figure 10-60-11
P-85729
Figure 10-60-9
1
P-85726
Connect the remote start tool to the engine harness

P-85728
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the remote start tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-13
WARNING 2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
P16118
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit. The traction lock switch (Item 1) [Figure 10-60-13] is
• Remove the operator panel key (key switch), lock used to turn traction lock ON or OFF. Push the switch to
the keypad with a unique password (keyless) or the override position. The switch will illuminate to indicate
otherwise disable the starter before working in traction lock OVERRIDE, in this position the wheels are
the engine area. able to turn.
W-2457-1110
The maximum flow / variable flow switch (Item 2) [Figure
Figure 10-60-12 10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when checking pressures and flow rate.
NOTE: With the engine running; pushing and holding

the pressure release switch (Item 3) [Figure
1 10-60-13] will cause the engine to stop.
WARNING
P16116
• Use traction lock override switch for service
work with seat bar raised.
• Traction lock is engaged when light is OFF.
The remote start tool (Item 1) [Figure 10-60-12] has
• Lift and block the loader. Check that wheels are
three rocker switches.
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

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

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-14].

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

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

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

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

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

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
The RUN button (Item 3) [Figure 10-61-2] is used to turn

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

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

7003031 (CONT'D)
2
Loader Service Tool Harness - 6689747
Figure 10-61-3
1
1
P-85725
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace
3] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].
Figure 10-61-4
P-85729
Loaders without an attachment control harness, remove

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7003031 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
1
2
P-76450
P-85726 The computer service tool harness (Item 1) [Figure 10-

61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

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

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

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

7003031 (CONT'D)
Remote Start Procedure
WARNING
Replaced by W-2457
W-2357-1110
The tool listed will be needed to do the following

procedure:
P-85729
7003031: Remote Start Tool (Service Tool) Kit
Loaders without an attachment control harness, remove
Figure 10-61-8
the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
NOTE: When using a Remote Start Tool (Service tool)

1
harness on loaders not equipped with an
attachment control device, the Remote Start
Tool (Service Tool) harness attachment
control device connector must be capped.
Figure 10-61-10
P-76450

10-61-8] is required when the operator cab is in the
raised position for service and the service technician
needs to turn on the loader or start the engine. Example: 1
adjusting the steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and P-85725
install an approved lift arm support device.
Raise the operator cab (if required by the procedure). Loaders with an attachment control harness (7 pin or 14
pin), the attachment harness (Item 1) must be
Open the rear door of the loader. disconnected from the loader harness (Item 2) [Figure
10-61-10].
When the remote start procedure is completed, replace

the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
harness.

7003031 (CONT'D)
2
Figure 10-61-11
5 3
2
1 6 4
P-76439

10-61-12] has five buttons.
P-85726
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when checking pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7003031 (CONT'D)
Figure 10-61-13
1 2
P-85311
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

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

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

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

[5] [5] [5]
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, Lift Links, Cylinders, Lubricate with multipurpose lithium based grease.
Bob-Tach, Pivot Pins, Wedges
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS™) bar raised. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Tracks Check for damaged and worn tracks and correct tension. [1]
Track Sprocket Nuts Check torque. Tighten as needed. See procedure in this manual.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Spark Arrester Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, air Check condition. 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. [2] [3]
Hydraulic Charge Filter, Replace the charge filter and the reservoir breather.
Hydraulic Reservoir Breather
Hydrostatic Drive Motors Replace oil with high performance synthetic oil P/N 7003026.
Hydraulic / Hydrostatic Filter Replace the hydraulic / hydrostatic filter.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. [4]
Coolant Replace the coolant Every 2 years
[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Perform at first 500 hours, then as scheduled.
[5] Or every 12 months.

AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-2
Figure 10-80-1
3 1 2
P-76460G
P100072
It is important to change the air filter element only when

necessary. The service indicator (Item 1) will FLASH. Open the latches (Item 1) and remove the dust cover
Press the information button (Item 3) until the display (Item 2) [Figure 10-80-2].
screen (Item 2) shows the service codes. Service code
[M0117] (Air Filter Plugged) will show in the display Figure 10-80-3
screen (Item 2) [Figure 10-80-1] when air filter change is
necessary.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
P-90523A
Pull the outer filter element (Item 1) [Figure 10-80-3] out

and discard.
NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air.
Install new filter element. Push all the way in until it

contacts the base of the housing.
Install the dust cover and secure the latches [Figure 10-
80-2].

AIR CLEANER SERVICE (CONT’D) Figure 10-80-5
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the 1 2

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

engine and run at full rpm. If service code [M0117]
(Air Filter Plugged) is still displayed in the data
display, replace the inner filter element. P100072
Remove the dust cover [Figure 10-80-2] and the outer

filter element [Figure 10-80-3]. Install the dust cover (Item 2) and secure the latches
(Item 1) [Figure 10-80-5].
Figure 10-80-4
P-90524A
Remove the inner filter element (Item 1) [Figure 10-80-

4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air.
Install new inner filter element. Push all the way in until it
contacts the base of the housing.
Install the outer filter element [Figure 10-80-3].

ENGINE COOLING SYSTEM Loaders With Air Conditioning
Check the cooling system every day to prevent over- Figure 10-90-2
heating, loss of performance or engine damage.
Maintenance Platform 1
Figure 10-90-1
2 2
1
P100180
Use low air pressure or water pressure to clean the top of

the air conditioning condenser (Item 1) [Figure 10-90-2].
P100040A
The area between the air conditioning condenser and the
oil cooler will require occasional cleaning. Remove the
A maintenance platform (Item 1) [Figure 10-90-1] is bolts (Item 2) and the brackets (Item 3) [Figure 10-90-2].
available from your Bobcat dealer to facilitate access
when cleaning the engine cooling system. Figure 10-90-3
WARNING 1

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
2
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P100056A
Cleaning
Open the rear door. (See REAR DOOR (TAILGATE) on NOTE: Be careful when raising and lowering the air
Page 50-70-1.) conditioning condenser so that the air
conditioning condenser does not fall on the
Remove the rear grille. (See REAR GRILLE on Page 50- oil cooler and damage the fins.
60-1.)
Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the
oil cooler (Item 2) [Figure 10-90-3].
Lower the air conditioning condenser (Item 1) [Figure 10-

90-3]. Install the brackets (Item 3) [Figure 10-90-2] and
the bolts (Item 2) [Figure 10-90-2].

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Unhook the two rubber straps (Item 2) [Figure 10-90-4].
Loaders Without Air Conditioning Figure 10-90-5
Figure 10-90-4
1 1
2
3
2
P100179
P100181
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into the last position to support the oil cooler. Use low air
Use low air pressure or water pressure to clean the top of pressure or water pressure to clean the top of the radiator
the oil cooler (Item 1) [Figure 10-90-4]. (Item 3) [Figure 10-90-5].
Raise the bar (Item 2) [Figure 10-90-5] slightly and lower

the oil cooler. Fasten the two rubber straps.
Check the cooling system for leaks.
Install the rear grille and close the rear door.

ENGINE COOLING SYSTEM (CONT’D)
Checking Level
Open the rear door and raise the rear grille.
Figure 10-90-6
P-90529B
Check coolant level using the level markers (Item 2)

[Figure 10-90-6] on the tank. Coolant must be between
top and bottom level markers when the engine is cold.
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Lower the rear grille and close the rear door.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

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

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

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

Removing And Replacing Coolant
For the service interval for replacing the engine

coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door and remove the rear grille.
Remove the coolant fill cap (Item 1) [Figure 10-90-6].
Figure 10-90-7
P-85606
Disconnect the coolant hose (Item 1) [Figure 10-90-7]

from the oil filter assembly. Drain the coolant into a
container. Connect the coolant hose to the oil filter
assembly. Recycle or dispose of coolant in an
environmentally safe manner.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-4.)
The correct mixture of coolant to provide a -37°C (-34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Add premixed coolant, 47% water and 53% propylene

glycol to the coolant tank until the coolant level reaches
the lower marker on the tank [Figure 10-90-6].
Install the coolant fill cap.
NOTE: When installing the coolant fill cap, the cap

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

the engine. Check the coolant level when cool. Add
coolant as needed.
Install the rear grille and close the rear door.

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

At a minimum, low sulfur diesel fuel must be used in this
as cleaning the fuel system and replacing fuel filters
machine. Low sulfur is defined as 500 mg/kg (500 ppm)
and fuel lines.
sulfur maximum.
• Using biodiesel blended fuels containing more than
The following fuels may also be used in this machine:
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Ultra low sulfur diesel fuel. Ultra low sulfur is defined
pump and seals.
as 15 mg/kg (15 ppm) sulfur maximum.
Apply the following guidelines if biodiesel blend fuel is
• Biodiesel blend fuel - Must contain no more than five
used:
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
• Ensure the fuel tank is as full as possible at all times
marketed as B5 blended diesel fuel. B5 blended
to prevent moisture from collecting in the fuel tank.
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,

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

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

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

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

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

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Open the rear door. NA1726
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
1 free movement of air and no open flames or sparks NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1].
Close the rear door.
WARNING
P100006
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the fill cap (Item 1) [Figure 10-100-1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

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

Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
2
Figure 10-100-4
1
P-85508
Loosen the drain (Item 1) [Figure 10-100-3] at the 1 2

bottom of the filter element to remove water from the
filter.
Replacing Element
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
P-85507
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 1) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
WARNING Close the vent (Item 2) [Figure 10-100-4].
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil 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)
P-85506
Park the machine on level ground. Open the rear door TEMPERATURE RANGE ANTICIPATED BEFORE
and remove the dipstick (Item 1) [Figure 10-110-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick. Do [1]Synthetic Oil - Use recommendation from Synthetic Oil
not overfill. Manufacturer.
Use good quality engine oil that meets API Service

Classification of CI-4 or better [Figure 10-110-2].
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Install and tighten the oil drain cap [Figure 10-110-4].
Removing And Replacing Oil And Filter Install the cover and the cover mounting bolts [Figure 10-
110-3]. Tighten all bolts.
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-110-5
Run the engine until it is at operating temperature. Stop

the engine.
Figure 10-110-3 2
1
P-85506
2
Open the rear door, remove the oil filter (Item 3) [Figure
10-110-5] and clean the filter housing surface.
3 P-90497A
P-90499A
Use genuine Bobcat filter only.
The oil drain hose is located behind a cover under the Put oil on the new filter gasket, install the filter and hand
right rear corner of the loader (Inset) [Figure 10-110-3]. tighten.
Remove two cover mounting bolts (Item 1) [Figure 10- Remove the oil fill cap (Item 1) [Figure 10-110-5].
110-3].
Put oil in the engine. For the correct quantity (See
Loosen one cover mounting bolt (Item 2) [Figure 10-110- Capacities on Page SPEC-10-4.) Do not overfill.
3] and slide the cover (Item 3) to the rear of the loader.
Start the engine and let it run for several minutes. Stop
Figure 10-110-4 the engine and check for leaks at the filter.
Remove the dipstick (Item 2) [Figure 10-110-5] 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.
WARNING
1 AVOID INJURY OR DEATH
P-90498A
explosion or fire.
Remove the oil drain cap (Item 1) [Figure 10-110-4] from W-2103-0508
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3
Check the hydraulic / hydrostatic fluid level every day 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
place the attachment flat on the ground or tilt the Bob-
Tach fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [2] VG 46; Minimum VI 150
[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
P100010
prevent oxidation and thermal breakdown at operating
temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1]. Keep the fluid level within the operating range. Use only recommended fluid in the hydraulic system
[Figure 10-120-3]. (See Hydraulic System on Page
Remove the rear grille. (See REAR GRILLE on Page 50- SPEC-10-3.)
60-1.)
Figure 10-120-2
WARNING
1 Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508
P100055
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-120-1].
Install the fill cap (Item 1) [Figure 10-120-2] and install

the rear grille.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after 1

major repair.
2
Always replace the hydraulic / hydrostatic filter and the
hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.)
Remove the rear grille. (See REAR GRILLE on Page 50- P100179
60-1.)
Figure 10-120-4 Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into the last position to support the oil
cooler. This will aid in draining the hydraulic fluid.
Figure 10-120-6
1
1
P100055
P100007
Remove the right side access cover bolts (Item 1)

[Figure 10-120-6] and remove the cover. (Lift arms
shown raised for visual clarity.)
P100181
Remove the hydraulic fill cap (Item 1) and unhook the two
rubber straps (Item 2) [Figure 10-120-4].

Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-120-7
1
P-90506
Remove and clean the hydraulic fill screen (Item 1)

P-85721 [Figure 10-120-8]. Use low air pressure to dry the
screen.
Remove the clamp (Item 1). Pinch off the hose (Item 2) Install hydraulic fill screen and add the correct fluid to the
[Figure 10-120-7] near the fitting and disconnect hose reservoir until the fluid level is within the operating range
from the fitting. Route the hose out the side of the loader of the sight gauge. (See Capacities on Page SPEC-10-
and drain the fluid into a container. 4.) and (See Checking And Adding Fluid on Page 10-
120-1.)
Connect the hose to the cooling fan motor when the fluid
stops draining. Install the hydraulic fill cap.
Recycle or dispose of used fluid in an environmentally Install the rear grille.

safe manner.
Start the engine and operate the loader hydraulic
controls.
WARNING Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)
explosion or fire.
W-2103-0508
Install the side access cover.
Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps.

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

Filter
For the correct service interval (See SERVICE

Remove the rear grille. (See REAR GRILLE on Page 50-

60-1.)
The filter housing is located behind the hydraulic fluid

reservoir.
1
Clean the top of the filter housing.
Figure 10-120-9
Earlier Model Later Model P-90500
Remove the filter (Item 1) [Figure 10-120-10] using a

socket wrench.
Figure 10-120-11
P-90500A P100047A
Two types of filters are used on this model loader [Figure

10-120-9]. Select the correct procedure for your machine.
P-85478
Discard the entire filter (Item 1) [Figure 10-120-11].
Clean the surface of the filter housing where the filter

seal contacts the housing.
Install new filter and tighten to 61 N•m (45 ft-lb) torque.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) All Models
Removing And Replacing Hydraulic / Hydrostatic

Filter (Cont’d)
Later Models
WARNING
Figure 10-120-12 AVOID INJURY OR DEATH
explosion or fire.
W-2103-0508
Install the rear grille.

controls.
1
P100047
WARNING
Remove the filter cap (Item 1) [Figure 10-120-12]. Diesel fuel or hydraulic fluid under pressure can
Figure 10-120-13 death. Fluid leaks under pressure may not be visible.
1 from a physician familiar with this injury.
W-2072-0807
Stop the engine and check for leaks at the filter.

2 P100044 P100046
Remove the filter element (Item 1) [Figure 10-120-13]

and discard.
Remove the O-ring (Item 2) [Figure 10-120-13] and

discard.
Install new O-ring and lubricate with clean oil.
Install new filter element ensuring that element is fully

seated in the housing.
Install the filter cap and tighten to 25 N•m (18 ft-lb)

torque.

Removing And Replacing Hydraulic Charge Filter
The hydraulic charge filter is located under the operator

cab. For the correct service interval (See SERVICE
1
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 10-120-14
1
P-85489A
2 Remove and discard the filter element (Item 1) [Figure

10-120-16].
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
P-85470 the element on the filter base. Install and tighten the filter
housing to 47 - 54 N•m (35 - 40 ft-lb) torque.
Unhook the rubber straps (Item 1) and remove the lower

fan duct (Item 2) [Figure 10-120-14].
Figure 10-120-15
WARNING
explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-120-14].
NOTE: Failure to install the lower fan duct correctly

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

P-85489 3.)

Place a suitable container below the filter housing and controls.
remove the filter housing (Item 1) [Figure 10-120-15]
using a socket wrench.
Recycle or dispose of used fluid in an environmentally

safe manner.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Removing And Replacing Hydraulic Charge Filter See the SERVICE SCHEDULE for the correct
(Cont’d) replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-

WARNING 60-1.)
Figure 10-120-17
enters skin or eyes, get immediate medical attention 1
W-2072-0807
Stop the engine and check for leaks at the filter.

P100055
Remove the breather cap (Item 1) [Figure 10-120-17]

and discard.
Install new breather cap.
Install the rear grille.

BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) must contact the lower
edge of the holes in the attachment mounting frame (Item
Inspection And Maintenance 2) [Figure 10-130-2].
Figure 10-130-1 If the wedges do not contact the lower edge of the holes
[Figure 10-130-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-130-3
P-85513A
Move the Bob-Tach levers down to engage the wedges

[Figure 10-130-1].
The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208
Figure 10-130-2
1 B-17460
2 Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-130-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Wedge must contact lower
edge of hole in the Look for cracked welds. Contact your Bobcat dealer for
attachment mounting repair or replacement parts.
frame.
Lubricate the wedges. (See SERVICE SCHEDULE on
P-31233A P-31233 Page 10-70-1.) (See LUBRICATING THE LOADER on
Page 10-140-1.)
The wedges (Item 1) [Figure 10-130-2] must extend
through the holes in the attachment mounting frame.

BOB-TACH (POWER) Figure 10-131-2
This machine may be equipped with a Power Bob-Tach.

1
Inspection And Maintenance
Figure 10-131-1 2
1 Wedge must contact lower

edge of hole in the
attachment mounting
frame.
P-31233A P-31233
2 The wedges (Item 1) [Figure 10-131-2] must extend

through the holes in the attachment mounting frame.
P-85320A The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-131-2].
Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure [Figure 10-131-2], the attachment will be loose and can
10-131-1] until the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208

BOB-TACH (POWER) (CONT’D)
Inspection And Maintenance (Cont’d)
Figure 10-131-3
B-17460
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-131-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

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

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)

LUBRICATING THE LOADER Figure 10-140-2
Lubrication Locations
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 2
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader.
Tilt the Bob-Tach forward until it contacts the ground (not
P-90572A
required on later models with Bob-Tach wedge grease
fittings that are accessible from the side).
2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-
Stop the engine. 140-2].
Lubricate the following:
Figure 10-140-3
Figure 10-140-1
1 3
P-90543A
P100011
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-140-3].

1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-
140-1].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-6
Lubrication Locations (Cont’d)
Figure 10-140-4
P-85720
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-90542A 140-6].
Figure 10-140-7
4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-140-4].
Figure 10-140-5
5
7
P-85719
P-85484 7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-

7].
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

140-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-10
Lubrication Locations (Cont’d)
Earlier Models
9
Figure 10-140-8
8
P100012
9. Rear Control Link (Both Sides) (2) [Figure 10-140-

10].
P-85487 Figure 10-140-11
Later Models
Figure 10-140-9
10
8 P-90544A
10. Front Control Link (Both Sides) (2) [Figure 10-140-

11].
P-31308A
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-140-8]

or [Figure 10-140-9].

SPARK ARRESTER MUFFLER
Cleaning Procedure WARNING

See the SERVICE SCHEDULE for service interval for
cleaning the spark arrester muffler. (See SERVICE When the engine is running during service, the
SCHEDULE on Page 10-70-1.) driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
Do not operate the loader with a defective exhaust cause injury or death.
system. W-2006-1209
Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
IMPORTANT wood over the outlet of the muffler.
This machine is factory equipped with a U.S.D.A. This will force contaminants out through the cleanout
Forestry Service approved spark arrester exhaust hole.
system.
Stop the engine.
The spark arrester muffler, if equipped, must be
cleaned to keep it in working condition. The spark Install and tighten the plug. Close the rear door.
arrester muffler must be serviced by dumping the
spark chamber every 100 hours of operation.
On some models, the turbocharger functions as the WARNING

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

WARNING
Figure 10-150-1 Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
1
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
P-85509 cause injury or death.
W-2068-1285
Remove the plug (Item 1) [Figure 10-150-1] from the

bottom of the muffler.

PIVOT PINS
Inspection And Maintenance
Figure 10-160-1
P100004
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-1].
Check that the lock nuts are tightened to 48 - 54 N•m (35

- 40 ft-lb) torque.

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

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
loader for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.
• Lubricate the loader. • Remove grease from exposed cylinder rods.
• Replace worn or damaged parts. • Check all belt tensions.
• Park the loader in a dry protected shelter. • Be sure all shields and guards are in place.
• Lower the lift arms all the way and put the bucket flat • Lubricate the loader.
on the ground.
• Check track condition and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tracks.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.
• Start the engine and let run for a few minutes while
• Put fuel stabilizer in the fuel tank and run the engine observing the instrument panels and systems for
a few minutes to circulate the stabilizer to the pump correct operation.
and fuel injectors.
• Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the
following: • Stop the engine and check for leaks. Repair as
needed.
Drain the fuel tank, refill with 100% petroleum diesel
fuel, add fuel stabilizer and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

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

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

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

condition.

STOPPING THE ENGINE AND LEAVING THE Remove the key from the switch (Standard Key Panel) to
LOADER prevent operation of the loader by unauthorized
personnel.
Procedure
NOTE: Activating the Password Lockout Feature on
Stop the loader on level ground. machines with the Keyless Start Panel or the
Deluxe Instrumentation Panel allows
Fully lower the lift arms and put the attachment flat on the operation of the loader without using a
ground. password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Figure 10-180-1 Feature on Page 60-191-1.)
Figure 10-180-3
P-85737A P-85735A
P-90525A
Exit the loader using grab handles, safety tread and steps
Push the engine speed control fully down [Figure 10- (maintaining a 3-point contact) [Figure 10-180-3].
180-1] to decrease the engine speed.
Engage the parking brake.
Figure 10-180-2 WARNING

1 AVOID INJURY OR DEATH
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
2 • Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
P-90688A P-90214A drive functions are deactivated.
The seat bar system must deactivate these functions

Turn the key switch to the STOP position (Item 1) or when the seat bar is up. See your Bobcat dealer for
press the STOP button (Item 2) [Figure 10-180-2]. service if controls do not deactivate.
W-2463-1110
NOTE: If the loader lights are ON, they will remain ON
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.

EMERGENCY EXIT Figure 10-190-3
The front opening on the operator cab and rear window

provide exits.
External Access
Figure 10-190-1
P-90563A
Exit through the rear of the operator cab [Figure 10-190-

3].
Front Door
P-85724
This machine may be equipped with a front door.
The rear window can be removed from outside the loader NOTE: Use this procedure to remove the front door
using a T40 TORX® driver. Turn both screws (Item 1) only under emergency conditions. Damage to
[Figure 10-190-1] in until the latches disengage from the machine may occur.
window frame. Pull the top of the window away from the
cab and lift up to remove. Figure 10-190-4
Rear Window
NOTE: Use this procedure to remove the rear window

only under emergency conditions. Damage to
machine may occur.
1
Figure 10-190-2
P-90725
Turn both latches (Item 1) [Figure 10-190-4] down until

they disengage from the door frame.
Push the door out of the operator cab door frame.
P-85309A Exit through the opening.
Turn both latches (Item 1) [Figure 10-190-2] in until they

disengage from the window frame.
Push the rear window out of the rear of the operator cab.

EMERGENCY EXIT (CONT’D) Figure 10-190-7
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-190-5
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-190-7] on the door. (Bottom
hinge shown)
2
Figure 10-190-8
P-85781A
1
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 10-190-5]. 2
Figure 10-190-6
2
3
P-90686A
Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
1 against door and rotate latch (Item 1) [Figure 10-190-8]
up to lock cast washer into place. (Bottom hinge shown)
(Plastic cap shown removed for clarity)
P-85588A P-85589A Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
Rotate and pull the clip (Item 1) out of the gas spring the clip into the hole in the gas spring socket. Rotate the
socket. Pull the gas spring socket (Item 3) straight off the clip to lock into place [Figure 10-190-6].
ball stud fitting (Item 2) [Figure 10-190-6].
Connect electrical connector (Item 2) and washer fluid
Remove the door hinges from the loader. hose (Item 1) [Figure 10-190-5].

SEAT BELT Figure 10-200-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

unusual wear, significant discolourations due to
ultraviolet UV exposure, dusty / dirty conditions, abrasion
to the seat belt webbing, or damage to the buckle, latch
plate, retractor (if equipped), hardware or any other
obvious problem should be replaced immediately.
B-22283
The items below are referenced in [Figure 10-200-1].
1. Check the webbing. If the system is equipped with a

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

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

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

rays from the sun or extreme dust or dirt. If the original
colour 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.

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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-10
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

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

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
T650 (S/N A3PO11001 AND ABOVE)
(S/N A3P111001 AND ABOVE)
(PRINTED NOVEMBER 2010)
V-1352legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 33 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal)
PRESSURE RELEASE (SAPR)
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal)
17 SOLENOID ACTIVATED DIRECTIONAL
2 SIGHT GUAGE CONTROL VALVE - BICS CONTROL 34 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – BRAKE VALVE
18 FILTER - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH:
(SCREEN) 35 FILTER – BRAKE VALVE
103 kPa (1,03 bar) (15 psi)
Normally Closed 19 CHECK VALVE - With 100 kPa (1,0 bar) 36 CHECK VALVE
(14.5 psi) Spring
4 FILTER - HYDRAULIC (CANISTER)
20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 37 CHARGE PUMP -
5 SPRING LOADED FILTER BY-PASS 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
VALVE: 172 kPa (1,7 bar) (25 psi) 21 PULL BUTTON ACTIVATED
38 HYDRAULIC PUMP . . . . . . . Gear Type
6 DIAGNOSTIC COUPLER DIRECTIONAL CONTROL VALVE - LIFT
87,1 L/min (23.0 U.S gpm) at High Engine Idle
ARM BY-PASS
39 VARIABLE CAPACITY DISPLACEMENT
7 RELIEF VALVE - MAIN: 22 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers 23 PROPORTIONAL RELIEF VALVE –
40 RELIEF/REPLENISHING VALVE - HIGH
8 RELIEF/ANTICAVITATION VALVE - (Fan Speed Regulator): 10797 – 12300 kPa PRESSURE: 36500 kPa (365 bar) (5294 psi)
PORT: 27579 kPa (276 bar) (4000 psi) (108 - 123 bar) (1566 - 1784 psi)
41 RELIEF VALVE - CHARGE INLET:
9 RELIEF/ANTICAVITATION VALVE - 24 SPRING LOADED FILTER BY-PASS VALVE: 3206 kPa (32, bar) (465 psi)
PORT (OPTIONAL): 27579 kPa
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) at High Engine Idle
(276 bar) (4000 psi)
With 60 ° C (140 ° F) Fluid
10 SOLENOID ACTIVATED DIRECTIONAL 25 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR 42 CHECK VALVE – COLD WEATHER BY-PASS
CONTROL VALVE - AUXILIARY
With 345 kPa (3,45 bar) (50 psi) Spring
11 LOAD CHECK VALVE 26 FILTER - HYDRAULIC (CANISTER)
12 ANTICAVITATION VALVE 27 SENSOR – CHARGE PRESSURE –

Fan Filter
13 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – HYD. TEMPERATURE
RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 29 RESTRICTION - 2,0 mm (0.079 inch)
14 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 30 CHECK VALVE - With 1400 kPa (14,0 bar)
(203 psi) Spring
15 PILOTED ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - TILT CONTROL
32 FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC NOTE: Unless otherwise specified
MOTOR springs have NO significant
pressure value.
Printed in U.S.A. V-1352legend (11-30-10)
INTEGRATED COUPLER BLOCK
14
DRIVE MOTOR Male
30 L
OUT
29 Male
31 HYDRAULIC CONTROL VALVE
14
Female
9
10
10
33 32 Auxiliary Spool
Z TILT
CYLINDERS
8
A B
11
BICS CONTROL VALVE

HYDROSTATIC PUMP
Tilt Spool
35
42 8 15
12
11
M4 M
3
16
D C
Lift Spool
40 40
Charge
Inlet 8 LIFT
CYLINDERS
41 40 13 20
11 18 18
B A 19 17 ?
IN 2
M M1 7
2 6
40
1
T 21
39
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER Oil Cooler RESERVOIR (VENTED)
2
38
5 1
37 26 24 3
4
27
BRAKE VALVE - PUMP
SPRING APPLIED SUPPLY
PRESSURE 33 WORKING
B
CIRCUIT
RELEASE (SAPR) A HYDRAULIC FILTER
PILOT
PRESSURE
3 25 22 DRAIN /
Z RETURN
36 2
P DR 23
35 32
35
1
34
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
31
29 WITH NO OPTIONS
30 T650 (S/N A3PO11001 & ABOVE)
L
(S/N A3P111001 & ABOVE)
DRAIN / RETURN MANIFOLD
DRIVE MOTOR Printable Version Click Here
7170814
PRINTED IN U.S.A.
WITH ALL OPTIONS
T650 (S/N A3P011001 – A3P011494)
(S/N A3P111001 – A3P111115)
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) 57 DRIVE MOTOR SHUTTLE VALVE
36
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 41,6 L (11.0 U.S. ARM BY-PASS 37 CHECK VALVE - With 552 kPa) (5,5 bar) 58 FIXED CAPACITY DISPLACEMENT
gal) (80 psi) Spring BIDIRECTIONAL HYDROSTATIC
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO MOTOR
RESTRICT FLOW DURING BOOM 38 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi)
3 DIFFERENTIAL PRESSURE SWITCH: 59 HYDRAULIC BRAKE – SPRING APPLIED –
DOWN BUT NOT DURING BOOM UP 39
103 kPa (1,03 bar) (15 psi) CHECK VALVE - With 2068 kPa (20,7 bar) (300 PRESSURE RELEASE (SAPR)
21 ANTICAVITATION VALVE
Normally Closed psi) Spring And With 0,40 mm (0.016 in) Orifice
60 SOLENOID ACTIVATED DIRECECTIONAL
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,6 mm (0.025 in)
CONTROL VALVE – BRAKE
(Fan Speed Regulator): 10797 – 12300 kPa 41 FILTER – BOB-TACH VALVE FILTER – BRAKE VALVE
5 SPRING LOADED FILTER BY-PASS 61
(108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 42 HYDRAULIC PUMP . . . . . . . Gear Type
23 SPRING LOADED FILTER BY-PASS VALVE: 62 CHECK VALVE
87,1 L/min (23.0 U.S. gpm) at High Engine Idle
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
43 CHARGE PUMP - 63 HIGH FLOW HYDRAULIC PUMP Gear Type
24 FIXED CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
7 RELIEF VALVE - MAIN: 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
HYDRAULIC MOTOR
24132 kPa (241 bar) (3500 psi) 44 PILOT ACTIVATED DIRECTIONAL 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers CONTROL VALVE - REAR AUXILIARY
8 RELIEF/ANTICAVITATION VALVE - 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 65 DUMP VALVE – ON / OFF
26 SENSOR – CHARGE PRESSURE –
PORT: 27579 kPa (276 bar) (4000 psi) Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL (5.0 psi) Spring
PORT (OPTIONAL): 27579 kPa CONTROL VALVE - BUCKET POSITION 47 RESTRICTOR - 0,8 mm (0.031 in)
(276 bar) (4000 psi) VALVE (ON/OFF) 67 FRONT AUXILIARY MANUAL PRESSURE
FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28
CONTROL VALVE - AUXILIARY 68 SENSOR – HYD. TEMPERATURE
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE CONTROL VALVE - BASE
CONTROL VALVE - FLOW CONTROL 69 RIDE CONTROL VALVE
12 ANTICAVITATION VALVE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL
30 CHECK VALVE - BUCKET POSITION 70 HIGH PRESSURE CHAMBER
CONTROL VALVE - ROD
13 PILOTED ACTIVATED DIRECTIONAL VALVE 51 VARIABLE CAPACITY DISPLACEMENT 71 LOW PRESSURE CHAMBER
31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - LIFT CONTROL
SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi)
32 PILOT ACTIVATED DIRECTIONAL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL
CONTROL VALVE - HYDRAULIC 3206 kPa (32, bar) (465 psi)
16 FILTER - BICS CONTROL VALVE
POWERED BOB-TACH at High Engine Idle
(SCREEN) With 60 ° C (140 ° F) Fluid
33 FILTER - BOB-TACH VALVE
17 54 CHECK VALVE – COLD WEATHER BY-PASS
CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring 34 RESTRICTION - 2,26 mm (0.089 in) With 345 kPa (3,45 bar) (50 psi) Spring
55 RESTRICTION - 2,0 mm (0.079 in)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1400 kPa (14,0 bar) springs have NO significant
(203 psi) Spring pressure value.
67
Male
DRIVE MOTOR Male

67
56 L
Female
57 55 HIGH FLOW VALVE (OPTIONAL)
BUCKET POSITIONING VALVE (OPTIONAL)
65 OUT D
HYDRAULIC CONTROL VALVE 29 30
66
31
64 28
?
REAR AUXILIARY COUPLERS (OPTIONAL)

9
58 A
C
10
FEMALE MALE 27
10 ?
Auxiliary Spool
Z
59 Base
? Rod ? 6
A B
48
B TILT
50 CYLINDERS
8
49 11
HYDROSTATIC PUMP 46
? ? BICS CONTROL VALVE
51 Tilt Spool
54
47
8 13
12
M4
45 11
M
3
LIFT
D C CYLINDERS
44 14
P - in P - out T
REAR AUXILIARY
52 VALVE (OPTIONAL)
52
Lift Spool
Charge
Inlet BOB-TACH CYLINDER 8
(OPTIONAL) RIDE CONTROL
53 18 (OPTIONAL)
20
BOBTACH VALVE 11 16 16
B A 41 (OPTIONAL) 17 15 ?
37 IN
M M1 41 38 7
2
2 36 6
69
DUAL STAGE
ACCUMULATOR
52 52 1
39
19
51 35
? ?
71 70
34 40 PP
DR Oil Cooler RESERVOIR (VENTED)
T 2
5
P1 P2 1
42 33 32 4
43 VARIABLE SPEED HYDRAULIC 3

FAN MOTOR W/ INTEGRATED FILTER
HYDRAULIC FILTER
63
25 23
BRAKE VALVE - PUMP
SUPPLY
SPRING APPLIED 26
WORKING
PRESSURE 59 CIRCUIT
RELEASE (SAPR)
B A PILOT
PRESSURE
3 DRAIN /
Z 24 21 RETURN
2
62
58 P DR 22
61 61
1
60
STANDARD WITH ALL OPTIONS
57 68
55 T650 (S/N A3P011001 - A3P011494)
56 (S/N A3P111001 - AP3111115)
L
Printable Version Click Here
DRIVE MOTOR DRAIN / RETURN MANIFOLD (PRINTED NOVEMBER 2010)
7170814
PRINTED IN U.S.A.
WITH ALL OPTIONS
T650 (S/N A3P011495 AND ABOVE)
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) 57 DRIVE MOTOR SHUTTLE VALVE
36
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 37 CHECK VALVE - With 552 kPa) (5,5 bar) 58 FIXED CAPACITY DISPLACEMENT
(80 psi) Spring BIDIRECTIONAL HYDROSTATIC MOTOR
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
38 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 59 HYDRAULIC BRAKE – SPRING APPLIED –
3 DIFFERENTIAL PRESSURE SWITCH: PRESSURE RELEASE (SAPR)
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) 21 ANTICAVITATION VALVE 60 PILOT ACTIVATED DIRECTIONAL
psi) Spring And With 0,40 mm (0.016 in) Orifice
Normally Closed CONTROL VALVE – 2 Speed
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,51 mm (0.020 in)
61 FIXED CAPACITY DISPLACEMENT
(Fan Speed Regulator): 10797 – 12300 kPa 41 SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC MOTOR
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 42 RESTRICTION - 0,51 mm (0.020 in) 62 CHARGE PUMP -
23 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
43 HYDRAULIC PUMP . . . . . . . Gear Type
24 FIXED CAPACITY DISPLACEMENT 63 HIGH FLOW HYDRAULIC PUMP Gear Type
7 RELIEF VALVE - MAIN: 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
HYDRAULIC MOTOR 28,4 L/min (7.5 U.S. gal) at High Engine Idle
24132 kPa (241 bar) (3500 psi) 44 PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 25 FILTER - HYDRAULIC (CANISTER) 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - REAR AUXILIARY
8 RELIEF/ANTICAVITATION VALVE -
26 SENSOR – CHARGE PRESSURE – 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 65 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi)
Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
CONTROL VALVE - TWO COIL
PORT (OPTIONAL): 27579 kPa CONTROL VALVE - BUCKET POSITION 67 FRONT AUXILIARY MANUAL PRESSURE
(276 bar) (4000 psi) 47 RESTRICTOR - 0,8 mm (0.031 in)
VALVE (ON/OFF) BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28 FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF SENSOR – HYD. TEMPERATURE
68
CONTROL VALVE - AUXILIARY
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL 69
11 LOAD CHECK VALVE RIDE CONTROL VALVE
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - BASE
12 ANTICAVITATION VALVE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL 70 HIGH PRESSURE CHAMBER
30 CHECK VALVE - BUCKET POSITION CONTROL VALVE - ROD
13 PILOTED ACTIVATED DIRECTIONAL 71 LOW PRESSURE CHAMBER
VALVE 51 VARIABLE CAPACITY DISPLACEMENT
31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE – BRAKE
SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi) 73 FILTER – BRAKE VALVE
32 PILOT ACTIVATED DIRECTIONAL CONTROL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL 74 CHECK VALVE
VALVE – HYDRAULIC POWERED BOB-TACH 3206 kPa (32, bar) (465 psi)
16 FILTER - BICS CONTROL VALVE With Build-up Valve 207 kPa (2,07 bar) (30 psi) at High Engine Idle 75 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) With 60 ° C (140 ° F) Fluid
CHECK VALVE - With 100 kPa (1,0 bar) 33 FILTER - BOB-TACH VALVE CONTROL VALVE – 2 Speed Shift
17 54 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring 76 SOLENOID ACTIVATED DIRECTIONAL
34 RESTRICTION - 2,08 mm (0.08 in) With 345 kPa (3,45 bar) (50 psi) Spring
CONTROL VALVE – 2 Speed Make-up
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 55 RESTRICTION - 1,5 mm (0.06 in)
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1379 kPa 13,8 bar springs have NO significant
(200 psi) Spring pressure value.
INTEGRATED QUICK COUPLER
67 BLOCK (FRONT AUXILIARY LEFT
DRIVE MOTOR Male
L
56 67
55 Male
57 66
Female
OUT
X HYDRAULIC CONTROL VALVE (SPOOL

VALVE) RIDE CONTROL
(FIELD INSTALLED OPTION)
W 70
60
58 REAR AUXILIARY COUPLERS (OPTION) 9
61
FEMALE MALE 10
LIFT CYLINDERS
71
10
Z
BASE
? ROD ?
A 59 B 48
6 69
50
8
49 11
HYDROSTATIC PUMP ? ?
46
BICS CONTROL VALVE
E1 E2 A1 A2
47
E3
27
51
52 52 8
B
28
12
2-SPEED & 13
SPRING 45
11 29
APPLIED M4 ?
M
PRESSURE
RELEASE
3 44 30
BRAKE VALVE D C 14 D2
(OPTIONAL) P in P out
75 T
B A D
72
T 53
73
Charge POWER BOBTACH CYLINDER 31
C2
Inlet (OPTIONAL)
8
BOBTACH VALVE C1 D1
(OPTIONAL)
P 17
20 16
B1 A1 C B A 36 37 11 16 15 ?
41 BUCKET POSITIONING
73 76 18 VALVE (OPTIONAL)
74 IN
74 M M1 39 7
2
2
6
35
19 TILT CYLINDERS
52 52
1
54 38 42
51
D 34 40
OIL COOLER 5 2 RESERVOIR (VENTED)
T
4
43 33 1
32
62
VARIABLE SPEED HYDRAULIC 3

FAN MOTOR W/ INTEGRATED
63 64 65
25 23
? WORKING CIRCUIT
26
CHARGE
PRESSURE
59 DRAIN / RETURN
B A
Z 21
24
P
22
61 58 DR
60 DRAIN/RETURN MANIFOLD
X
68
STANDARD WITH ALL OPTIONS
57 (S/N AP3111116 AND ABOVE)
55
56
L
DRIVE MOTOR
7170814

PRINTED IN U.S.A.
SJC WITH NO OPTIONS
T650 (S/N A3PO11001 AND ABOVE)
LEGEND
1 RESERVOIR: 14 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – CHARGE PRESSURE – 42 HYDRAULIC BRAKE – SPRING APPLIED –
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) RESTRICT FLOW DURING BOOM Fan Filter PRESSURE RELEASE (SAPR)
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) DOWN BUT NOT DURING BOOM UP
29 HYDRAULIC PUMP . . . . . . . Gear Type 43 SOLENOID ACTIVATED DIRECECTIONAL
2 SIGHT GUAGE 15 PILOTED ACTIVATED DIRECTIONAL 87,1 L/min (23.0 U.S. gpm) at High Engine Idle CONTROL VALVE – BRAKE
CONTROL VALVE - TILT CONTROL 44 FILTER – BRAKE VALVE
30 CHARGE PUMP -
3 DIFFERENTIAL PRESSURE SWITCH: 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
16 PILOTED ACTIVATED DIRECTIONAL 45 CHECK VALVE
103 kPa (1,03 bar) (15 psi)
CONTROL VALVE - LIFT CONTROL 31 VARIABLE CAPACITY DISPLACEMENT
Normally Closed
17 BIDIRECTIONAL HYDROSTATIC PUMP
4 FILTER - HYDRAULIC (CANISTER) SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 32 RELIEF/REPLENISHING VALVE - HIGH
5 SPRING LOADED FILTER BY-PASS 18 FILTER - BICS CONTROL VALVE PRESSURE: 36500 kPa (365 bar) (5294 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) (SCREEN) 33 RELIEF VALVE - CHARGE INLET:
19 CHECK VALVE - With 100 kPa (1,0 bar) 2654 kPa (26,5 bar) (385 psi) at High
6 DIAGNOSTIC COUPLER
(14.5 psi) Spring Engine Idle With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 34 SERVO PISTON – Swash Plate
24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers 21 PULL BUTTON ACTIVATED 35 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE – FORWARD/REVERSE
ARM BY-PASS 36 FILTER
PORT: 27579 kPa (276 bar) (4000 psi)
22 SENSOR – HYD. TEMPERATURE
9 RELIEF/ANTICAVITATION VALVE - 37 CHECK VALVE – COLD WEATHER BY-PASS
PORT (OPTIONAL): 27579 kPa 23 ANTICAVITATION VALVE With 345 kPa (3,45 bar) (50 psi) Spring
(276 bar) (4000 psi)
10 SOLENOID ACTIVATED DIRECTIONAL 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797 – 12300 kPa
CONTROL VALVE - AUXILIARY 39 CHECK VALVE - With 1400 kPa (14,0 bar)
(108 - 123 bar) (1566 - 1784 psi)
(203 psi) Spring
11 LOAD CHECK VALVE
25 SPRING LOADED FILTER BY-PASS VALVE: 40 DRIVE MOTOR SHUTTLE VALVE
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
12 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 26 FIXED CAPACITY DISPLACEMENT 41 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR BIDIRECTIONAL HYDROSTATIC
13 ANTICAVITATION VALVE MOTOR
NOTE: Unless otherwise specified

springs have NO significant
pressure value.

DRIVE MOTOR
39 Male
12
L
40
38 OUT Male
HYDRAULIC CONTROL VALVE (SPOOL
VALVE)
12
Female
9
41 10
10
Z
6
42
A B
8 TILT CYLINDERS
31 37 11
R BICS CONTROL VALVE

TANDEM
T
HYDROSTATIC
DRIVE PUMP
36 35
X
34 15
8
X
11
16 LIFT CYLINDERS
13
M 36
M
A B
M
32 32
Charge
8
33 G Inlet
20
A B
M 14 19
M 36 11 18 18 17 ?
IN 2
32 7 6
?
32
X
VARIABLE SPEED HYDRAULIC
34 FAN MOTOR W/ INTEGRATED FILTER
1
X ?
36
35 27
25 RESERVOIR (VENTED) 21
T OIL COOLER 3 2
5
31 28
R
1
29
4
23
30 26 PUMP
SUPPLY
P WORKING
DR 24 HYDRAULIC FILTER CIRCUIT
PILOT
BRAKE VALVE - 42 PRESSURE
DRAIN /
SPRING APPLIED B A RETURN
3
Z
2
45
44 41
44
1
43 22
40
38 DRAIN/RETURN
MANIFOLD
SJC WITH NO OPTIONS
39
L
T650 (S/N A3PO11001 & ABOVE)
DRIVE MOTOR
(S/N A3P111001 & ABOVE)
PRINTED IN U.S.A. 7170815

SJC WITH ALL OPTIONS
T650 (S/N A3P011001 – A3P011494)
(S/N A3P111001 – A3P111115)
LEGEND
60 CHECK VALVE – COLD WEATHER BY-PASS
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa) (5,5 bar)
With 345 kPa (3,45 bar) (50 psi) Spring
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) (80 psi) Spring
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) 21 PULL BUTTON ACTIVATED 40 FILTER – BOB-TACH VALVE 61 RESTRICTION - 2,0 mm (0.079 in)
DIRECTIONAL CONTROL VALVE - LIFT
2 SIGHT GUAGE 41 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 62 CHECK VALVE - With 1379 kPa 13,8 bar
ARM BY-PASS
3 (200 psi) Spring
DIFFERENTIAL PRESSURE SWITCH: 22 RIDE CONTROL VALVE 42 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,40 mm (0.016 in) Orifice 63 DRIVE MOTOR SHUTTLE VALVE
23 ANTICAVITATION VALVE
Normally Closed
43 RESTRICTION - 0,6 mm (0.025 in) 64 FIXED CAPACITY DISPLACEMENT
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE –
SENSOR – HYD. TEMPERATURE BIDIRECTIONAL HYDROSTATIC
(Fan Speed Regulator): 10797 – 12300 kPa 44
5 SPRING LOADED FILTER BY-PASS MOTOR
(108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 45 HYDRAULIC PUMP . . . . . . . Gear Type
65 HYDRAULIC BRAKE – SPRING APPLIED –
6 DIAGNOSTIC COUPLER 25 SPRING LOADED FILTER BY-PASS VALVE: 87,1 L/min (23 U.S. gpm) at High Engine Idle
PRESSURE RELEASE (SAPR)
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
7 RELIEF VALVE - MAIN: 46 CHARGE PUMP - 66
26 FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECECTIONAL
24132 kPa (241 bar) (3500 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
CONTROL VALVE – BRAKE
at Front Quick Couplers HYDRAULIC MOTOR
47 PILOT ACTIVATED DIRECTIONAL 67 FILTER - BRAKE
8 27 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - REAR AUXILIARY
RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 68 CHECK VALVE
28 SENSOR – CHARGE PRESSURE – 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
9 RELIEF/ANTICAVITATION VALVE - Fan Filter 69 HIGH FLOW HYDRAULIC PUMP Gear Type
PORT (OPTIONAL): 27579 kPa SOLENOID ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
29 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
(276 bar) (4000 psi) CONTROL VALVE - BUCKET POSITION CONTROL VALVE - TWO COIL
10 VALVE (ON/OFF) 50 RESTRICTOR - 0,8 mm (0.031 in) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE 71 DUMP VALVE – ON / OFF
11 51 LOAD SHUTTLE VALVE - BLEED OFF
LOAD CHECK VALVE
31 PILOTED ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL 72 CHECK VALVE - With 34,5 kPa (0,34 bar)
12 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL 52
CONTROL VALVE - Female (5.0 psi) Spring
BLEED-OFF VALVE SPOOL
53 SOLENOID ACTIVATED DIRECTIONAL 73 HIGH PRESSURE CHAMBER
13 ANTICAVITATION VALVE 32 CHECK VALVE - BUCKET POSITION
VALVE CONTROL VALVE - Male
14 LIFT CYLINDER SPOOL - MADE TO 74 LOW PRESSURE CHAMBER
33 PILOTED ACTIVATED DIRECTIONAL 54 VARIABLE CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
DOWN BUT NOT DURING BOOM UP
SPOOL 55 RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 36500 kPa (365 bar) (5294 psi)
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC 56 RELIEF VALVE - CHARGE INLET:
POWERED BOB-TACH 2654 kPa (26,5 bar) (385 psi) at High
Engine Idle With 60 ° C (140 ° F) Fluid
17 SOLENOID ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE
57 SERVO PISTON – Swash Plate
CONTROL VALVE - BICS CONTROL RESTRICTION - 2,26 mm (0.089 in)
36
18 FILTER - BICS CONTROL VALVE 58 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) 37 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE NOTE: Unless otherwise specified
19 CHECK VALVE - With 100 kPa (1,0 bar) CONTROL VALVE (TWO COIL) 59 FILTER springs have NO significant
(14.5 psi) Spring 38 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) pressure value.

Male
12
DRIVE MOTOR Male
63
12
L
Female
53 HIGH FLOW VALVE (OPTIONAL)
61 70
BUCKET POSITIONING VALVE
71 OUT (OPTIONAL) D
31 32
HYDRAULIC CONTROL VALVE (SPOOL
VALVE) 33
30
?
72 9
64 A
C
REAR QUICK COUPLERS
10
10
?
FEMALE MALE
Z
65 ? ?
6
A B 51
29
B
8 TILT CYLINDERS
53
54 60 11
52
R
49
TANDEM
? ?
BICS CONTROL VALVE
T
HYDROSTATIC
59 58
X
50
57 15
8
X
48 11
16 LIFT CYLINDERS
47 13
M 59 P in P out T
M REAR AUXILIARY
A B VALVE (OPTIONAL)
M
55 55
Charge 8
56 G Inlet
BOBTACH CYLINDER (OPTIONAL)
20
A B 22
M 14 19
40 POWER BOBTACH
M 59 11 18
VALVE (OPTIONAL) 18 17 ?
39 IN 2
55 38 40 41 7
? 6
55
X
57
1
X ?
42
59 37 ? ?
58
36 43 PP
DR
OIL COOLER 3 RESERVOIR (VENTED) 21
T 2
5 73
54 P1 P2 74
R
1
45 35 34
4
46 VARIABLE SPEED HYDRAULIC

HYDRAULIC FILTER
69
27
25 PUMP
SUPPLY
65 28 WORKING
BRAKE VALVE - CIRCUIT
SPRING APPLIED B A
PILOT
PRESSURE
3 DRAIN /
Z RETURN
2 23
68 26
64
67 67 P DR 24
1
66
DRAIN/RETURN MANIFOLD
63
61
L
SJC WITH ALL OPTION
62 T650 (S/N A3P011001 - A3P011494)
44
DRIVE MOTOR (S/N A3P111001 A3P111115)
7170815
PRINTED IN U.S.A.
SJC WITH ALL OPTIONS
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa) (5,5 bar) 62 CHECK VALVE - With 1379 kPa 13,8 bar
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) (80 psi) Spring (200 psi) Spring
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) 21 PULL BUTTON ACTIVATED 40 SHUTTLE VALVE 63 DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - LIFT
2 SIGHT GUAGE 41 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 64 FIXED CAPACITY DISPLACEMENT
ARM BY-PASS
3 22 RIDE CONTROL VALVE 42 BIDIRECTIONAL HYDROSTATIC MOTOR
DIFFERENTIAL PRESSURE SWITCH: CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 65 HYDRAULIC BRAKE – SPRING APPLIED –
23 ANTICAVITATION VALVE PRESSURE RELEASE (SAPR)
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE – 66 PILOT ACTIVATED DIRECTIONAL
(Fan Speed Regulator): 10797 – 12300 kPa 44 RESTRICTION - 0,51 mm (0.020 in) CONTROL VALVE – 2 Speed
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi) 67 FIXED CAPACITY DISPLACEMENT
VALVE: 172 kPa (1,7 bar) (25 psi) 45 SENSOR – HYD. TEMPERATURE
25 SPRING LOADED FILTER BY-PASS VALVE: BIDIRECTIONAL HYDROSTATIC
6 DIAGNOSTIC COUPLER 46 NOT USED FOR THIS MODEL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) MOTOR – 2 Speed
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT PILOT ACTIVATED DIRECTIONAL 68 HYDRAULIC PUMP . . . . . . . Gear Type
47
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR CONTROL VALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER) RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
8 48 69
RELIEF/ANTICAVITATION VALVE - 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR – CHARGE PRESSURE – 49 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter CONTROL VALVE - TWO COIL 70 HIGH FLOW HYDRAULIC PUMP Gear Type
SOLENOID ACTIVATED DIRECTIONAL 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 27579 kPa 29 50 RESTRICTOR - 0,8 mm (0.031 in)
(276 bar) (4000 psi) CONTROL VALVE - BUCKET POSITION 71 FILTER - BRAKE
10 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 51 LOAD SHUTTLE VALVE - BLEED OFF 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE – BRAKE
11 LOAD CHECK VALVE
31 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - BASE 73 CHECK VALVE
12 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL 53 SOLENOID ACTIVATED DIRECTIONAL 74 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
BLEED-OFF VALVE SPOOL CONTROL VALVE - ROD
13 ANTICAVITATION VALVE 32 CHECK VALVE - BUCKET POSITION 75 DUMP VALVE – ON / OFF
54 VARIABLE CAPACITY DISPLACEMENT
VALVE BIDIRECTIONAL HYDROSTATIC PUMP CHECK VALVE - With 34,5 kPa (0,34 bar)
14 LIFT CYLINDER SPOOL - MADE TO 76
RESTRICT FLOW DURING BOOM 33 PILOTED ACTIVATED DIRECTIONAL RELIEF/REPLENISHING VALVE - HIGH (5.0 psi) Spring
55
DOWN BUT NOT DURING BOOM UP CONTROL VALVE - UNLOADING PRESSURE: 36500 kPa (365 bar) (5294 psi) 77 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE – 2 Speed Shift
15 PILOTED ACTIVATED DIRECTIONAL 56 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 78 SOLENOID ACTIVATED DIRECTIONAL
PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC Engine Idle With 60 ° C (140 ° F) Fluid CONTROL VALVE – 2 Speed Make-up
16
CONTROL VALVE - LIFT CONTROL POWERED BOB-TACH 57 SERVO PISTON – Swash Plate 79 HIGH PRESSURE CHAMBER
17 SOLENOID ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE
CONTROL VALVE - BICS CONTROL 80 LOW PRESSURE CHAMBER
36 RESTRICTION - 2,08 mm (0.08 in) CONTROL VALVE – FORWARD/REVERSE
18 FILTER - BICS CONTROL VALVE 59 FILTER
(SCREEN) 37 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
19 CHECK VALVE - With 100 kPa (1,0 bar) CONTROL VALVE (TWO COIL) 60 CHECK VALVE – COLD WEATHER BY-PASS springs have NO significant
38 With 345 kPa (3,45 bar) (50 psi) Spring pressure value.
(14.5 psi) Spring RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
61 RESTRICTION – 1,5 mm (0.06 in)
DRIVE MOTOR Male
L
62 12
61
Male
63 75
12
Female
OUT
X HYDRAULIC CONTROL VALVE
RIDE CONTROL
66 80 (FIELD INSTALLED OPTION) 79
W
67
64
REAR QUICK
FEMALE COUPLERS MALE 10
65
10 LIFT CYLINDERS
Z
Auxiliary Spool
?
51 ? 9
A B
22
53
8
52
49 6 11
HYDROSTATIC PUMP BOBCAT INTERLOCK CONTROL SYSTEM
? ?
R (BICS)
54 TILT BASE
T
E1 E2 A1 A2
58 50
TILT ROD E3
X 59 Tilt Spool
B 30
57 8
55 15
X 48
?
11 32
LIFT ROD 29
78 47 16 D2
77
B A D M 59 REAR AUXILIARY P in P out T 13
72 M 31
A B
VALVE (OPTION)
T LIFT BASE
M
Lift Spool
56 55
33 C2
8
G BOBTACH CYLINDER (OPTIONAL) C1 D1
P A B
POWER BOBTACH
M VALVE (OPTIONAL) 18
B1 14
2-SPEED & 59 18
M 11 19
SAPR BRAKE 17 ?
BUCKET POSITIONING
71 VALVE 40
39 VALVE (OPTIONAL)
73 (OPTIONAL) 38 IN
2 20
7
55 ? 6
55
X
41
42
57 TILT CYLINDERS
1
X ? 58 Oil Cooler
59 21
54 60 44
37 36 RESERVOIR
T D 43 (VENTED)
5 2 1
R
68
35
34
69
VARIABLE SPEED HYDRAULIC 3 4

HYDRAULIC FILTER
70
74 75
27 25
WORKING CIRCUIT
?
28 CHARGE
PRESSURE
23
DRAIN / RETURN
65
B A
Z 26
P DR
24
67 64
W
66
X HYDRAULIC/HYDROSTATIC SCHEMATIC
45
SJC WITH ALL OPTION
63
61 Printable Version Click Here
62
L DRAIN / RETURN MANIFOLD (PRINTED NOVEMBER 2010)
DRIVE MOTOR
7170815
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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


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

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
Lift Arm Bypass Control valve stuck. 12
Lift Arm Bypass Control valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

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

CYLINDER (LIFT) Figure 20-20-2
Testing
Figure 20-20-1
P-90617
1
Install a cap (Item 1) [Figure 20-20-2] on the hose and
P-90616 tighten.
Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.
Operate the controls that lower the lift arms.
WARNING If there is any leakage from the fitting on the cylinder

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

(Item 1) [Figure 20-20-1] which goes to the base end of
the cylinder.

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

WARNING
Lift and block the loader. (See Procedure on Page 10-10-
1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-90824
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

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

safe manner.
1
WARNING
P-90616 AVOID INJURY OR DEATH
Mark and disconnect the two hydraulic hoses (Item 1) death. Fluid leaks under pressure may not be visible.
[Figure 20-20-3]. Use a piece of cardboard or wood to find leaks. Do
W-2072-0807

Removal And Installation (Cont’d)
Figure 20-20-5
P-90602A
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-5] from the pin on the rod end of the cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54

N•m (35 - 40 ft-lb) torque.
Figure 20-20-6
P-90611
With a slide hammer, remove the pin (Item 1) [Figure 20-

20-6] from the rod end of the cylinder.

CYLINDER (LIFT) (CONT'D) Figure 20-20-7
DANGER
1
P-90605
P-90328
AVOID DEATH Install a sling in the middle of the Bob-Tach as shown in

• Disconnecting or loosening any hydraulic (Item 1) [Figure 20-20-7].
can cause lift arms to drop. Using a chain hoist raise the lift arms and install an
• Keep out of this area when lift arms are raised approved lift arm support device on the cylinder that is
unless supported by an approved lift arm connected to the lift arm.
D-1009-0409
Figure 20-20-8
2
WARNING 1

W-2059-0598
P-90823
Install a bolt (Item 1) [Figure 20-20-8] through the eyelet

of the cylinder and install a strap (Item 2) [Figure 20-20-
8] to secure the cylinder.

Open the rear door.

1
NOTE: When removing the left side lift cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery (If required). (See Removal And

Installation on Page 60-20-1.)
Figure 20-20-9
P-90827
1
20-11] from the base end of the lift cylinder.
Figure 20-20-12
P-90834

20-9] from the pin on the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54 1

Figure 20-20-10 P-90823
Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.
P-90825
Remove the grease fitting (Item 1) [Figure 20-20-10]

from the base end of the lift cylinder.
Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.

Parts Identification
1. Seal
2. Hydraulic Tubeline
3. Cylinder Case Tube
4. Plug
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring 4
9. Piston Assembly
10. Spacer
11. O-ring
3
12. Back-up Ring
13. O-ring
14. Head 4
15. Rod Seal 5
16. Wiper Seal
17. Rod
18. Grease Fitting
6
7
8
2 9
10
1
13
14
15
16
11
12
17
18
NA1413S

Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.

3
Figure 20-20-13
P-48038
1
Remove the back-up ring (Item 1) and O-ring (Item 2)
[Figure 20-20-15] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-15]

on the piston, becomes damaged, the
complete piston must be replaced.
Figure 20-20-16
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-13] from the cylinder case.
2
Figure 20-20-14 3
4
3
2
P-48039
1
Remove the O-ring (Item 1). Remove the O-ring (Item 2)
and the back-up ring (Item 3) [Figure 20-20-16] from the
cylinder head.
NOTE: The O-ring (Item 2) and back-up ring (Item 3)

[Figure 20-20-16] are no longer available
parts. The seal kit will contain a one piece seal
P-48036 that is used in place of the O-ring and back-up
ring.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].

Disassembly (Cont'd)
Figure 20-20-17
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-17] from

the cylinder head.
Figure 20-20-18
P-48042
Remove the rod seal (Item 1) [Figure 20-20-18] from the

cylinder head.

Assembly
Use the following tools to assemble the cylinder: 1
MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Figure 20-20-19
P-48038
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-20] on the cylinder piston.
Figure 20-20-21
P7424 1
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-20-21].
fits the piston [Figure 20-20-19].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-20-21] must be installed
on the piston. toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-21].

Assembly (Cont'd)
Figure 20-20-22
1
P101716
Install the O-ring (Item 1) and the seal (Item 2) [Figure

P7425 20-20-24] on the cylinder head.
Figure 20-20-25
Install the rod seal in the head [Figure 20-20-22].
Figure 20-20-23
1
2
3
2 4
P-48036
P-48041 P-48042 NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Install the wiper seal, with the wiper side of the seal (Item Install the head (Item 1), spacer (Item 2) piston (Item 3),
1) toward the outside of the head (Item 2) [Figure 20-20- and nut (Item 4) [Figure 20-20-25].
23].
Tighten the nut (Item 4) [Figure 20-20-25] to 1152 N•m
(850 ft-lb) torque.

Assembly (Cont'd)
Figure 20-20-26
P-48035
Put the base end of the hydraulic cylinder in a vise.
Using a spanner wrench, tighten the head (Item 1)

[Figure 20-20-26] until the head is flush with the end of
the cylinder tube assembly.

CYLINDER (TILT) Figure 20-21-2
Testing
Figure 20-21-1
P100721
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

P-85553 hose and tighten.
Remove the attachment. Roll the Bob-Tach fully back. engine and press the PTOL button.
Stop the engine. Raise the seat bar.
Operate the controls that rolls the Bob-Tach forward.
If there is any leakage from the fitting on the cylinder

WARNING (Item 2) [Figure 20-21-2]. Remove the cylinder for repair.
Repeat procedure to check the other cylinder.

immediately.
W-2145-0290
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the rod end of the cylinder.

CYLINDER (TILT) (CONT'D) Figure 20-21-5
Figure 20-21-3
2
1
1
P-85562
Disconnect the two hydraulic hoses (Items 1 and 2)

P-85554 [Figure 20-21-5] from the cylinder.
Cap the hoses and plug the fittings on the cylinder.

Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Figure 20-21-6
Remove the retainer bolt and nut (Item 1) [Figure 20-21-

3] from the rod end pivot pin.
1
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.
Figure 20-21-4
P-85648
Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].
Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.
Installation: Tighten the retainer nut to 257,6 N•m (190

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

CYLINDER (TILT) (CONT'D)
Removal And Installation (Cont'd)
Figure 20-21-7
P-85564
Slide the cylinder from the base pin and remove the
cylinder from the loader [Figure 20-21-7].

Base End Pivot Pin Removal And Installation
Figure 20-21-8
P-85567
1
Check pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a 0,875 mm (7/8 in) shaft (Item 1) [Figure 20-21-9]

and a hammer to remove the cylinder base pin from the
lift arms.

Parts Identification (Early Models)
1. Tubeline
2. Case
3. Plug
4. Grease Fitting
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring
9. Piston
10. O-ring
11. Back-up Ring
12. O-ring 4
13. Head
14. Seal
15. Wiper 5
1
16. Rod
17. Bushing 2
18. Seal
8 6
3
7
8
9
8
3
18
12
13
14
15
10
11 16
18
17
18
NA1210S

Parts Identification (Later Models)
1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. O-ring
10. Piston
5
11. Seal
12. O-ring
13. Head 6
14. Seal
15. Wiper 4 2
16. Rod 3
17. Bushing
7
1 8
4 9
3
10
11
12
13
14
15
16
17
NA6008S

Early
Disassembly Models
3
Use the following tools to disassemble the cylinder: 2
MEL1074 - O-ring Seal Hook

1
Spanner Wrench
Figure 20-21-11
P-48071
1
Figure 20-21-14
2
Later
Models
3 2
1
1
P-85651
Remove the seals (Item 1) [Figure 20-21-11] on both

sides of the pivot bushing. P106017
Remove and replace bushing (Item 2) with a driver tool

and hammer [Figure 20-21-11]. Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13] and [Figure 20-21-14].
Figure 20-21-12
P106021
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-12] from the cylinder case.

1
Figure 20-21-15
Early
Models 2
3
1
2
P-48039
Remove the O-ring (Item 1). Remove the O-ring (Item 2)

P-48073 and back-up ring (Item 3) [Figure 20-21-17].
Figure 20-21-16
NOTE: The O-ring (Item 2) and back-up ring (Item 3)
Later 2
[Figure 20-21-17] are no longer available
Models
parts. The seal kit will contain a one piece seal
that is used in place of the O-ring and back-up
ring.
1
Figure 20-21-18
P106020
Remove the seal (Item 1), and O-ring (Item 2) [Figure

20-21-15] and [Figure 20-21-16] from the piston.
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-18] from

the cylinder head.

Figure 20-21-19
P-48042
Remove the rod seal (Item 1) [Figure 20-21-19] from the

cylinder head.

Assembly Early
Models
1
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Spanner Wrench

P-48073
Lubricate all O-rings and seals with hydraulic oil during Figure 20-21-22
installation.
Later 1
Models
Figure 20-21-20
P106020
P7424
Install the O-ring (Item 1), and seal (Item 2) [Figure 20-
21-21] and [Figure 20-21-22] on the cylinder piston.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Cont'd)
Figure 20-21-23 2
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
25].
Install the rod seal on the rod seal tool [Figure 20-21-23]. Figure 20-21-26
NOTE: During installation the spring side of the seal 1

(Item 1) [Figure 20-21-23] must be installed
toward the inside of the cylinder. 2

21-23].
Figure 20-21-24
P101716
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-26] on the cylinder head.
P7425

Assembly (Cont'd)
1
Figure 20-21-27
Early
Models
1
2
P106021
Using a spanner wrench, tighten the head (Item 1)

P-48071 [Figure 20-21-29] until the head is flush with the end of
the cylinder tube assembly.
Figure 20-21-28 Figure 20-21-30

Later
Models
1 2
2
3
P106017 P-85650
NOTE: Clean and dry the threads before installing the Install the bushing (Item 1) and seals (Item 2) [Figure 20-
nut. Install the new nut from the kit. 21-30] using a driver tool and hammer.
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-27] and [Figure 20-21-28].
Tighten the nut (Item 3) [Figure 20-21-27] and [Figure

20-21-28] to 1152 N•m (850 ft-lb) torque.

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

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

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

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

P-85570 (Front Accessory Panel).
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the cylinder for repair.
[Figure 20-22-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

CYLINDER (BOB-TACH) (CONT'D)
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -

24 ft-lb) torque.
Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-85569
Remove the bolts and washers (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

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

1. Tube 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2
3
4
5
6
7
8
9
10
11
12
13
PE3954S

CYLINDER (BOB-TACH) (CONT'D) Figure 20-22-8
Disassembly 3 2 1
Figure 20-22-6
P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2)

P-85647 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook

Spanner Wrench 4
2
1
Use a spanner wrench to loosen the head [Figure 20-22-

5
6]. 3
Figure 20-22-7
N-20611
2
4 3 1
Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P16294
Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.

Assembly
3 1
2
Figure 20-22-10
P16295
Piston: Install the O-ring (Item 1) and seal (Item 2) on the

P7424 piston (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Spanner Wrench

Lubricate all O-rings and seals with hydraulic oil during

installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].
NOTE: During installation the spring side of the seal

must be toward the inside of the cylinder.

Assembly (Cont'd)
Figure 20-22-13
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
22-13]. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16
3
2 4
1
P7425
P16294

Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 122 N•m (90 ft-lb) torque.

Assembly (Cont'd)
Figure 20-22-17
P-85647
Tighten the head using a spanner wrench [Figure 20-22-

17].

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

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

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

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1
Testing
1
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
WARNING P-85571
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
cause injury or death.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.

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

procedure: 1
TWX-RFIK200-S-6 204,4 L/min (54 U.S. gpm) FLOW

METER
MEL10006 - Hydraulic Test Kit
P-76460C
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and
loaders equipped with SJC option. The main Start the engine and run at low idle.
relief valve is located in the same place on all
of the loaders. • Press the AUXILIARY HYDRAULICS Button (Item 1)
[Figure 20-30-2] once to engage the auxiliary
Lift and block the loader. (See Procedure on Page 10-10- hydraulics.
1.)
NOTE: The light (Item 2) [Figure 20-30-2] will be on.

MAIN RELIEF VALVE (CONT’D) With the engine at high idle and hydraulic oil at 60°C
(140°F) turn the restrictor control on the tester until the
Testing (Cont’d) flow through the tester drops to zero. Check the relief
pressure.
Figure 20-30-3
If the relief pressure is not correct, stop the engine and
Right adjust the main relief valve.
Steering
Lever
Control
P-85572
Figure 20-30-4
Joystick Option Only
Right
Steering
1 Lever
Control
P-26697
• Push the front switch (Item 1) [Figure 20-30-3] and

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

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

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

both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.

MAIN RELIEF VALVE (CONT’D)
Adjusting

loaders equipped with ACS option and
loaders equipped with SJC option. The main
of the loaders.
Figure 20-30-5
1
2
P-85573
If the pressure is not correct, adjust the main relief valve.

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

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

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

MAIN RELIEF VALVE (CONT’D) Figure 20-30-7
IMPORTANT
damage the system.
I-2003-0888
P-37689
Clean the area around the control valve. Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-7].
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.
of the loaders. Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Check the pressure again. (See Testing on Page 20-30-

2.)
1
P-85573
The main relief valve (Item 1) [Figure 20-30-6] is located

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

20-30-6].

HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P-90327
The hydraulic control valve is located inside the main

frame 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 hydraulic control valve are
operated by linkage connected to the foot pedals.
The auxiliary function is operated by pilot pressure.

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

valve which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) Drain the hydraulic reservoir. (See Removing And
(CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the control linkage. (See Linkage Removal And

DANGER Installation on Page 50-90-2.)
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.
NOTE: Cap and plug all hydraulic connection points

when tubelines or hoses are removed.
Clean area around control valve.
P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2
• Keep out of this area when lift arms are raised 3
D-1009-0409 1
WARNING
the lift arms are secured by an approved lift arm 2
support device. Failure to use an approved lift arm P-90187

to fall and cause injury or death. Remove the two bolts (Item 1), move the hose clamp
W-2059-0598
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-40-2] off to the side.
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(CONT’D)
Figure 20-40-3
2
1
P-90270
Disconnect the hose (Item 1) [Figure 20-40-5] that

routes from the control valve to the brake valve.
P-90267
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed Figure 20-40-6
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1)[Figure 20-40-3].
Figure 20-40-4 1
P-90271
2

1 routes from the top of the control valve to the hydraulic
filter.
P-90269
Disconnect the wire harness connectors (Item 1) [Figure

20-40-4] from the control valve.

routes from the control valve to the drain manifold.

routes from the control valve to the inlet fitting of the
hydraulic pump.

(CONT’D)
Figure 20-40-7
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-40-9]

that route from the control valve to the junction block at
P-90272 the rear of the loader.
Figure 20-40-10
Remove the tubeline clamp (Item 1) [Figure 20-40-7].
Disconnect the two tubelines (Item 2) [Figure 20-40-7]

that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-40-8
P-90275

1 routes from the control valve to the junction block at the
rear of the machine.
P-90273 Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-40-10] from the control valve.

HYDRAULIC CONTROL VALVE (STANDARD) Mount Bracket Removal And Installation
(CONT’D)
Figure 20-40-13
Figure 20-40-11
1
P-90280
P-90276 Support the mounting bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14
routes from the bottom of the control valve to the outlet
2
fitting of the hydraulic pump.
Figure 20-40-12
P-90279
Remove the two control valve mount bolts (Item 1)

[Figure 20-40-14].
P-90278
Remove the two frame bolts (Item 2) [Figure 20-40-14]
Support the control valve and remove the two bolts (Item Installation: Torque the two frame bolts (Item 2) [Figure
1) [Figure 20-40-12]. 20-40-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve from the loader. Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-15
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307
ITEM T650 LOADER ITEM T650 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 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™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27,6 MPa H3 BICS™ Lock Valve (Lift)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27,6 MPa
J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27,6 MPa MR Main Relief Valve – 24,1 MPa (241,3 bar)
(275,8 bar) (4000 psi) (3500 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27,6 MPa (275,8 bar) (4000 psi) (Optional)

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

1
Figure 20-40-16
3
1 P-90309
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-18].
P-90308
Check the free movement load check valve and spring
(Item 3) [Figure 20-40-18].
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS™ valve fitting on the top of the lift load
check valve.
Figure 20-40-17
P-90310
Remove the lift load check valve (Item 1) [Figure 20-40-

17] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

(CONT'D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
1
Figure 20-40-19
2
3
4
2
1
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-20].
P-90311 Check the orifice (Item 3) [Figure 20-40-20] in the

poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section Installation: Install a new O-ring (Item 4) [Figure 20-40-
load check valve (Item 1) [Figure 20-40-19]. 20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
At the front side of the control valve locate the auxiliary torque.
section load check valve (Item 2) [Figure 20-40-19].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
IMPORTANT
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-23

Rod End)
Figure 20-40-21
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-40-23].
At the back side of the control valve, remove the lift Figure 20-40-24
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
3 1
4
P-90315
P-90312 Replace the O-ring (Item 1) [Figure 20-40-24] before

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-40-22].
Check the orifice (Item 3) [Figure 20-40-22] in the

Installation: Install a new O-ring (Item 4) [Figure 20-40-

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

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-27

Installation (Tilt, Base End)
Figure 20-40-25
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-27] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1) Figure 20-40-28
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-40-26] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

(CONT'D)
Port Relief Valve Removal And Installation 1
Figure 20-40-29
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-31].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-29] Figure 20-40-32
from the auxiliary circuit of the control valve.
Figure 20-40-30
P-51640
2
P-90318 Installation: Always use new O-rings (Item 1) [Figure
20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure


(CONT'D)
Plug Removal And Installation
Figure 20-40-33
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-35].
P-68016
Figure 20-40-36
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-33].
Figure 20-40-34
P-51462

1 20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.
P-51460A

20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.

(CONT'D)
Rubber Boot Removal And Installation
Figure 20-40-37
P-51506
Remove the three screws (Item 1) [Figure 20-40-37] on

the rubber boot retainer plate.
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-40-38
1
2
P-51701
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-38].

(CONT'D)
End Cap Block Removal And Installation
Figure 20-40-39
1 1
1 1
P-51699A
1
Figure 20-40-42
P-51697
1
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-39] from the
end cap / spool lock block.
4
Figure 20-40-40
1
P-51701
Remove the four end cap / spool lock block mount screws
(Item 1) [Figure 20-40-41] and [Figure 20-40-42].
1
100 in-lb) torque.
P-90320 Remove the rubber boots and retainer plate (Item 2)

[Figure 20-40-42] from the lift and tilt spools.
Disconnect the tube line (Item 1) [Figure 20-40-40] from Remove the end cap / spool lock block (Item 4) [Figure
the end cap / spool lock block. 20-40-42] from the control valve.

(CONT'D)
Lift Spool And Detent Removal And Installation
The tool listed will be needed to do the following 1

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap / spool lock block from the control
valve.
Figure 20-40-43
P-90321
Remove the end cap (Item 1) [Figure 20-40-45].
Figure 20-40-46
P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-43]. 2
Installation: Replace the O-ring, and lubricate the o-ring

lightly with grease or oil before installation of the end cap
P-51514
/ spool lock block.
Figure 20-40-44 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-46].
Remove the washer (Item 2) [Figure 20-40-46].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-44] from the lift spool.

HYDRAULIC CONTROL VALVE (STANDARD) Put a rag around the detent assembly [Figure 20-40-48].
(CONT'D) This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
(Cont'd) Figure 20-40-49
Figure 20-40-47
2 1
3
1
2 P-51517
1 2
P-51515
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-49].
Remove the screws (Item 1) [Figure 20-40-47] from the
detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-47].
Installation: Lubricate the screws and tighten to 10,2 -

11,3 N•m (90 - 100 in-lb) torque.
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-48
P-51516

(CONT'D)

(Cont'd)
Figure 20-40-50
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-52].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-53
Remove the lift spool assembly and seal (Item 1) [Figure
20-40-50] from the control valve. 2
Figure 20-40-51
1
3
1
N-18915
Install the spring tool (Item 1) [Figure 20-40-53] over the

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

Remove the lift spool seal (Item 1) [Figure 20-40-51] (Item 2) [Figure 20-40-53] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

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

(Cont'd)
Figure 20-40-54
N-19009
Remove spring tool (Item 1) [Figure 20-40-56] from the

1 spring assembly.
2
N-18916 Figure 20-40-57
Put a rag around the detent assembly [Figure 20-40-54]. 1

2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Alan wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-54].
Figure 20-40-55
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-55]

from the spring assembly.

(CONT'D)

(Cont'd)
2
Figure 20-40-58
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-60].
N-18918 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
Remove the stud from the end of the spool [Figure 20-
recheck the lift spool before the control valve
40-58].
is replaced.
Figure 20-40-59
Figure 20-40-61
N-18920
N-18963
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in) Install the plastic plug and O-ring in the spool [Figure 20-
drill. 40-61].
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-59] into the plug.

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

THREADS.

(CONT'D)

(Cont'd)
2
Figure 20-40-62
O-ring
1 3
2
N-18958
Plastic
Plug
15,2 mm Apply grease on all the detent component surfaces
(0.60 inch)
before assembly [Figure 20-40-64].
B-14712 Install the spring (Item 1) [Figure 20-40-64] and detent

balls (Item 2) [Figure 20-40-64] into the adapter (Item 3)
[Figure 20-40-64] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-40-65].
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-62]. Figure 20-40-65
Figure 20-40-63
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-65].
Clamp the collar (Item 1) [Figure 20-40-63] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

(CONT'D)

(Cont'd)
Figure 20-40-66
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-68].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the

Install the spring tool (Item 1) [Figure 20-40-66] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).
Figure 20-40-67
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-68].
Figure 20-40-69
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-67].
CD-15051
Install the detent balls and spring [Figure 20-40-69].

(CONT'D)

(Cont'd)
Figure 20-40-70
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-72].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-72].
Install the mounting screws (Item 2) [Figure 20-40-72].

Hold the detent balls in place with the detent pliers
[Figure 20-40-70]. Installation: Lubricate the screws and tighten to 10 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-71
Figure 20-40-73
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-71] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-73].

(CONT'D)

(Cont'd)
Figure 20-40-74
1
1
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-76] on the lift spool.
P-90321 Figure 20-40-77
Install the end cap (Item 1) [Figure 20-40-74].
Figure 20-40-75
P-51511A
Install the O-ring (Item 1) [Figure 20-40-77] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-75] on the

linkage end of the valve.

(CONT'D)

(Cont'd)
Figure 20-40-78
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap / spool lock block (Item 1) and the (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
mount bolt (Item 2) [Figure 20-40-78]. 45 ft-lb) torque [Figure 20-40-80].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-78].

100 in-lb) torque.
Figure 20-40-79
P-90320
Connect the tubeline (Item 1) [Figure 20-40-79].

(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap / spool lock block. (See
End Cap Block Removal And Installation on Page 20-40- 2
14.)
Figure 20-40-81
P-90323
Remove the spool centering block (Item 1) [Figure 20-

1 2
40-83] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

83] and lubricate the O-ring lightly with grease or oil
before installation of the end cap / spool lock block.
P-51521
Figure 20-40-84

20-40-81] from the tilt spool.
Figure 20-40-82
P-51544
2 1 Remove the tilt spool, centering spring, back-up washer

and spool seal [Figure 20-40-84].
P-90321
Assembly: Always use a new spool seal.

from the spool centering block.
Remove the three screws (Item 2) [Figure 20-40-82]

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

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

2 1
Figure 20-40-85
3
4
1
N-18944A
N-18942
Figure 20-40-88
Put the linkage end of the spool in the vice [Figure 20-
40-85]. 2
1
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

N-19014
Remove the bolt (Item 1) [Figure 20-40-86] holding the

centering spring to the spool.

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

(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-89
1
1
2 3 2
P-51547
2 1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-91] from the auxiliary spool.
P-90321
Figure 20-40-92
Remove the two tubelines (Item 1) [Figure 20-40-89]



in-lb) torque. 2
1
40-89] from the control valve.
Figure 20-40-90
P-51549A
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-92] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

2 20-40-92] must be replaced, replace the
1 retainer on the opposite end also.
P-51546A


20-40-90] must be replaced, replace the
retainer on the opposite end also.

(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-93
1
2
P-51550

Figure 20-40-94
P-51551
Remove the spool (Item 1) [Figure 20-40-94].

(CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-95
1
2
P-85528
Remove the screws (Item 1) [Figure 20-40-95] from both

solenoids.
Remove the solenoids (Item 2) [Figure 20-40-95] from

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

26.4 in-lb) torque.
Figure 20-40-96
P-85556
Check and remove the O-rings (Item 1) [Figure 20-40-

96] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

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

(CONT'D)
Solenoid Removal And Installation
Figure 20-40-97 1
1
2
P-85528
Remove the solenoid stem (Item 1) [Figure 20-40-99].
P-90310 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-97] from the Figure 20-40-100
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-97]. 3

2
Figure 20-40-98
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-100] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-98] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-100] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-98] and

[Figure 20-40-100] and new back-up rings (Item 2)
[Figure 20-40-100] on the solenoid stem.

(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-101 1
1
1
1
2
2
1
2
2 P-51564

[Figure 20-40-103] from the lift lock valve, and replace
P-90310 with new.
Figure 20-40-104
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-101] is for the lift
circuit.
Figure 20-40-102
P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

104].
P-90321
Remove the lift lock valve (Item 1) [Figure 20-40-102]

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


(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105 1
1
1
2
1
2
2
1 2
P-51564

[Figure 20-40-107] from the tilt lock valve, and replace
P-90325 with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-105].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-105].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-106
P-90324
Remove the tilt lock valve (Item 1) [Figure 20-40-106]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-110
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-108
1
P-51707
P-90308 Remove the main relief valve (Item 1) [Figure 20-40-

110].
Remove the fitting (Item 1) [Figure 20-40-108] from the Figure 20-40-111
valve.
Figure 20-40-109
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Check the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 52 - 61
109]. N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve

casting.

(CONT'D)
Check Valve Removal And Installation
Figure 20-40-112
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-40-115
Remove the tubeline (Item 1) [Figure 20-40-112].
Figure 20-40-113
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-40-115].
Remove the check valve fitting (Item 1) [Figure 20-40-

113] from the hydraulic control valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P-90337
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operator’s cab. D-1009-0409
The hydraulic control valve is the hydraulic component

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

IMPORTANT
valve which is adjustable.
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)
device. (See LIFT ARM SUPPORT DEVICE on Page 10- 1
20-1.)
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
P-90267
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
Clean area around control valve. 1)[Figure 20-41-3].
Open rear door.
Figure 20-41-2
2
P-90187
Remove the two bolts (Item 1), move the hose clamp

(CONT’D)
Figure 20-41-4
1
3
1 2
P-90271

routes from the top of the control valve to the hydraulic
P-90269 filter.
Figure 20-41-7
Disconnect the wire harness connectors (Item 1) [Figure

routes from the control valve to the drain manifold.
2 2
routes from the control valve to the inlet fitting of the 1
hydraulic pump.
Figure 20-41-5
P-90272
2
1

that route from the control valve to the front auxiliary
hydraulics.
P-90270

routes from the control valve to the brake valve.

routes from the control valve to the fan motor.

(CONT’D)

1
Figure 20-41-8
P-90275
1
routes from the control valve to the junction block at the
P-90273 rear of the machine.
Disconnect the lift arm bypass drain hose (Item 2)

Remove the tubeline clamp (Item 1) [Figure 20-41-8]. [Figure 20-41-10] from the control valve.
Figure 20-41-9 Figure 20-41-11
1 1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-41-9] Disconnect the hose (Item 1) [Figure 20-41-11] that
that route from the control valve to the junction block at routes from the bottom of the control valve to the outlet
the rear of the loader. fitting of the hydraulic pump.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (In Loader)
(CONT’D)
Figure 20-41-12
WARNING
W-2059-0598
1
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Mark the actuator wiring harness connectors for proper

P-90278 installation.
Figure 20-41-13
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-12].
Remove the control valve from the loader.
P-90330
Unplug the actuator connectors (Item 1) [Figure 20-41-

13] from the loader harness.

(CONT’D)
Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-41-14
1
2
1
P-54568
Inspect the O-ring (Item 1) [Figure 20-41-16] on the face

of the actuator, and replace as needed.
P-54587 Check the linkage pin (Item 2) [Figure 20-41-16] and

replace as needed.
Remove the two screws (Item 1) [Figure 20-41-14] from

the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-41-15
P-54566
Pull the actuator (Item 1) [Figure 20-41-15] away from

the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure

20-41-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)

(CONT’D)
Actuator Removal And Installation (Out Of Loader)
Remove the control valve from the loader.
Figure 20-41-17
P-54339
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-19] from the actuator
and the tilt spool.
P-54337 Remove the actuator and linkage pin from the valve.
Figure 20-41-20
Remove the two mount bolts (Item 1) [Figure 20-41-17]
from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-18
P-54340
1 Inspect the O-ring (Item 1) [Figure 20-41-20] on the face

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

P-54338 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

18] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-18].

(CONT’D)

(Cont’d)
Figure 20-41-21
1 1
P-54343
Using a punch and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-23] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-41-21] Figure 20-41-24
from the lift actuator.

Figure 20-41-22
P-54340
Inspect the O-ring (Item 1) [Figure 20-41-24] on the face

1 of the actuator, and replace as needed.
P-54342 Check the linkage pin (Item 2) [Figure 20-41-24] and

replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

22] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-22].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)

(Cont’d)
Figure 20-41-25
4 3
1
3
P-90329
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-41-25] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-41-25].

N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-41-25]

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (CONT’D)
Figure 20-41-26
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 E2
C4
D1
D2
A1
H3
E1
H2 B1
F1 MR J3
H1 J1 C1
P-90307
ITEM T650 LOADER ITEM T650 LOADER

A1 Lift Cylinder Base End E1 Lift Spool
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS™ Solenoid
C3 Load Check Valve Auxiliary Function
H2 BICS™ Lock Valve (Tilt)
C4 Check Valve
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief / Anti-Cavitation Valve – 27,6 MPa J2 Outlet Fluid Flow (Return to Tank)
(275,8 bar) (4000 psi) J3 Lift Arm Bypass Orifice
Lift (Base End)
J4 Drain (Case)
(275,8 bar) (4000 psi) MR Main Relief Valve – 24,1 MPa (241,3 bar)
Tilt (Base End) (3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27,6 MPa (275,8 bar) (4000 psi) (Optional)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Figure 20-41-29
Mount Bracket Removal And Installation
Figure 20-41-27
P-90308
P-90280 Remove the charge tubeline (Item 1) [Figure 20-41-29]

from the BICS™ valve fitting on the top of the lift load
check valve.
Support the mounting bracket (Item 1) [Figure 20-41-27].
Figure 20-41-30
Figure 20-41-28
P-90310
P-90279
Remove the lift load check valve (Item 1) [Figure 20-41-

Remove the two control valve mount bolts (Item 1) 30] and fitting from the top of the control valve.
[Figure 20-41-28].
Installation: Lubricate the O-ring and threads and
Remove the two frame bolts (Item 2) [Figure 20-41-28] tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-28] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

(CONT’D)
Lift Load Check Valve Removal And Installation

(Cont’d)
2
Figure 20-41-31
1
1
2 P-90311
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
3
P-90309 At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-32].
Remove and install new O-rings (Item 1) and back-up NOTE: The tilt and auxiliary load check valves are
ring (Item 2) [Figure 20-41-31]. interchangeable.
Check the free movement load check valve and spring Figure 20-41-33
(Item 3) [Figure 20-41-31].
IMPORTANT 1
2
clean the work area before disassembly and keep all 3
parts clean. Always use caps and plugs on hoses, 4
damage the system.
I-2003-0888
Load Check Valve Removal And Installation (Tilt And P-90312

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

20-41-33].


torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-36

Rod End)
Figure 20-41-34
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-41-36].
At the back side of the control valve, remove the lift Figure 20-41-37
section anti-cavitation valve (Item 1) [Figure 20-41-34].
Figure 20-41-35
3 1
4
P-90315

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-41-35].


torque.

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

Installation (Tilt, Base End)
Figure 20-41-38
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-40] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1) Figure 20-41-41
[Figure 20-41-38] from the base end of the tilt section.
Figure 20-41-39
1
1
P-90319

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

(CONT’D)
Port Relief Valve Removal And Installation 1
Figure 20-41-42
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-41-44].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-41-42] Figure 20-41-45
from the auxiliary circuit of the control valve.
Figure 20-41-43
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure



(CONT’D)
Plug Removal And Installation
Figure 20-41-46
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-48].
P-68016
Figure 20-41-49
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-46].
Figure 20-41-47
P-51462

1 20-41-49]. Tighten to 81,3 N•m (60 ft-lb) torque.
P-51460A

20-41-47]. Tighten to 81,3 N•m (60 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
(CONT’D)
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL 1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-5.) Remove the end cap block from the control valve.
Figure 20-41-50 Figure 20-41-52
1 2
P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-41-50] from Remove the O-ring (Item 1) [Figure 20-41-52].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-41-50].
Figure 20-41-53
100 in-lb) torque.
Figure 20-41-51
P-68047
1
P-90339 20-41-53] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-51]

from the control valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-54
1
1
P-68045
1
Remove the lift spool assembly and seal (Item 1) [Figure

P-68043
Figure 20-41-57

the lift spool end cap.

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-55
P-68046
1 Remove the lift spool seal (Item 1) [Figure 20-41-57]

from the linkage end of the valve.
P-68044
Remove the lift spool end cap (Item 1) [Figure 20-41-55]

from the control valve.

(CONT’D)

1
Figure 20-41-58
N-190146

P-51772
in-lb) torque.
Clamp the linkage end of the spool in a vise [Figure 20-
41-58]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-61
Figure 20-41-59
3
4 1
1
P-51776
P-51773
centering spring.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) NOTE: Check the O-ring for damage. The lift spool
(CONT’D) will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
Lift Spool Removal And Installation (Cont'd) recheck the lift spool before the control valve
is replaced.
Figure 20-41-62
Figure 20-41-64
N-18920
P-74184
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in) Install the plastic plug and O-ring in the spool [Figure 20-
drill. 41-64].
Drill a hole all the way through the plug using a 2,8 mm Figure 20-41-65
(7/64 in) tap drill.
Turn a 6-32 tap (Item 1) [Figure 20-41-62] into the plug.

Pull the tap and plug out of the spool. Be careful, do not 2
1
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.
1
Figure 20-41-63
P-68046 P-51775
2
1 Remove the spool seal(s) (Item 1) and the back-up

P-74183
Install the O-ring (Item 1) over the nipple on the plastic


(CONT’D)
Figure 20-41-66
1 1
2
2
P-68047
3
3
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-41-68] on the lift spool.
P-68044
Figure 20-41-69
Install the lift spool assembly (Item 1) [Figure 20-41-66]

in the spool bore.
1
Install the end cap (Item 2) [Figure 20-41-66].
Install the mounting screws (Item 3) [Figure 20-41-66].

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-67
P-68042
Install the O-ring (Item 1) [Figure 20-41-69] on the

1
control valve.
Installation: Replace the O-ring, lubricate lightly with oil

or grease before installation of the end cap block.
P-68048
Install the spool seal (Item 1) [Figure 20-41-67] on the

linkage end of the valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Tilt Spool Removal And Installation
(CONT’D)
Remove the end cap block. (See End Cap Block
Lift Spool Removal And Installation (Cont'd) Removal And Installation on Page 20-41-17.)
Figure 20-41-70 Figure 20-41-71
2
2
1
P-68040
P-68049
Install the end cap block (Item 1) and the two mount bolts Remove the spacer (Item 1) and O-ring (Item 2) [Figure
(Item 2) [Figure 20-41-70]. 20-41-71] from the tilt spool.
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 - Figure 20-41-72
100 in-lb) torque.
Connect the tubeline (Item 3) [Figure 20-41-70] to the

end cap block.
1
Install the lift and tilt actuators to the control valve.
P-90321
Disconnect the two tubelines (Item 1) [Figure 20-41-72].


in-lb) torque.

(CONT’D)
Figure 20-41-73 1
N-18942
1
Put the linkage end of the spool in the vice [Figure 20-
41-75].
P-90342
centering spring.
41-73] from the control valve. Figure 20-41-76
Installation: Replace the O-ring (Item 2) [Figure 20-41-

73] and lubricate lightly with oil / grease before
installation of the end cap block.
1
Figure 20-41-74
1
N-19014

P-68052 Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100
in-lb) torque.
Remove the tilt spool, centering spring, back-up washer Remove spring tool from the spring assembly.
and spool seal (Item 1) [Figure 20-41-74].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Spool Removal And Installation
(CONT’D)
Figure 20-41-79
Figure 20-41-77
2 1
3
2
4
1
P-90321
N-18944A Disconnect the two tubelines (Item 1) [Figure 20-41-79]

Inspect the adapter (Item 1), collar (Item 2), spring (Item Remove the three screws (Item 2) [Figure 20-41-79]
3) and washer (Item 4) [Figure 20-41-77]. from the spool centering block.
Figure 20-41-78 Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
2
1 Remove the spool centering block from the control valve.
Figure 20-41-80
2
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up 1

P-68053



(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-81
2
2
P-68077
1
P-68054
Figure 20-41-84

Figure 20-41-82
2
1 P-68078
Remove the auxiliary spool (Item 1) [Figure 20-41-84].
P-68076



HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Auxiliary Solenoid Removal And Installation
Figure 20-41-85
1
2
P-90337
Remove the screws (Item 1) [Figure 20-41-85] from both

solenoids.
Remove the solenoids (Item 2) [Figure 20-41-85].
Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6

- 26.4 in-lb) torque.
Figure 20-41-86
P-85556
Check and remove the O-rings (Item 1) [Figure 20-41-

86] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

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

(CONT’D)
Figure 20-41-87 1
P-90346
P-90337 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-87] from the Figure 20-41-90
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-87]. 3

2
Figure 20-41-88
N-18694

[Figure 20-41-90] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-88] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-90] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-88] and

[Figure 20-41-90] and new back-up rings (Item 2)
[Figure 20-41-90] on the solenoid stem.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-91
1
2 P-51792
Remove the tilt lock valve (Item 1) [Figure 20-41-93]

P-90310
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-41-91] is for the lift circuit. Figure 20-41-94
Figure 20-41-92
1
1
1
1
1
2
2
2
P-51564
P-90321
[Figure 20-41-94] from the valve, and replace with new.
Remove the lift lock valve (Item 1) [Figure 20-41-92]


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-97
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-95
1
P-51794
P-90308 Remove the main relief valve (Item 1) [Figure 20-41-97].
Figure 20-41-98
Remove the fitting (Item 1) [Figure 20-41-95] from the
valve.
Figure 20-41-96
1
1
P-90344
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-41-98].
Installation: Always use new O-rings. Tighten to 52 - 61

Check the lift arm bypass orifice (Item 1) [Figure 20-41- N•m (38 - 45 ft-lb) torque.
96].
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-41-99
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

101] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-41-102
Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-41-102].
Remove the check valve fitting (Item 1) [Figure 20-41-

100] from the hydraulic control valve.

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

side of the machine.
The lift arm bypass control valve is manually operated by

pulling on the valve (Item 1) [Figure 20-50-1] and turning
the knob clockwise a 1/4 turn. The valve releases the
hydraulic fluid from the base end of the lift cylinder(s)
which allows the lift arm to slowly come down to the
transport position.
Testing
Figure 20-50-1
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms
slowly lower.
The knob should return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure
support. Replace if damaged. 20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
W-2059-0598
Lower the lift arms.
Raise the operator cab. (See Raising on Page 10-30-2.) 1
P-85671
Disconnect and cap the hydraulic tubeline and hose (Item

1) [Figure 20-50-3].
Remove the two mounting bolts and nuts (Item 2) [Figure

20-50-3].
Installation: Tighten the mounting bolts to 21 - 23 N•m

(180 - 200 in-lb) torque.
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.
Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Reverse the removal procedure to install the lift arm lb) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.

HYDRAULIC PUMP Start the engine and run at low idle rpm. Press the
Auxiliary hydraulics button. Engage the front auxiliary
Description with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
The hydraulic pump is attached to the end of the the tester, the hoses are connected wrong. With the
hydrostatic pumps and is located on the right side of the hoses connected correctly, increase the engine speed to
loader between the hydraulic control valve and the full rpm*.
engine.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump is a combination of gear pumps that control clockwise on the tester so it reads about 6,9 MPa
provide hydraulic flow to several hydraulic systems. (68,9 bar) (1000 psi).
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If the tester counterclockwise to obtain free flow, the flow
any of the main components of the pump are damaged, should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
the entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The U.S. gpm should drop off
Pump Test At Quick Couplers slightly until the pressure reaches approximately 21,4
MPa (213,7 bar) (3100 psi). At approximately 21,4 MPa
The tools listed will be needed to do the following (213,7 bar) (3100 psi) the flow should start decreasing
procedure: rapidly until the pressure reaches 23,8 - 24,1 MPa (237,9
- 241,3 bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9
TWX-RFIK200-S-6 204,4 L/min (54 U.S. gpm) Flow Meter - 241,3 bar) (3450 - 3500 psi) the flow should be at 0 L/
MEL10006 - Fitting Kit min (0 U.S gpm). Turn the restrictor (Item 2) [Figure 20-
60-1] counterclockwise to free flow. Shut the auxiliary
Figure 20-60-1 hydraulics off.
1 If flow and pressure specifications 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.
2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

the front auxiliary quick couplers.
This procedure will require one operator in the cab and

one operator running the tester.

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

procedure:

TWX-RFIK200-S-6 204,4 L/min (54 U.S. gpm) Flow Meter
MEL10006 - Fitting Kit
1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

1
WARNING 2

P-90177
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE 20-60-3] from the tester to the control valve fitting (Item
START TOOL (SERVICE TOOL) KIT - 7003031 on Page 2) [Figure 20-60-2] on the control valve.
10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6,9 MPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the remote start tool engage the auxiliary hydraulics,

the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (U.S. gpm). The high pressure
flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
FREE FLOW (U.S. gpm)
A low percentage may indicate a failed pump.


Direct Pump Test (Charge Section)

procedure:
MEL1563 - Remote Start Tool Kit

1
WARNING
P-85897A
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-4].
W-2017-0286
Figure 20-60-5

1.)

1
2
WARNING
P-90177
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the inlet fitting on the fan (Item
Tester, to prevent any contamination to the 1) [Figure 20-60-4].
Hydrostatic Pumps.
Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE
START TOOL (SERVICE TOOL) KIT - 7003031 on Page
10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
IMPORTANT
I-2024-0284
rpm*.

psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6,9 MPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
*Refer to the Hydraulic Schematics for pump flow and

rpm.

HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

to fall and cause injury or death. 1
W-2059-0598
1
1
1
DANGER
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-6] from the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

P-90328 Removal And Installation on Page 20-130-1.)
AVOID DEATH Figure 20-60-7

unless supported by an approved lift arm 1
D-1009-0409
2
1
IMPORTANT
3
clean the work area before disassembly and keep all P-90509
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
damage the system.
I-2003-0888
60-7] from the hydraulic pump.
Remove the two mounting bolts (Item 2) [Figure 20-60-7]

Lift and block the rear of the loader. (See Procedure on from the hydraulic pump.
Page 10-10-1.)
Raise the lift arms and install an approved lift arm (55 - 60 ft-lb) torque.
Remove the hydraulic pump (Item 3) [Figure 20-60-7]
Raise the operator cab. (See Raising on Page 10-30-2.) from the loader.

Figure 20-60-8
1
1
P100685
Figure 20-60-10
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-8] on the

hydraulic pump. 1
Reverse the removal procedure to install the hydraulic

pump. 1
Hydraulic Pump Startup
NOTE: This procedure is necessary to prevent a dry

startup of the hydraulic pump.
Fill the system with hydraulic fluid. (See Removing And P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-9] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-10].
Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
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.
Check for hydraulic leaks.

Figure 20-60-11
18
12
6
11
4
17
2 15
5
5 13 14
6
2
3
7
6
10
2
5
8 9
6
4 5
3
16 2
P-66540

HYDRAULIC PUMP (STANDARD) (CONT'D) Disassembly And Assembly
Parts Identification (Cont’d)
The items listed below refer to Page 20-60-8 [Figure 20-

60-11]. IMPORTANT
1. Auxiliary Pump End Section When repairing hydrostatic and hydraulic systems,
2. Section Seal parts clean. Always use caps and plugs on hoses,
3. Pre-Load Seal damage the system.
I-2003-0888
4. Load Seal
Mark the pump sections for correct assembly.
5. Wear Plate
To disassemble and assemble the hydraulic pump, follow
6. Alignment Pins the Parts Identification page (See Parts Identification on
Page 20-60-8.) for proper placement of components
7. Drive Gear (Auxiliary Pump) along with the information below.
8. Idler Gear (Auxiliary Pump) NOTE: A seal kit is available through Bobcat Service
Parts.
9. Auxiliary Pump Center Section
Assembly: Tighten the eight pump housing bolts (Item
10. Auxiliary Pump End Section 19) [Figure 20-60-11] to 50 N•m (37 ft-lb) torque.
11. Spline Shaft NOTE: Position the wear plate (Item 5) [Figure 20-60-
11] inlets and traps as shown with the bronze
12. Drive Gear (Charge Pump) side toward the gears on all wear plates.
13. Idler Gear (Charge Pump) NOTE: Inspect all gears, shafts and pump end
sections. If any of these components have
14. Charge Pump Center Section excessive wear or damage is visible, the
complete pump must be replaced.
15. Charge Pump End Section
16. Shaft Seal
17. Bolts (4)
18. Bolts (4)

HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one 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
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6,9 MPa
The high flow hydraulic pump has an additional pump (68,9 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700
from a button on the panel in the cab. psi).
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, the tester counterclockwise to obtain free flow, the flow
the entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The U.S. gpm should drop off
slightly until the pressure reaches approximately 21,4
The tools listed will be needed to do the following MPa (213,7 bar) (3100 psi). At approximately 21,4 MPa
procedure: (213,7 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23,8 - 24,1 MPa (237,9
TWX-RFIK200-S-6 204,4 L/min (54 U.S. gpm) Flow Meter - 241,3 bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9
MEL10006 - Fitting Kit - 241,3 bar) (3450 - 3500 psi) the flow should be at 0 L/
min (0 U.S. gpm). Turn the restrictor (Item 2) [Figure 20-
Figure 20-61-1 61-1] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-2
Direct Pump Test (Standard Section)

procedure:

1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

1
WARNING 2

P-90177
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE 20-61-3] from the tester to the control valve fitting (Item
START TOOL (SERVICE TOOL) KIT - 7003031 on Page 2) [Figure 20-61-2] on the control valve.
10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6 204,4 L/min (54 U.S. gpm) Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

psi). DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (U.S. gpm) at
full rpm*. Put jackstands under the front axles and rear corners
On the remote start tool engage the auxiliary hydraulics, Failure to use jackstands can allow the machine to
the light will come ON. Pull the trigger on the right handle fall or move and cause injury or death.
or joystick for fluid flow to the quick coupler (fluid W-2017-0286
pressure will go over main relief). Record the highest
pressure (psi) and flow (U.S. gpm). The high pressure Lift and block the loader. (See Procedure on Page 10-10-
flow must be at least 80% of free flow. 1.)
%= HIGH PRESSURE FLOW (U.S. gpm) X 100 Raise the lift arms and install an approved lift arm
FREE FLOW (U.S. gpm) support device. (See Installing on Page 10-20-1.)

WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

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

10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Direct Pump Test (Charge Section) (Cont’d)

IMPORTANT
Figure 20-61-4
I-2024-0284
1 rpm*.

psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
P-85897A gpm) at full rpm*.
Turn the restrictor down to system operating pressure

Disconnect the inlet hose (Item 1) [Figure 20-61-4].
approximately 6,9 MPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Figure 20-61-5
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
1 *Refer to the Hydraulic Schematics for pump flow and

2
rpm.
P-90177
Connect the INLET hose (Item 1) [Figure 20-61-5] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-61-4].

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-6] onto the

front auxiliary quick couplers.
the lift arms are secured by an approved lift arm Raise the lift arms and install an approved lift arm
support device. Failure to use an approved lift arm support device. (See Installing on Page 10-20-1.)
W-2059-0598
IMPORTANT
I-2024-0284

procedure:

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

1.)

10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 60°C (140°F) by turning the restrictor
Direct Pump Test (High Flow Section) (Cont'd) psi).
Figure 20-61-7 NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700
psi).
1 gpm) at full rpm. Increase the restriction and the flow
should drop to 0 L/min (0 U.S. gpm) between 24,1 MPa
(241,3 bar) (3500 psi) and 25,5 MPa (255,1 bar) (3700
psi).
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)
2
Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.
P-90183
%= HIGH PRESSURE FLOW (U.S. gpm) X100
Disconnect the high flow pump OUTLET hose (Item 1) FREE FLOW (U.S. gpm)
from the high flow check valve INLET fitting (Item 2)
[Figure 20-61-7]. A low percentage may indicate a failed pump.
Figure 20-61-8 *Refer to Legend Hydraulic Schematics for system relief

pressure and full rpm.
1
2
P-90177
Connect the INLET hose (Item 1) [Figure 20-61-8] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

High Flow Relief Valve Adjustment
If the pump is unable to reach 24,1 MPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
P-45443
[Figure 20-61-11] will need to be turned clockwise a 1/4
turn and retested with the procedure above. (1/4 turn
equals approximately 1,4 MPa (13,8 bar) (200 psi).)
1
NOTE: If the relief screw has been turned in 1/4 turn 2
and the pressure remains the same, go to the
high flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been checked and is OK, go to the P-64022
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-13.) Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove the track from the right side of the loader. (See
Track Removal And Installation on Page 40-20-4.) OR Remove the plug (Item 2) [Figure 20-61-10] located on
(See Track Removal And Installation on Page 40-21-4.) the bottom of the high flow relief valve.
1 1
1
1
1
P-90352 P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-9] NOTE: [Figure 20-61-11] shows adjusting the relief
from the access cover and remove the cover from the screw on a wheeled machine for photo clarity.
loader.
If the pump reaches 25,5 MPa (255,1 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned counterclockwise 1/4 turn and retested with the
procedure above.

High Flow Relief Valve Removal And Installation
WARNING
Failure to use jackstands can allow the machine to 1
W-2017-0286
Remove the track from the right side of the loader. (See P-64022
Track Removal And Installation on Page 40-20-4.) OR
(See Track Removal And Installation on Page 40-21-4.)
Locate the high flow relief valve through rear door along
Figure 20-61-12 the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-13] from

the pump.
Installation: Tighten the relief valve to 41 - 47 N•m (30 -

35 ft-lb) torque.
1 1
Figure 20-61-14
1
1 1 1
P-90352 3
Remove the mounting bolts (Item 1) [Figure 20-61-12] 2

from the access cover and remove the cover from the
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
If the relief valve is bad, it must be replaced as a

complete unit.
Remove the plug (Item 3) and inspect the O-ring [Figure

20-61-14] damage and replace as needed.

Solenoid Removal And Installation 2
Figure 20-61-15
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 17] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 1) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-16
Figure 20-61-18
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-16].

Inspect the O-ring (Item 1) [Figure 20-61-18] and
Remove the solenoid (Item 2) [Figure 20-61-16]. replace as needed.
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 - Inspect the O-ring and back-up washer (Item 2) [Figure
72 in-lb) 20-61-18] and replace as needed.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
Never work on a machine with the lift arms up unless 1

1
W-2059-0598
DANGER 1
1
P-90184
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

61-19] from the front of the hydraulic pump.
Figure 20-61-20
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P-90185

clean the work area before disassembly and keep all Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
parts clean. Always use caps and plugs on hoses, from the back of the hydraulic pump.
damage the system. Remove the Power Bob-Tach block if equipped. (See
I-2003-0888 Removal And Installation on Page 20-130-1.)
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Hydraulic Pump Startup
Removal And Installation (Cont’d) NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Figure 20-61-21
Fill the system with hydraulic fluid. (See Removing And
1 Replacing Hydraulic Fluid on Page 10-120-2.)
2
Figure 20-61-23
Momentary Switch
2
3
P-90509A
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

61-19] from the hydraulic pump. Starter Bypass Tool
P-59354
Remove the two mounting bolts (Item 2) [Figure 20-61-

19] from the hydraulic pump. To crank the engine without starting, the machine key
switch can be bypassed. Obtain a starter bypass tool
Installation: Tighten the mounting bolts to 75 - 85 N•m from a local source which can be used as a universal
(55 - 60 ft-lb) torque. connection to remotely crank the engine without starting.
Remove the hydraulic pump (Item 3) [Figure 20-61-19] The starter bypass tool consists of two wires, each with a
from the loader. clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Figure 20-61-22
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
tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
1
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
P-43940 P-43938A of cylinder stroke.
With the loader parked on a level surface and lift arms

Replace the O-ring (Item 1) [Figure 20-61-22] on the down, check and fill the hydraulic reservoir as required.
hydraulic pump. Check for hydraulic leaks.
Reverse the removal procedure to install the hydraulic

pump.

Figure 20-61-24
21
1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Pre-load Seal
8. Load Seal
22 9. Spline Connector
24 10. Pin
11. Gear Set
1 12. Gear Housing
10 13. Gear Housing
2
14. Gear Set
3
11 15. Gear Housing
8 9
7 16. Gear Set
23 4 17. Center Housing
10
17 12 18. Center Housing
19. Front Housing
4 20. Shaft Seal
3
21. High Flow Relief
22. Seal
10 23. Nut
3 24. Coil
9 14
8
7
4
10 13
18
4
3
10
4
8
7
4 15
16
19
20
10
MS1456S

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-12.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 6)

[Figure 20-61-24 on Page 20-61-12] to 50 N•m (37 ft-lb)
torque.
NOTE: Position the wear plate (Item 3) [Figure 20-61-

19 on Page 20-61-10] inlets and traps as
shown with the bronze side toward the gears
on all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage is visible, the
complete pump must be replaced.
NOTE: The relief valve and the solenoid can be

replaced along with the o-rings and back-up
washers.

HYDRAULIC / HYDROSTATIC FILTERS Figure 20-70-1
Description
2
The hydraulic / hydrostatic filters help to remove 2
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including oil returning from the main valve.
1
2
The charge flow filter removes contaminants after the
charge pump. P-90010
Housing Removal And Installation

device. (See Installing on Page 10-20-1.)
DANGER Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the fluid from the reservoir. (See Removing And

Disconnect the electrical connector (Item 1) [Figure 20-

70-1] from the hydraulic / hydrostatic filter sender.
Disconnect and plug the three hoses (Item 2) [Figure 20-

70-1] from the hydraulic / hydrostatic filter housing.
P-90328
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTER (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
P-90011
Remove and plug the two hoses (Item 1) [Figure 20-70-

2] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-70-3
1
1 P-90537
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the

operator’s cab under the rear grille on the right side of the
loader.

P-90579
Remove the two bolts, (Item 1) [Figure 20-80-2] nuts,
Raise the operator cab. (See Raising on Page 10-30-2.) and bracket.
Drain the fluid from the reservoir. (See Removing And Remove the hydraulic fluid reservoir from the loader.
Installation: Tighten the mount bolts and nuts to 21,7 -
Remove the Hydraulic / Hydrostatic Filter Housing (See 24,4 N•m (16 - 18 ft-lb) torque.
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille (See Removal And Installation on

Page 50-60-1.)
Figure 20-80-1
P-90013
Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen
Remove the rear grille (See Removal And Installation on

Page 50-60-1.)
Figure 20-80-3
P-90506
Remove the hydraulic fluid reservoir breather cap

[Figure 20-80-3] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-3] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER Figure 20-90-2
Description
The oil cooler is used to cool the loaders hydraulic and 2

1
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 3
radiator.
P-85936
IMPORTANT Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-2] and
When repairing hydrostatic and hydraulic systems, pull hose out.
parts clean. Always use caps and plugs on hoses, Cap or plug all hoses and fittings.
damage the system.
I-2003-0888
Remove the rear grille from the loader. (See Removal

And Installation on Page 50-60-1.)
Figure 20-90-1
1 2
P-85938
Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-1] and
pull hose out.
Cap or plug all hoses and fittings.

OIL COOLER (CONT’D)
Figure 20-90-3
4 4
2
5
3
P-85905
Undo the rubber straps (Item 1) [Figure 20-90-3]
Remove the bolts (Item 2) and remove the condenser

guards (Item 3) [Figure 20-90-3].
Remove the clips and pins (Item 4) [Figure 20-90-3].
Remove the bolt (Item 5) [Figure 20-90-3] from the prop

rod.
NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.

BUCKET POSITION VALVE Cover the fuel tank inlet.
Description Figure 20-100-2

The Bucket Position Valve is an option that allows the
operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function. 3
The bucket position valve is mounted to the inside lower
right rear side of the loader frame.
See Hydraulic Schematic for more circuit information. 2
DANGER
1 P-90197
Disconnect the wire harness connector (Item 1) [Figure

20-100-2] from the bucket position shut-off solenoid.
Disconnect the cap the two tubelines (Item 2) [Figure 20-

100-2].
P-90328
Remove the solenoid nut, coil, and stem (Item 3) from the
AVOID DEATH
bucket positioning valve [Figure 20-100-2].
Installation: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
D-1009-0409
torque. Overtightening may cause valve failure.
Drain the hydraulic reservoir. (See Removing And NOTE: The engine is shown removed for photo
Replacing Hydraulic Fluid on Page 10-120-2.) clarity.
Figure 20-100-1 Figure 20-100-3
1
1 2
2
P-90187 N-18191
(Item 2) to the middle of the hose, and the place the fuel Inspect the solenoid stem and replace the O-rings (Item
inlet assembly (Item 3) [Figure 20-100-1] off to the side. 1) and the back-up washer (Item 2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT'D) Cover the fuel tank inlet.
Solenoid Testing Figure 20-100-5
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
DANGER
1 P-90197
NOTE: The engine is shown removed for photo

clarity.
P-90328 NOTE: Mark all hoses and tubelines for correct

installation.
AVOID DEATH
• Disconnecting or loosening any hydraulic Disconnect the electric solenoid connector (Item 1)
tubeline, hose, fitting, component or a part failure [Figure 20-100-5].
• Keep out of this area when lift arms are raised Figure 20-100-6
D-1009-0409
Drain the hydraulic reservoir. (See Removing And 1

Figure 20-100-4
3 2
4 3
1
P-90188
Disconnect and cap the tilt base inlet hose (Item 1), the
tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.
2
P-90187

BUCKET POSITION VALVE (CONT'D) Figure 20-100-9
Figure 20-100-7
P-90190A
2
1
Remove the mounting screws (Item 1) [Figure 20-100-9].
P-90189A
Remove the bucket position valve from the loader.
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]
from the valve block.
Figure 20-100-8
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-12
Figure 20-100-10
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear, inspect the O-ring and replace as needed.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-10]. ft-lb) torque.
Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-13

lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3
Figure 20-100-11
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-13].
Inspect all parts and replace as needed. Install a new O-

P-90195 ring on the plug before installing.
Assembly: Tighten the plug to torque.

Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-100-11].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new O-rings before any parts

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

REAR AUXILIARY DIVERTER VALVE
Description
The rear auxiliary diverter valve is an optional valve that

diverts oil from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing
Figure 20-110-1
P9137
Use a test meter to measure coil resistance [Figure 20-

110-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-3
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-3]
can cause lift arms to drop. Figure 20-110-4
D-1009-0409
1
Put jackstands under the rear corners of the loader.


P-93312
Figure 20-110-2
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-4] from the main harness.
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20-

110-2]

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-110-6
Figure 20-110-5
1
1
P-48751
P-90581
Figure 20-110-7
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-5]
P-48752
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-6] and [Figure 20-

110-7] are located all over the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up

washers.Tighten to 13,6 N•m (10 ft-lb) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-48755
Figure 20-110-8
Figure 20-110-11
1
2
2
P-48755
P-48757
Figure 20-110-9
Remove the differential sensing valve (Item 1) [Figure

20-110-10] and [Figure 20-110-11] from diverter valve
and inspect the O-rings and back-up washers (Item 2)
[Figure 20-110-11] for damage.
2
2 2
Assembly: Put oil on O-ring and back-up washers.
1 Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-8] and

[Figure 20-110-9] from diverter valve and inspect the O-
rings and back-up washers (Item 2) [Figure 20-110-9] for
damage.
Assembly: Put oil on the O-rings and back-up washers.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

Figure 20-110-12
P-48759
1
Figure 20-110-15
P-48753
Figure 20-110-13
1
2 2
P-48760
NOTE: Before removing the solenoid coils mark the

P-48754 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-14] and [Figure

Remove the relief valve (Item 1) [Figure 20-110-12] and 20-110-15] from the solenoid valve stem.
[Figure 20-110-13] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20- Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
110-13] for damage. torque.
Assembly: Put oil on O-ring and back-up washers. Remove the spacer (Item 2) and solenoid valve coils
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-15].

Figure 20-110-16
1
1
P-48762
Figure 20-110-18
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-16] from the

solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

2 2
torque. 1 1
P-48763
Remove the solenoid valve stem (Item 1) [Figure 20-

110-17] and [Figure 20-110-18] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-18] for
damage.
Assembly: Put oil on O-rings and back-up washers.


Figure 20-110-19
P-48765
Remove the plug (Item 1) [Figure 20-110-21].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-20 Figure 20-110-22
1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-19] and [Figure 20-110-20] and inspect the O-rings 22] for dirt and debris.
and back-up washers (Item 2) [Figure 20-110-20] for
damage. Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.
Assembly: Put oil on O-rings and back-up washers.

Figure 20-110-23
1
1
P-48758
Remove the plugs (Item 1) [Figure 20-110-25].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-110-23]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Figure 20-110-24
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48786
Remove the orifice (Item 1) [Figure 20-110-24].
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

BOB-TACH (POWER) BLOCK Removal And Installation
Description
The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
The power Bob-Tach block is mounted on the right side to fall and cause injury or death.
of the machine in front of the engine on the back side of W-2059-0598
the hydraulic pump.
DANGER
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-2
Removal And Installation (Cont'd) 1
Figure 20-120-1
2 4
3
3
3
P-90969
Mark the hydraulic hoses for proper installation.

P-90968
Disconnect and cap the outlet hose (Item 1) [Figure 20-
120-2] from block.
1.) Remove the hydraulic muffler (if equipped) (Item 2)
[Figure 20-120-2] from block.
device. (See Installing on Page 10-20-1.) Disconnect and cap the hoses (Item 3) [Figure 20-120-2]
from block.
Remove the four mounting bolts (Item 4) [Figure 20-120-
Drain the hydraulic reservoir. (See Removing And 2] from block.
Disconnect and cap the two electrical solenoid (35 - 40 ft-lb) torque.
connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness. Remove the power Bob-Tach block.

Figure 20-120-3
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-4].
Inspect the O-ring (Item 4) [Figure 20-120-4] on the plug

Clean the block (Item 1) [Figure 20-120-3] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct
assembly. Figure 20-120-5
Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-5].
Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.

Figure 20-120-6
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-120-8].

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 20-120-6]. will be altered.
Installation: Oil the check valve and O-rings and tighten Figure 20-120-9
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-120-7
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-120-9], inspect the

O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-9]
(Item 2) [Figure 20-120-7]. to 16,3 - 19 N•m (12 - 14 ft-lb) torque.
Inspect the O-rings and back-up washers (Item 3)

[Figure 20-120-7] on the check valve and piston
assembly and replace as needed.

Figure 20-120-10 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-120-12].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
Figure 20-120-13
Installation: Tighten the orifice screw (Item 2) [Figure
20-120-10] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.
Figure 20-120-11
1
1
2
P-48386

P-48127
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-11].
Remove the solenoid nut (Item 2) [Figure 20-120-11].
Installation: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.

Figure 20-120-14
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-16].
Installation: Tighten the screened orifice plug to 14,9 -

Remove the armature assembly (Item 1) [Figure 20-120- 16,3 N•m (11 - 12 ft-lb) torque.
14].
Figure 20-120-17
Figure 20-120-15
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 120-17] 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.
120-15].
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 20-120-
15].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
The front auxiliary hydraulic coupler block is the 1

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
2
The front auxiliary coupler block is located at the front of
the left side lift arm.
Removal And Installation 3
IMPORTANT P-90002

clean the work area before disassembly and keep all Figure 20-130-3
damage the system. 1
I-2003-0888
Figure 20-130-1 2
P-90003
P-85281

1].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-1].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-5
(CONT’D)
Disassembly And Assembly (Cont’d)

1
Figure 20-130-4
4
4 1
4
4 2
2
P-34665
3
Inspect the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-130-5].
P-90001
Figure 20-130-6
Remove the male coupler, spring, and fitting (Item 1)
[Figure 20-130-2], [Figure 20-130-3] and [Figure 20-
1
130-4]
Assembly: Tighten the male coupler (Item 1) [Figure 20-

130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Remove the drain coupler, spring, and fitting (Item 2)

130-4].
Assembly: Tighten the drain coupler (Item 2) [Figure 2

20-130-3] and [Figure 20-130-4] to 50 N•m (37 ft-lb)
P-34664
Remove the female coupler, spring, and fitting (Item 3)
130-4]. Inspect the O-rings (Item 1) back-up O-rings (Item 2) for
damage and replace as needed [Figure 20-130-6].
Assembly: Tighten the female coupler (Item 3) [Figure
20-130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Inspect the O-rings (Item 4) [Figure 20-130-4] and

replace as needed.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-40-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-14
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-26

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in 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 do to internal leakage in the components
of the hydrostatic system.

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

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5, 9
The hydrostatic system is overheating. 6,7,8

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.
5. Track tension is to tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct rpm.
9. The hydrostatic pump is to properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR Removing And Replacing Oil
Description For the correct service interval (See SERVICE

The hydrostatic drive motors are driven by the hydrostatic
pump. Machines equipped with SJC are monitored by a Park the loader so that the plug in the hydrostatic drive
sensor mounted onto the motor housing. The sensor is motor is at the bottom.
used for detection of motion and for rate of speed for the
SJC option. Standard machines use the same motor but Remove the plug and let the oil drain from the hydrostatic
have a plate and O-ring that covers the sensor hole. drive motor.
The hydrostatic drive motors contain a spring applied Figure 30-20-1

pressure release braking system to stop the loader. In
addition there is a separate oil chamber in the motor that
is filled with high performance synthetic oil for maximum
durability, this oil has a recommended service interval.
(See SERVICE SCHEDULE on Page 10-70-1.)
There are two hydrostatic drive motors and they are

located on the track carriage. 1
P-85356A
Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-20-1] is at the top. Add high performance
synthetic oil (P/N 7003026). (See Capacities on Page
SPEC-10-4.)
Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.
Repeat for the other hydrostatic drive motor.
Recycle or dispose of the used oil in an environmentally

safe manner.

HYDROSTATIC DRIVE MOTOR (CONT’D) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
Figure 30-20-2
IMPORTANT 1

clean the work area before disassembly and keep all 1 1
damage the system.
I-2003-0888
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
P-85927
DANGER Remove the mounting bolts (Item 1) [Figure 30-20-2]

from the access cover and remove the cover from the
loader.
Remove the sprocket. (See Sprocket Removal And

Installation on Page 40-20-12.) OR (See Sprocket
Removal And Installation on Page 40-21-13.)
(SJC equipped machines only) Disconnect and remove

the speed sensor (SJC). (See Removal And Installation
P-90328 on Page 60-80-2.)
AVOID DEATH NOTE: Speed sensor removal is recommended to

• Disconnecting or loosening any hydraulic prevent damage while removing the
tubeline, hose, fitting, component or a part failure hydrostatic motor from the track carriage.
D-1009-0409
WARNING
W-2059-0598


HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-4
Figure 30-20-3 1 1
1
P-85991
3 With an arm hoist support the hydrostatic motor.
P-85992 Remove the ten hydraulic motor mounting bolts (Item 1)

[Figure 30-20-4].
Remove the case drain hydraulic hose (Item 1) [Figure
30-20-3] from the motor. Installation: Tighten the motor mounting bolts to 257,6
N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-20-
3] from the motor. Remove the hydrostatic motor from the loader.
Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-20-3].
Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.

HYDROSTATIC DRIVE MOTOR (CONT’D)
10
9
7 8
5 6
4
2 3
25
24
1 23
22
10 21
12
20
11
17 15
16
18
16
13 15
14
19 52
50 51
48 49
37 46
35 33 47
27 33
29 31 40
30 38 36
26 32 34 53 54
28
39
43 44
41 42 60 62
59 61
45
58
57
56
55 63
P-90205

HYDROSTATIC DRIVE MOTOR (CONT’D)
Ref. Description Ref. Description

1. PLUG 33. SPRING
2. SHAFT 34. SPOOL
3. SEAL 35. WASHER
4. BEARING 36. O-RING
5. HOUSING / FRONT 37. PLUG
6. SEAL 38. BOLT
7. BEARING 39. PIN
8. WASHER 40. O-RING
9. RINGS 41. O-RING
10. O-RING 42. PLUG
11. NUT 43. O-RING
12. STUD 44. PLUG
13. RPM TARGET DISK 45. HOUSING / REAR
14. ROLL PIN 46. HOUSING / BRAKE
15. SNAP RING 47. SHAFT
16. RETAINER 48. SHIM
17. ROLLER 49. SHIM
18. PISTON 50. DISC / OUTER
19. BLOCK 51. DISC / INNER
20. CAM 52. SEAL
21. DISTRIBUTOR 53. WASHER
22. SPRING 54. BOLT
23. SEAL W / O-RING 55. BUSHING
24. SEAL W / O-RING 56. PISTON
25. SEAL W / O-RING 57. SEAL
26. PLUG 58. WASHER
27. O-RING 59. GASKET
28. SPRING 60. COVER
29. SHIM 61. O-RING
30. POPPET 62. PLUG
31. PLUG 63. BOLT
32. O-RING

Figure 30-20-5
1
1 N-18295
Remove the twenty four mounting bolts (Item 1) and the

P-48683 brake cover plate (Item 2) [Figure 30-20-7].
NOTE: The bolts should be removed and / or

NOTE: Motors that do not have the SJC sensor (Item tightened, one turn at a time to maintain equal
1) [Figure 30-20-5] will be covered by a plate preload on the end cap.
with and O-ring. The plate will need to be
ordered separately when ordering a new Assembly: Replace the gasket and end cap.
motor from Bobcat Parts.
Assembly: Tighten the bolts to 14 - 16 N•m (10 - 12 ft-lb)
Figure 30-20-6 torque.
Figure 30-20-8
N-18294
N-18296
NOTE: Mark the motor, brake and motor housings for
proper alignment during assembly [Figure 30-
20-6]. Remove the disk spring (Item 1) [Figure 30-20-8] from
the brake housing.
Drain the oil from the motor casing.
NOTE: Mark the top side of the disk spring for proper
Check for the vendor motor serial number (Item 1) installation.
[Figure 30-20-6], these serial numbers may be needed
when ordering replacement parts. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.

Figure 30-20-9
2 1
N-18299
1
Inspect the piston surface (Item 1) and the bushing

N-18297 surface (Item 2) [Figure 30-20-11] in the brake shaft.
NOTE: The bushing (Item 2) [Figure 30-20-11] can be

Remove the piston from the brake housing [Figure 30- replaced in the brake shaft. When the bushing
20-9]. is replaced, install the bushing flush with the
top of the brake shaft.
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-20-9] will aid in
piston removal.
Figure 30-20-10
N-18298
Inspect the brake piston (Item 1) [Figure 30-20-10] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-20-10].
Assembly: Apply oil to the seal (Item 2) [Figure 30-20-

10] for added protection when installing the brake piston.

Figure 30-20-12
1
1
2 1
3
N-18350
1
Assembly: Install the needed amount of shims (Item 1)
1
N-18300 [Figure 30-20-13]. Outer discs can also be used as
shims.
Remove the eight mounting bolts (Item 1) [Figure 30-20- Figure 30-20-14
12] and washers from the brake housing.
Remove the brake housing (Item 2) [Figure 30-20-12]

from the rear housing.
Remove the inner piston seal (Item 3) [Figure 30-20-12].
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake

housing on the rear housing.
Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-20-12]. N-18347
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers Assembly: Clamp the disc pack in a vise and check the
into the rear housing. Start each bolt by hand, tighten disc pack height [Figure 30-20-14].
opposite bolts to maintain squareness.
Assembly: The correct disc pack specifications is 37,7 +
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb) 0,05 mm (1.48 + 0.002 in).
torque.
Assembly: Extra outer disc's are used to reduce the
number of required shims to make up the required
thickness for the brake pack [Figure 30-20-14].

Figure 30-20-15
1
2
1
N-18302
Remove the brake shaft (Item 1) [Figure 30-20-17] from

N-18348 the rear housing.
NOTE: Be sure shaft seats fully into the cylinder

Assembly: Assemble the brake discs into a pack making block.
sure the inner discs, alternate with the outer disc and an
outer disc is placed at each end of the disc pack (Item 1) Assembly: Install new O-ring (Item 2) [Figure 30-20-17]
[Figure 30-20-15]. on the rear housing.
Figure 30-20-16 Figure 30-20-18
1
1 1
1 1
N-18301 P-48684
Disassembly: Remove the brake disks (Item 1) [Figure Remove the eight mounting bolts (Item 1) [Figure 30-20-
30-20-16] and shims from the brake shaft. 18] from the rear housing.
Assembly: Use Loctite® #243 on the threads and install

the eight mounting bolts (Item 1) [Figure 30-20-18].
Assembly: Tighten the bolts to 282 - 300 N•m (208 - 221

ft-lb) torque.

Figure 30-20-19
1
1
N-18318
Remove the two seals and back-up O-rings (Item 1)

P-48685 [Figure 30-20-21] under the seals, from the rear
housing.
Remove the rear housing assembly (Item 1) [Figure 30- Assembly: Apply a slight amount of oil to the O-rings
20-19] from the rotating group / front housing assembly. and seals (Item 1) [Figure 30-20-21].
Figure 30-20-20 Remove and inspect the stop pin (Item 2) [Figure 30-20-
21].
1
Figure 30-20-22
2
P-48686
Remove and replace with a new O-ring (Item 1) [Figure P-48713

30-20-20].
Remove the distributor (Item 2) [Figure 30-20-20] from Remove the twelve springs from the distributor (Item 1)
the rear housing. [Figure 30-20-22].
Assembly: Install the distributor (Item 2) [Figure 30-20- Remove and replace the two seals and back-up O-rings
20] by using the alignment pin. (Item 2) [Figure 30-20-22] under the seals, from the
distributor.
Inspect the distributor surfaces for scratches.
Assembly: Apply a small amount of grease to the

springs to hold them in place during installation.

Figure 30-20-23
1 1
1 N-18309
Remove the plugs (Item 1) [Figure 30-20-25] from the

N-18323 rear housing assembly to check alignment of springs,
washer and spool when reassembling.
Assembly: When installing the distributor align the stop Figure 30-20-26
pin (Item 1) with the notch in the distributor marked L
(Item 2) [Figure 30-20-23].
4
When the distributor is aligned correctly, the distributor
can be depressed slightly. 3
Figure 30-20-24
2
1
N-18315
Inspect all parts and replace as needed [Figure 30-20-

26].
N-18308

rear housing assembly.
Remove the spring (Item 1), spool (Item 2), and washer
(Item 3) and rear spring (Item 4) [Figure 30-20-26].

Figure 30-20-27 2
N-18312
Remove the internal plug (Item 1) [Figure 30-20-29].

N-18310
replace as needed.
Remove the drain plug (Item 1) [Figure 30-20-27].
Figure 30-20-30
Figure 30-20-28
N-18313
N-18311

and replace as needed.


2
Figure 30-20-31 1
4
1
3
2
P-48688
Remove and replace the O-ring (Item 1) [Figure 30-20-

N-18314 33] from the front housing assembly.
Assembly: Slightly smear the O-ring (Item 1) [Figure

Remove the spring (Item 1) shim (Item 2) and poppet 30-20-33] with grease to hold in place.
(Item 3) [Figure 30-20-31].
Remove the rotating group (Item 2) [Figure 30-20-33]
Inspect all parts and replace as needed. from the front housing assembly.
Install a new O-ring (Item 4) [Figure 30-20-31] on the Figure 30-20-34

plug before installation.
Figure 30-20-32
2 1
P-48690
P-48687 Remove the snap ring (Item 1) [Figure 30-20-34] from

the bottom side of the rotating group.
Remove the cam ring (Item 1) [Figure 30-20-32] from the

front housing assembly.
Inspect the cam ring inside surface for wear and

scratches.
Assembly: Align the marks (Item 2) [Figure 30-20-32]

on the cam rings to the front housing.

Figure 30-20-35
P-48694
1 The retainer ring (Item 1) [Figure 30-20-37] cannot be

P-48691 removed from the top side of the rotating group, because
the rpm target disk is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-20-35] from
the bottom side of the rotating group. Figure 30-20-38
Figure 30-20-36
P-48695
1
P-48689
Lift the retaining ring (Item 1) [Figure 30-20-38].
Remove the snap ring (Item 1) [Figure 30-20-36] from Use low air pressure and remove the roller / piston
the top side of the rotating group. assembly (Item 2) [Figure 30-20-38] from the cylinder
block.
NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-20-38] in oil and put all roller /
piston assembles back in the original bore.
NOTE: The roller / piston assembly (Item 2) [Figure

30-20-38] is not a serviceable part.

Figure 30-20-39
1 2
N-18343
Disassembly: With a hammer and punch remove the

P-48693 split ring and the preload washer located under the split
Inspect the rpm target disk (Item 1) [Figure 30-20-39] for Figure 30-20-42
wear and replace as needed.
If the rpm target disk needs to be changed, remove the 1

heads of the five roll pins (Item 2) [Figure 30-20-39] and 2
remove the disk. Replace the target disk and use new roll
pins. Using a small hammer, tap the new roll pins through
the new target disk into the cylinder block.
Figure 30-20-40 3
N-18345
Assembly: Install the front housing (Item 1) and bearing

1
over the shaft. Install the special tool (MEL1562) (Item 2)
[Figure 30-20-42] over the bearing and press the
bearing onto the shaft. Apply 40034 N (9000 lbf) to set
the bearing. Rotate the housing to check for free travel.
NOTE: The 40034 N (9000 lbf), is NOT the amount of

P0076
pressure required by the press. It is the
amount of downward force applied by the
Disassembly: Remove the oil fill plug (Item 1) [Figure press.
30-20-40] from the housing to drain the oil from the Assembly: Install the split ring (Item 3) [Figure 30-20-
bearing and face seal area. 42] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.
Assembly: Add the necessary washer to get closest to

the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

remove the tool.

Figure 30-20-43
2
2
1
1
P13083
Assembly: Remove and replace the face seal (Item 1)

P0020 [Figure 30-20-45] from the shaft.
Assembly: Install a new bearing (Item 2) [Figure 30-20-

Disassembly: Install the bearing puller (Item 1) [Figure 45] onto the shaft.
30-20-43] under the front housing and support the puller
and housing with blocks. Figure 30-20-46
Disassembly: Press the shaft (Item 2) [Figure 30-20-43]

from the housing. 2
1
Figure 30-20-44
P0123
Remove and replace the face seal (Item 1) [Figure 30-

20-46] on the front housing.
P0682
NOTE: When installing face seals, apply a layer of
good quality lithium grease to the mating
Disassembly: Use a bearing puller to remove the surfaces of the face seal.
bearing from the shaft [Figure 30-20-44].
Remove and replace the bearing cup (Item 2) [Figure
NOTE: The bearing will be destroyed during the 30-20-46] on the front housing.
removal procedure. Be sure to have a new
bearing on hand before removing the old NOTE: The bearing cup in the housing may be loose
bearing. after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.


3/4
Figure 30-20-47
Full
1 Range
1/2
P-24562
Fill housing with synthetic Mobilgear SHC XMP 150 to

P0122 [Figure 30-20-49] 1/2 to 3/4 full.
Remove and inspect the bearing (Item 1) [Figure 30-20-

47] located in the front housing.
Replace the bearing if worn or damaged.
Figure 30-20-48
1
3
P0126
Remove the shaft seal (Item 1) [Figure 30-20-48].
Replace the outer O-ring and inner shaft seal (Item 2)

[Figure 30-20-48].
Remove the bearing cup (Item 3) [Figure 30-20-48] if it

needs replacement.

HYDROSTATIC DRIVE MOTOR (TWO SPEED) Removing And Replacing Oil
Description For the correct service interval (See SERVICE

The hydrostatic drive motors are driven by the hydrostatic
pump. Machines equipped with SJC are monitored by a Park the loader so that the plug in the hydrostatic drive
sensor mounted onto the motor housing. The sensor is motor is at the bottom.
used for detection of motion and for rate of speed for the
SJC option. Remove the plug and let the oil drain from the hydrostatic
drive motor.
The hydrostatic drive motors contain a spring applied
pressure release braking system. In addition there is a Figure 30-21-1
separate oil chamber in the motor that is filled with high
performance synthetic oil for maximum durability, this oil
has a recommended service interval. (See SERVICE
There are two hydrostatic drive motors and they are

located on the track carriage. 1
P100737A
Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-21-1] is vertical with the center of the
hydrostatic drive motor. Add high performance synthetic
oil (P/N 7003026). (See Capacities on Page SPEC-10-4.)

plug.
Repeat for the other hydrostatic drive motor.
Recycle or dispose of the used oil in an environmentally

safe manner.

HYDROSTATIC DRIVE MOTOR (TWO SPEED) Remove the track. (See Track Removal And Installation
(CONT’D) on Page 40-20-4.)
Removal And Installation Figure 30-21-2
IMPORTANT 1

clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888

10-10-1.) P100811
Remove the mounting bolts (Item 1) [Figure 30-21-2]

DANGER from the access cover and remove the cover from the
loader.
Remove the sprocket. (See Sprocket Removal And

Disconnect and remove the speed sensor. (See Removal

NOTE: Speed sensor removal is recommended to

P-90328 prevent damage while removing the
hydrostatic motor from the track carriage.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598


HYDROSTATIC DRIVE MOTOR (TWO SPEED) Figure 30-21-5
(CONT’D)

1 1
Figure 30-21-3
1 P-85991
With an arm hoist support the hydrostatic motor.

3
Remove the ten hydraulic motor mounting bolts (Item 1)
P-85992 [Figure 30-21-5].
Remove the case drain hydraulic hose (Item 1) [Figure Installation: Tighten the motor mounting bolts to 257,6
30-21-3] from the motor. N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-21- Remove the hydrostatic motor from the loader.
3] from the motor.
Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-21-3].
Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.
Figure 30-21-4
2 3
4 1
P100901
Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-21-4]. Retighten all bolts to required torque in
the same sequence.

HYDROSTATIC DRIVE MOTOR (TWO SPEED) (CONT’D)
10
9
8
65 7
6
5
4
3
12
2 23
11 22
65
21
10
20
1
14
40
39
17
18
38
13 36 37
15 41
16
36
19 42
16 29 42
15 35 30
31
43
34 64
24 32 44 36
25 33
26 31
28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56

HYDROSTATIC DRIVE MOTOR (TWO SPEED) (CONT’D)
Ref. Description Ref. Description

1. PLUG 34. BOLT
2. SHAFT 35. BOLT
3. SEAL 36. PIN
4. BEARING 37. WASHER
5. HOUSING / FRONT 38. BOLT
6. SEAL 39. DISC / OUTER
7. BEARING 40. DISC / INNER
8. WASHER 41. BUSHING
9. SPLIT RINGS 42. SHIM
10. O-RING 43. HOUSING / BRAKE
11. NUT 44. SHAFT
12. STUD 45. O-RING
13. RPM TARGET DISC 46. BOLT
14. ROLL PIN 47. COVER PLATE
15. SNAP RING 48. GASKET
16. RETAINER 49. PIN
17. ROLLER 50. SEAL
18. PISTON 51. CLIP
19. BLOCK 52. SPRING
20. CAM 53. SPOOL
21. DISTRIBUTOR 54. PLUG
22. SPRING 55. HOUSING / REAR
23. SEAL W / O-RING 56. SEAL
24. PLUG 57. O-RING
25. O-RING 58. SNAP RING
26. SPRING 59. PISTON
27. SHIM 60. SEAL
28. POPPET 61. DISC SPRING
29. PLUG 62. GASKET
30. O-RING 63. COVER PLATE
31. SPRING 64. BOLT
32. WASHER 65. PLUG
33. SPOOL

HYDROSTATIC DRIVE MOTOR (TWO SPEED) Assembly: Replace the gasket and torque bolts to 35 -
(CONT’D) 39 N•m (26 - 29 ft-lb).
Disassembly And Assembly Figure 30-21-8
Figure 30-21-6
N-18296
P100869
Remove the disc spring (Item 1) [Figure 30-21-8] from
the brake housing.
NOTE: Mark the motor (Item 1), brake and motor
housings for proper alignment during NOTE: Mark the top side of the disc spring for proper
assembly [Figure 30-21-6]. installation.
Drain the oil from the motor casing. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Inspect for the vendor motor serial number (Item 2)
[Figure 30-21-6], these serial numbers may be needed
when ordering replacement parts.
Figure 30-21-7
P100799
Remove the mounting bolts (Item 1) and the brake cover

plate (Item 2) [Figure 30-21-7].
NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

(CONT’D)
Figure 30-21-9
1
2
P100868
1 Inspect the piston surface (Item 1) and the bushing

surface (Item 2) [Figure 30-21-11] in the brake shaft.
P100804
NOTE: The bushing (Item 2) [Figure 30-21-11] can be
replaced in the brake shaft. When the bushing
Remove the piston from the brake housing [Figure 30- is replaced, install the bushing flush with the
21-9]. top of the brake shaft.
NOTE: The use of air pressure through the brake line

connection (Item 1) [Figure 30-21-9] will aid in
piston removal.
Figure 30-21-10
2
P100801
Inspect the brake piston (Item 1) [Figure 30-21-10] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-21-10].
Assembly: Apply oil to the seal (Item 2) [Figure 30-21-

10] for added protection when installing the brake piston.

(CONT’D)
Figure 30-21-12
N-18347
3
2
Assembly: Clamp the disc pack in a vise and inspect the
disc pack height [Figure 30-21-13].
1 P100866
Assembly: The correct disc pack reference
specifications is 37,7 mm (1.48 in).
Remove the five mounting bolts (Item 1) [Figure 30-21-
12] and washers from the brake housing. Assembly: Extra outer disc's are used to reduce the
number of required shims [Figure 30-21-13] to make up
Remove the brake housing (Item 2) [Figure 30-21-12] the required thickness for the brake pack.
from the rear housing.
NOTE: Brake pack height is for reference only.
Remove the snap ring and inner piston seal (Item 3)
[Figure 30-21-12]. Figure 30-21-14
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake

housing on the rear housing.
Assembly: Install new washers on the brake housing 1

mount bolts (Item 1) [Figure 30-21-12].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
P100867
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)
torque.
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-21-14]. Outer discs can also be used as
shims.

HYDROSTATIC DRIVE MOTOR (TWO SPEED) NOTE: The 20 kN (4500 lbf) is NOT the amount of
(CONT’D) pressure required by the press. It is the
Disassembly And Assembly (Cont'd) press.
Figure 30-21-15 Figure 30-21-17
2
3
1
P100805 P100858
Assembly: Assemble the brake discs into a pack making

sure the inner discs (Item 1), alternate with the outer disc Disassembly: Remove the brake discs (Item 1) [Figure
(Item 2) and an outer disc is placed at each end of the 30-21-17] and shims from the brake shaft.
disc pack with the shims (Item 3) [Figure 30-21-15] and
the base of the pack. Figure 30-21-18
Figure 30-21-16
1
1
2
P100859
3
P100800
Remove the brake shaft (Item 1) [Figure 30-21-18] from
Assembly: Assemble the brake piston into the brake the rear housing.
housing without the inner brake piston seal (Item 3)
[Figure 30-21-12 on Page 30-21-8] and brake piston NOTE: Be sure shaft seats fully into the cylinder
outer seal (Item 2) [Figure 30-21-10 on Page 30-21-7]. block.
Apply 20 kN (4500 lbf) to set the brake pack. Using a
depth gauge (Item 1), measure from the gasket mating Assembly: Install new O-ring (Item 2) [Figure 30-21-18]
surface (Item 2) to the inner machined groove (Item 3) on on the rear housing.
the brake piston [Figure 30-21-16].
The dimensional measurement must be 8,7 ± 0,1 mm
(0.343 ± 0.003 in), if not adjust brake pack discs to the
required measurement.

(CONT’D)
Figure 30-21-19
P100872

rear housing.
P100870
Figure 30-21-22
Remove the two speed spool assembly (Item 1) [Figure

30-21-19] from the rear housing.
Figure 30-21-20
1 2
P100871
2
4
3 Remove the spool (Item 1) [Figure 30-21-22].
N-22501 Assembly: Install new O-ring (Item 2) [Figure 30-21-22]

on the plug and torque to 50 N•m (37 ft-lb)
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-20].
NOTE: If the spool (Item 1) [Figure 30-21-20] is

damaged the entire rear housing assembly
has to be replaced.

(CONT’D)

1
Figure 30-21-23 1 1
1
2 4 3
1 1
1
2 2
P100861
Remove the ten mounting bolts (Item 1) [Figure 30-21-

24] from the rear housing.
N-22504
Remove the two (8 mm) cam ring mount bolts (Item 2)
[Figure 30-21-24].
Remove the spring (Item 1), washer (Item 2) and rear
spring (Item 3) from the spool (Item 4) [Figure 30-21-23]. Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Inspect all parts and replace as needed.
Assembly: Clean the threads on the bolts and front
housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-24] to 210 - 220 N•m
(154 - 162 ft-lb) torque. Clean the threads on the two (8
mm) bolts (Item 2) [Figure 30-21-24] and the cam ring.
Apply Loctite® #243 and tighten the bolts to 70 - 77 N•m
(52 - 57 ft-lb).

(CONT’D)
Figure 30-21-25
1
P100856
Remove the springs from the distributor (Item 1) [Figure

30-21-27].
P100860
Inspect the distributor surfaces for scratches.
Remove and replace with a new O-ring (Item 1) [Figure Assembly: Apply a small amount of grease to the
30-21-25]. springs to hold them in place during installation.
Remove the distributor (Item 2) [Figure 30-21-25] from Figure 30-21-28

the rear housing.
Assembly: Install the distributor (Item 2) [Figure 30-21-

25] by using the alignment pin.
Figure 30-21-26
2 1
P100855
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) [Figure 30-21-28] from the distributor.
2
N-18318
Remove the seal and back-up O-ring (Item 1) [Figure 30-

21-26] under the seal, from the rear housing.
Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-21-26].
Remove and inspect the stop pin (Item 2) [Figure 30-21-

26].

(CONT’D)
Figure 30-21-29
P100873
1

and replace as needed. Torque to 60 N•m (44 ft-lb)
P100812
Figure 30-21-32
Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor (Item 2)
[Figure 30-21-29].
When the distributor is aligned correctly, the distributor

1
can be depressed slightly by hand and will return to its
original position.
Figure 30-21-30
1
P100875
P100874

(CONT’D)
Disassembly And Assembly (Cont'd) 2

1
Figure 30-21-33
4
1
3
2
P100924
Remove and replace the O-ring (Item 1) [Figure 30-21-

35] from the front housing assembly.
N-18314
Assembly: Slightly smear the O-ring (Item 1) [Figure
30-21-35] with grease to hold in place.
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-21-33]. Remove the rotating group (Item 2) [Figure 30-21-35]
from the front housing assembly.
Inspect all parts and replace as needed.
Figure 30-21-36
Install a new O-ring (Item 4) [Figure 30-21-33] on the
plug and replace as needed. Torque to 25 N•m (18 ft-lb)
Figure 30-21-34
2
1
1
P-48690
Remove the snap ring (Item 1) [Figure 30-21-36] from

P100925 the bottom side of the rotating group.
Remove the cam ring (Item 1) [Figure 30-21-34] from the

front housing assembly.
Inspect the cam ring inside surface for wear and

scratches.
Assembly: Align the marks (Item 2) [Figure 30-21-34]

on the cam rings to the front housing.

(CONT’D)
Figure 30-21-37
P100927
The retainer ring (Item 1) [Figure 30-21-39] cannot be

1 removed from the top side of the rotating group, because
P-48691 the rpm target disc is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-21-37] from Figure 30-21-40
the bottom side of the rotating group.
Figure 30-21-38
2
1
P100928
P100926 Lift the retaining ring (Item 1) [Figure 30-21-40].
Use low air pressure and remove the roller / piston

Remove the snap ring (Item 1) [Figure 30-21-38] from assembly (Item 2) [Figure 30-21-40] from the cylinder
the top side of the rotating group. block.
NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-21-40] in oil and put all roller /
piston assembles back in the original bore.
NOTE: The roller / piston assembly (Item 2) [Figure

30-21-40] is not a serviceable part.

(CONT’D)

2
Figure 30-21-41
1
P100932
Assembly: Install the front housing (Item 1) and bearing

over the shaft. Install the special tool (MEL1562) (Item 2)
P100929 [Figure 30-21-43] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
bearing. Rotate the housing to inspect for free travel.
Disassembly: Remove the oil fill plug (Item 1) [Figure
30-21-41] from the housing to drain the oil from the NOTE: The 40 kN (9000 lbf) is NOT the amount of
bearing and face seal area. pressure required by the press. It is the
Clean the threads of the plug and drain hole. Apply press.
Assembly: Install the split ring (Item 3) [Figure 30-21-
plug.
43] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.
Figure 30-21-42
Assembly: Add the necessary preload washer to get
closest to the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

remove the tool.
1
P100931
Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split

(CONT’D)
Figure 30-21-44
2
1
2
P13083
Assembly: Remove and replace the face seal (Item 1)

[Figure 30-21-46] from the shaft.
P100934
Assembly: Install a new bearing (Item 2) [Figure 30-21-
46] onto the shaft.
Disassembly: Install the bearing puller (Item 1) [Figure
30-21-44] under the front housing and support the puller Figure 30-21-47
and housing with blocks.
Disassembly: Press the shaft (Item 2) [Figure 30-21-44] 1

from the housing.
Figure 30-21-45
P100941
Remove and inspect the bearing (Item 1) [Figure 30-21-

47] located in the front housing.
P0682 Replace the bearing and bearing cup if worn or

damaged.
Disassembly: Use a bearing puller to remove the

bearing from the shaft [Figure 30-21-45].
NOTE: The bearing will become unserviceable during

the removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.

(CONT’D)
Figure 30-21-48 2 1
2
1
P100940
Remove the shaft seal (Item 1) [Figure 30-21-49].
P100939 Remove the bearing cup (Item 2) [Figure 30-21-49] if it

needs replacement.
Remove and replace the face seal (Item 1) [Figure 30- Figure 30-21-50
21-48] on the front housing.
NOTE: When installing face seals, apply a layer of

good quality lithium grease to the mating
surfaces of the face seal. 1
Remove and replace the bearing cup (Item 2) [Figure

30-21-48] on the front housing.
NOTE: The bearing cup in the housing may be loose

after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.
P100930
Rotate the hydrostatic drive motor so that the drain plug

(Item 1) [Figure 30-21-50] is vertical with the center of
the hydrostatic drive motor. Fill housing with 180 mL (6.1
U.S. fl oz) high performance synthetic oil (P/N 7003026).

plug.

CHARGE PRESSURE Testing
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
2 4
hydraulic control valve. 1 3
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6,9 MPa (68,9 bar) (1000 psi) (Item 3) and adapter
fitting (P/N 93F-5) (Item 4) [Figure 30-30-1].
WARNING
W-2059-0598
Raise the loader lift arms and install an approved lift arm

10-10-1.)

CHARGE PRESSURE (CONT’D) Figure 30-30-4
Testing (Cont’d)
Figure 30-30-2
1
1
2
3 3
2
P-90301
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].

P-43197
Install the hose (Item 2) [Figure 30-30-4], that was
disconnected from the motor, to the T fitting.
Connect the gauge (Item 1), to the adapter fitting (P/N
93F5) (Item 2) [Figure 30-30-2]. Install the hose (Item 3) [Figure 30-30-4], that is
attached to the pressure gauge, to the T fitting.
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to
the adapter fitting. Tighten all connections. Tighten the hydraulic fittings.
Figure 30-30-3 Connect the remote start tool. (See REMOTE START
10-61-1.)
Start the loader and warm the hydraulic fluid to 140

degrees Farenheit.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 140 degree
Farenheit is 3,0 - 3,4 MPa (30,0 - 34,1 bar) (435 - 495
1
psi) with the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 2,5 - 2,8
P-90302 MPa (24,8 - 28,3 bar) (360 - 410 psi) at 60°C
(140°F) fluid @ High idle.
Disconnect the hydraulic hose (Item 1) [Figure 30-30-3].

CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-30-5
P-90302
Disconnect the wire (Item 1) [Figure 30-30-5] from the

sender.
Remove the sender (Item 2) [Figure 30-30-5] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Inspect the O-ring on the sender before

installation.

CHARGE PRESSURE (CONT'D) Figure 30-30-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-30-6 Remove the plug, spring and poppet [Figure 30-30-7].
Inspect the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-30-8
P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item 1)
[Figure 30-30-8] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55,2 kPa

(0,55 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is 3,0
- 3,4 MPa (30,0 - 34,1 bar) (435 - 495 psi) with the pump
in neutral.

CHARGE PRESSURE (CONT'D) Figure 30-30-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
P-64435
I-2003-0888
Figure 30-30-9 Inspect the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-30-10] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim (Item 1) [Figure 30-30-10] = 299,9

kPa (3,0 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2,5 - 2,8 MPa (24,8

- 28,3 bar) (360 - 410 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.

HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate 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
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
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT'D) Figure 30-40-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

50-1.)
P-90222
IMPORTANT
Use a puller (Item 1)
clean the work area before disassembly and keep all [Figure 30-40-2] to loosen the pulley from the pump
parts clean. Always use caps and plugs on hoses, drive shaft.
damage the system. NOTE: DO NOT strike puller or pump shaft with a
I-2003-0888 hammer. Internal pump damage may result.
Figure 30-40-1 Remove the nut and washer from the pump drive shaft.
Remove the pump pulley and key from the pump drive
shaft.
Figure 30-40-3
P-90221
1
1
Loosen the nut (Item 1) [Figure 30-40-1] on the
hydrostatic pump drive shaft.
P-90223
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque
30-40-3].
Installation: Tighten the mounting bolts and nuts to 88 -

95 N•m (65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (CONT'D)
Figure 30-40-4
P-90224

at the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 125 - 135 N•m (90

- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-40-3.)
Hydrostatic Pump Startup
Follow the hydraulic pump startup procedure. (See

Hydraulic Pump Startup on Page 20-60-7.)

HYDROSTATIC PUMP (CONT’D) Inspect the O-ring (Item 2) [Figure 30-40-6] for damage
Replenishing / High Pressure Relief Valve Removal
And Installation If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
Figure 30-40-5
The pressure setting for a new high pressure relief valve
is 36,2 MPa (362,0 bar) (5250 psi).
P-43857
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-40-5] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
Figure 30-40-6
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-40-5] and [Figure 30-40-6] from the pump.
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)

torque.
Inspect for damage and replace as needed.

Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block
19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10
18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

HYDROSTATIC PUMP (CONT'D) Figure 30-40-9
Disassembly
Figure 30-40-7
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-40-9].

P-43858
Remove the large O-ring (Item 2) [Figure 30-40-9].
Remove the four mounting bolts (Item 1) [Figure 30-40- Remove the two small O-rings (Item 3) [Figure 30-40-9].
7].
Figure 30-40-10
Figure 30-40-8
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-40-10] from

Separate the two hydrostatic pumps [Figure 30-40-8]. the pump housing end cap.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-13
Disassembly (Cont’d)
2
1
Figure 30-40-11
N-17194
2
Inspect the valve plate locating pin (Item 1) [Figure 30-
N-19551 40-13] for wear and replace if needed.
Inspect the needle bearing (Item 2) [Figure 30-40-13] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
40-11].
Figure 30-40-14
Remove the gasket (Item 2) [Figure 30-40-11].
Figure 30-40-12
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-40-14]

from the pump.
Remove the valve plate (Item 1) [Figure 30-40-12].
Inspect the valve plate for wear. (Both Sides.)

3 3
Figure 30-40-15
1 1
3 2
3
2
N-17200
Inspect the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-40-17] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-40-17] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-40-15] from the cylinder block.
Inpsect the cylinder block for wear and replace as
Inspect all the pistons (Item 2) [Figure 30-40-15] for needed.
wear and replace the rotating group as needed.
Inspect pins (Item 3) [Figure 30-40-17] to see if they are
Figure 30-40-16 all the same length.
Figure 30-40-18
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-40-
16] from the cylinder block.
Remove the thrust plate (Item 1) [Figure 30-40-18] from
the pump housing.

Figure 30-40-19
1
1
2
N-17240
3
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
Remove the driveshaft key (Item 1) the snap ring (Item 2) Figure 30-40-22
and the support washer (Item 3) [Figure 30-40-19] from
the drive shaft end of the pump.
Figure 30-40-20
N-17241

N-17239 the driveshaft and remove the bearing.
Inspect the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-40-20] from the pump housing.

Figure 30-40-23
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-40-25] from the pump housing.
Figure 30-40-26
Inspect the pump shaft (Item 1) [Figure 30-40-23] for
wear and replace if needed.
Figure 30-40-24
N-17245
1 1
Inspect the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-40-26] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-40-24]

from the lower trunnion cover. Remove the cover.

Figure 30-40-27
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-40-29] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-40-30
Inspect the dust seal on the pintle shaft.
Remove the four mount bolts (Item 1) from the pump

housing and remove the linkage bracket (Item 2) [Figure
30-40-27].
Figure 30-40-28
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-30] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-40-

28].

1
Figure 30-40-31
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-40-33] and

N-17249 remove the swash plate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-31] and replace as needed.
Figure 30-40-32
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-40-32] from
the swash plate shaft.

Assembly
Figure 30-40-34
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-36] on

N-17253 the swash plate shaft.
Figure 30-40-37
Install the lower bearing (Item 1) [Figure 30-40-34] on
the swash plate.
Figure 30-40-35
N-17248
Install the bearing race (Item 2) [Figure 30-40-36] and O-

N-17252 ring (Item 3) [Figure 30-40-36] as shown in [Figure 30-
40-37].
Install the swash plate and bearing into the pump

housing [Figure 30-40-35].

Assembly (Cont’d)
Figure 30-40-38
1 N-17245
Figure 30-40-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-38]

and cover.
Figure 30-40-39
1
N-17244
Install the bearing race (Item 1) [Figure 30-40-40] and O-

ring (Item 2) [Figure 30-40-40] at the lower trunnion as
shown in [Figure 30-40-41].
N-17246
Install the linkage bracket (Item 1) [Figure 30-40-39] and

the four mounting bolts and tighten to 24 - 30 N•m (18 -
22 ft-lb) torque.
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-40-42
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-40-

N-17243 44] on the pump shaft.
Figure 30-40-45
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-42].
Install the four mounting bolts and tighten to 24 - 30 N•m

Figure 30-40-43
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-45].
Install the snap ring (Item 1) [Figure 30-40-45].

N-17242
Install the snap ring (Item 1) [Figure 30-40-43] on the

pump shaft.

Assembly (Cont’d)
Figure 30-40-46
1
1
1
1 2 3
N-17198
Assemble the piston assemblies into the slipper guide.

N-17200 Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
40-48].
Install the four slipper pins (Item 1) [Figure 30-40-46]
into the cylinder block. Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
Apply a small amount of grease to the washer (Item 2)
and install into the ball guide retainer (Item 3) [Figure 30- Figure 30-40-49
40-46].
Figure 30-40-47
N-17197
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-40-49].
Install the ball guide retainer and washer (Item 1) [Figure

30-40-47] onto the slipper holddown pins.

Assembly (Cont’d)
Figure 30-40-50
1
1
2
N-17193
Coat the backside of the valve plate with petroleum jelly

N-17194 to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-52].
Replace the needle bearing (Item 1) and valve plate The notch (Item 1) [Figure 30-40-52] on the valve plate
locating pin (Item 2) [Figure 30-40-50] in the charge must engage the locating pin.
pump.
Figure 30-40-53
Figure 30-40-51
2
1
N-19551
N-17196
Coat a new end cap gasket (Item 1) [Figure 30-40-53]

The bearing cage (Item 1) [Figure 30-40-51] will with petroleum jelly and install onto the end cap.
protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

40-51] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.

Assembly (Cont’d)
Figure 30-40-54
1 1
N-19570
Install the two pumps together [Figure 30-40-56].

N-19550
Figure 30-40-57
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-40-54] to 47 - 61
N•m (35 - 45 ft-lb) torque. 1
Figure 30-40-55
1
1
3 P-43858
2 Tighten the four bolts (Item 1) [Figure 30-40-57] to 47 -

1 61 N•m (35 - 45 ft-lb) torque.
N-19571
Install the two small O-rings (Item 1) [Figure 30-40-55].
Install the large new O-ring (Item 2) [Figure 30-40-55].
Install the pump coupler (Item 3) [Figure 30-40-55].

HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The endcaps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-41-1
P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
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 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-41-3] from both sides of the hydrostatic
pump.
Removal:
WARNING
of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-41-2 I-2003-0888
Figure 30-41-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
41-2] on the hydrostatic pumps.
from the hydraulic controller.

HYDROSTATIC PUMP (SJC) (CONT'D) Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
Hydraulic Controller Removal And Installation [Figure 30-41-5].
(Cont'd)
Figure 30-41-7
Figure 30-41-5
1
1 2
3 1
P-90210
P-90210
Alternately tighten bolts (Item 1) [Figure 30-41-7] to 10,4

Remove the controller (Item 1) [Figure 30-41-5] from the N•m (7.7 ft-lb) torque. Ensure bolts are tightened to
pump. specifications.
Remove the controller gaskets (Item 2) [Figure 30-41-5] NOTE: When a hydraulic controller is replaced, the
from the pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Installation: Page 30-41-26.)
Figure 30-41-6
2 2
P-90209
NOTE: Do NOT remove the three screens (Item 2)

[Figure 30-41-6] they will be damaged during
removal and must be replaced.
Be sure the feedback lever (Item 3) [Figure 30-41-5] is in

the center of the servo piston groove (Item 1) [Figure 30-
41-6].

Remove the hydrostatic pump / engine assembly from

Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

50-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-41-9] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-41-8 Remove the pump pulley from the pump drive shaft.
Figure 30-41-10
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-41-8] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 30-41-10].
ft-lb) torque

HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-41-11
P-90224

11] at the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 125 - 135 N•m (90

- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-41-6.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.
Figure 30-41-12
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-41-12].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

3 1
1. O-ring 5 4
2. Bolt
3. End Housing 7
4. O-ring 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer / Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. O-ring 11 9 2
13. Position Sensor 12
14. Washer 13
15. Bolt 14
15
16
22 17
21 19
23 24
20 18
26
18
25 27
19
29 26
16. Steel Cover

17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
6 21. Bolt
2 7 22. Plug
23. Plug
24. Dowel Pin
28 25. Charge Pressure Relief
26. Left Servo
4 27. Right Servo
28. Left Rotating Assembly
29. End Housing
P-90240

High Pressure Relief And Bypass Valve
Figure 30-41-13
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-41-15]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-15] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-13] in the back of the hydrostatic pump.
Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-13].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36,2 MPa (362,0 bar)
Figure 30-41-14 (5250 psi).
4
3
2 1
P-64436
Inspect the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-14], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-14]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-41-14] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-41-16 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-41-18] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-41-16] is Inspect the sealing ring (Item 3) [Figure 30-41-18] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or
foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 70 N•m (52 ft- shims (Item 5) [Figure 30-41-18].
lb) torque.
NOTE: 1,0 mm shim (Item 5) [Figure 30-41-18] = 300,0
Figure 30-41-17 kPa (3,0 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
1
P-64435
Inspect and replace the O-ring (Item 1) [Figure 30-41-

17].

HYDROSTATIC PUMP (SJC) (CONT'D) Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.
Disassembly And Assembly Note the connectors facing each other.
Remove the hydrostatic pump / engine assembly from Figure 30-41-21

Page 70-10-7.)
Remove the hydrostatic pump. (See Removal And

Installation on Page 30-41-4.) 1
Figure 30-41-19
2
1 1 P-90228
Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-41-21].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-41-

19]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.)
Figure 30-41-20
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-41-20].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-41-20] from both sides.

HYDROSTATIC PUMP (SJC) (CONT'D) Right End Housing
Disassembly And Assembly (Cont'd) Figure 30-41-24
Figure 30-41-22
3
1
1
1
P-64445
P-90217
Left End Housing
Assembly: Note the slotted portion (Item 1) of the Figure 30-41-25

positioning pin tightly fits the machined section on the
swash plate angle sensor shaft (Item 2) [Figure 30-41- 3 1
22].
Figure 30-41-23
1
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-41-24] and [Figure 30-41-25].
Assembly: Alternately, tighten mount bolts to 130 N•m

Inspect and replace the O-ring (Item 1) [Figure 30-41- (96 ft-lb) torque.
23].

Figure 30-41-26
P-64466
Ensure servo follower (Item 2) [Figure 30-41-27] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-41-28].
Pull the end housings from the case housing [Figure 30- Figure 30-41-29
41-26].
Figure 30-41-27
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-41-29] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-41-27].

Figure 30-41-30
RIGHT SIDE
P-64454
Figure 30-41-31
LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-41-30] and

[Figure 30-41-31] 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

30-41-30] and [Figure 30-41-31] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.


LEFT SIDE
Figure 30-41-32 1
2
RIGHT SIDE
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64455 32] and [Figure 30-41-33] in the case housing with the
notch (Item 1) [Figure 30-41-34] and [Figure 30-41-35]
that does not go through the valve plate.
Figure 30-41-33
Align the shoulder of the roller bearing (Item 2) [Figure
LEFT SIDE 30-41-32] and [Figure 30-41-33] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-34] and [Figure
30-41-35].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.
1
2
P-64502
Figure 30-41-34
RIGHT SIDE
1
2
P-64456

Figure 30-41-36
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-38].

B25012
Figure 30-41-39
Right Side Rotating Group [Figure 30-41-36].
Figure 30-41-37
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-39] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-37].


1
Figure 30-41-40
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 42].
Figure 30-41-43
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-40] in the
1
slippers, are not plugged.
Figure 30-41-41
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-43]. 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 30-41-41].


3
Figure 30-41-44
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-41-46].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-41-46].
1) [Figure 30-41-44].
Remove the slide ring (Item 3) [Figure 30-41-46], ensure
Figure 30-41-45 it pivots freely.
Figure 30-41-47
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-45] 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 30-41-47].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-41-45] are not bent or damaged.


1 1
Figure 30-41-48
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 50].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-50] on them. The edges face towards
swash plate (Item 1) [Figure 30-41-48]. the outside of the endcap housing
Figure 30-41-49 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-41-50].

2
Figure 30-41-51
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-49].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-41-49] on swash plate.
Replace O-ring (Item 1) [Figure 30-41-51].
Inspect wear surfaces (Item 2) [Figure 30-41-51] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-41-52
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-41-54] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-41-55
Figure 30-41-53
RIGHT SIDE 1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-41-52] and a rubber mallet.
[Figure 30-41-53] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-41-55] and remove
bearing.

Figure 30-41-56
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-58].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-41-59
B25013
Servo Piston Assembly [Figure 30-41-56].

1
The Servo Piston Assembly [Figure 30-41-56] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-41-57
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-59].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-57].

Figure 30-41-60
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-41-62] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-41-
61].
Slide the servo piston assembly out of the bore. [Figure
30-41-60]. Figure 30-41-63
Figure 30-41-61
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-41-63] from the pump housing.

Figure 30-41-64 1
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-41-66] from

P-64494 the servo piston.
Figure 30-41-67
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-41-64].
Figure 30-41-65
P-64497
1
Remove snap ring (Item 1) [Figure 30-41-67] from the
P-64495 servo piston.
Remove the lock nut (Item 1) [Figure 30-41-65] from the

servo piston.
Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-41-68 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.

10-10-1.)
WARNING
P-64498
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-41-68] from the servo piston. Raise the lift arms, and install an approved lift arm
Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-41-68]
Figure 30-41-69 TOOL KIT-MEL1563 on Page 10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
2 find an accessible connector to disconnect.
1 Disconnect the speed sensors located on the top of the

drive motors. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
P-64502
WARNING
Bearings (Item 1) [Figure 30-41-69] in case housing are
replaced by using a press and bearing driver. Hydraulic fluid escaping under pressure can have
Inspect center coupler (Item 2) [Figure 30-41-69]. penetrating the skin. This can cause serious injury
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-70
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-72] from the

P-64973 MA ports on the bottom of the pump, and install 51,7
MPa (517,1 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-41-70] Figure 30-41-73

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 30-41-71
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-41-73]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51,7 MPa (517,1
bar) (7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-41-71] from the pump mechanical neutral setting.
MB ports on the front side of the pump, and install 51,7
MPa (517,1 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-74
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-41-76]

P-90226 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 30-41-74]. Figure 30-41-77
Start the loader using the remote start tool and run at
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-41-75
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-41-78 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
2 NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-41-78] to 30 N•m
(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-2.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Connect the remote start tool. (See REMOTE START
26.) TOOL KIT-MEL1563 on Page 10-60-1.) or (See REMOTE
10-61-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-79
P-64975
1 Install 3,4 MPa (34,5 bar) (500 psi) pressure gauges in

P-90239 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-41-82

[Figure 30-41-79] from the loader wiring harness for the
hydraulic controller you are adjusting.
Figure 30-41-80
1
1
P-90236
Loosen the locking screw (Item 1) [Figure 30-41-82].

P-90226
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 30-41-80] pertaining to the side of the
hydrostatic pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-83
P-90236

P-90236 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 30-41-86
in system pressure. Mark the position of the adjustment
screw.
Figure 30-41-84
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-41-86] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-41-84] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

DRIVE BELT Belt Replacement
Belt Adjustment Stop the engine and open the rear door.
The drive belt does not need adjustment. The belt has a Remove the battery. (See Removal And Installation on
spring loaded idler which constantly maintains the correct Page 60-20-1.)
belt tension.
Figure 30-50-1
P-85518
Remove the drive belt shield bolt (Item 1) [Figure 30-50-

1].
Figure 30-50-2
P-90467
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
toward the back of the loader to unseat the shield from
the top and bottom drive belt shield mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-50-2].

DRIVE BELT (CONT’D) Tighten the spring loaded idler adjustment bolt (Item 1)
[Figure 30-50-3] to 105 - 115 N•m (78 - 85 ft-lb) torque.
Belt Replacement (Cont’d)
Figure 30-50-5
Figure 30-50-3
Top Mounting Bolt
1
1
2
P-90468A
Bottom Mounting Bolt
P-90470
2
Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30-
50-3] into the slot provided in the stop arm as shown and
push breaker bar down to release tension on drive belt.
P-90469A
Tighten the adjustment bolt (Item 1) [Figure 30-50-3] to
hold the spring loaded idler off the drive belt.
Position the drive belt shield over the drive belt shield
Remove the drive belt from the hydrostatic pump pulley mounting bolts and slide the drive belt shield toward the
and flywheel pulley. Inspect the pulleys for wear. front of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-50-5].
Install new drive belt.
Figure 30-50-6
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-50-3] and allow the idler to contact the drive
belt.
Figure 30-50-4
1
P-85518
Install the drive belt shield bolt (Item 1) [Figure 30-50-6].
Install the battery. (See Removal And Installation on

P-90471
Page 60-20-1.)
Move the breaker bar to adjust the stop arm until a gap of Close the rear door.
3,2 mm (0.125 in) (Item 1) [Figure 30-50-4] is achieved.

DRIVE BELT (CONT’D)
Stop Adjustment
Figure 30-50-7
P-90470
Loosen the spring loaded idler adjustment bolt (Item 1)

and insert a 12,7 mm (1/2 in) breaker bar (Item 2)
[Figure 30-50-7] into the slot provided in the stop arm as
shown.
Figure 30-50-8
P-90471
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-50-8] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-7] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation Figure 30-50-11
Remove the engine air cleaner. (See Housing Removal

1
Remove the belt. (See Belt Replacement on Page 30-50-
1.)
Figure 30-50-9 2
1
1
3
P-90306
2
Loosen the two bolts (Item 1) [Figure 30-50-11] but do
not remove.
Release the spring tension by allowing the adjustment

plate (Item 2) to slide past the tensioner pulley stop (Item
P-85520 3) [Figure 30-50-11].
Remove the two bolts (Item 1) and the adjustment plate

Loosen the spring loaded idler adjustment bolt (Item 1). (Item 2) [Figure 30-50-11].
Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30-
50-9] into the slot provided in the stop arm as shown and Figure 30-50-12
push breaker bar down to release tension on drive belt.
Tighten adjustment bolt (Item 1) [Figure 30-50-9] to hold

the spring loaded idler off the drive belt.
Figure 30-50-10
1 1
2
P-90304
Remove the pivot sleeve (Item 1) [Figure 30-50-12].
P-85741

10].
Remove the tensioner pulley (Item 2) [Figure 30-50-10].

DRIVE BELT (CONT'D)
Tensioner Pulley Disassembly And Assembly

(Cont’d)
Figure 30-50-13
P-90303
Disassembly the tensioner pulley as shown [Figure 30-

50-13].
Inspect the parts for wear and replace as needed.
NOTE: The wheel and arm assembly (Item 1) [Figure

30-50-13] are not serviceable and must be
replaced as a complete assembly.

DRAIN MANIFOLD Figure 30-60-2
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic oil to the reservoir.
2
Drain Manifold Removal And Installation
IMPORTANT 2
2
P100002
damage the system. Disconnect the wiring harness from the oil temperature
I-2003-0888 switch (Item 1) [Figure 30-60-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the three hoses (Item 2) [Figure 30-60-2].
Drain the hydraulic reservoir. (See Removing And Mark and cap all hoses and tubelines.
Figure 30-60-3
Figure 30-60-1
1
1
1
2
P100003
P100001
Remove the two hoses (Item 1) [Figure 30-60-3].

Remove the tubeline (Item 1) [Figure 30-60-1] from the
drain manifold. Remove the two bolts and nuts (Item 2) [Figure 30-60-3].
Mark and cap all hoses and tubelines. Mark and cap all hoses and tubelines.

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) . . . . . . . . . . . 40-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-12
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-13
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-14
TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

BRAKE
Description
WARNING
Figure 40-10-1
W-2059-0598

1
Figure 40-10-2
P-85426
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the left panel.
Block Removal And Installation
DANGER
1 P-85428
Disconnect the electrical connector (Item 1) [Figure 40-

10-2] located on the side of the transmission.
P-90328
AVOID DEATH
D-1009-0409

BRAKE (CONT'D) Block Disassembly And Assembly
Block Removal And Installation (Cont'd) Figure 40-10-5
Figure 40-10-3
1
2
P-85431
P-85427
Loosen the electrical brake solenoid nut (Item 1) and the
three fittings (Item 2)[Figure 40-10-5].
Disconnect and cap the tube line (Item 1) [Figure 40-10-
3] from the rear of the brake valve. Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48 -
60 in-lb) torque.
Figure 40-10-4
Figure 40-10-6
2 2
1
1 1
1
1 3
P-85430
P-85429
Mark the hydraulic hoses for proper installation.

Remove the solenoid nut (Item 1) and solenoid coil (Item
Remove and cap the four hydraulic hoses (Item 1) 2) [Figure 40-10-6].
[Figure 40-10-4].
Remove the solenoid valve (Item 3) [Figure 40-10-6]
Remove the two mount bolts (Item 2) [Figure 40-10-4]. from the block.
Remove the brake block from the loader.

BRAKE (CONT'D)
Block Disassembly And Assembly (Cont’d)
Figure 40-10-7
1
2 1
2 1
2 3
P-85432
Inspect the O-rings (Item 1) and back-up ring (Item 2)

[Figure 40-10-7] on the solenoid valve and replace as
needed.
Check the screens (Item 3) [Figure 40-10-7] and clean

with solvent.
Assembly: Tighten the solenoid valve to 21,7 - 27,1 N•m


TRACK UNDERCARRIAGE COMPONENTS (SOLID-
MOUNTED)
Description
Figure 40-20-1
MS2786S
The track carriage components consist of front and rear

idlers, rollers, the track, track tensioner, the drive
sprocket and the track housing [Figure 40-20-1].

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Figure 40-20-3
MOUNTED) (CONT'D)
Checking Tension
Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
prematurely.
1
NOTE: The wear of track rollers vary with the working
conditions and different types of soil
conditions.
Park the loader on a level surface.
Figure 40-20-2
P-85869A
Figure 40-20-4
Track
13 - 16 mm
Roller
(1/2 - 5/8 in)
P-85870A
Track
Raise one side of the loader and put jackstands at the B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-20-2].
Lower the loader to the jackstands. Be sure the DO NOT put your fingers into the pinch points between
jackstands do not touch the tracks. the track and the roller. Use a 13 - 16 mm (1/2 - 5/8 in)
bolt, dowel or block to check the gap [Figure 40-20-3]
Measure the track sag at either middle track roller (Item and [Figure 40-20-4].
1) [Figure 40-20-2]. The correct gap is 13 - 16 mm (0.50
- 0.625 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

MOUNTED) (CONT'D)
Adjusting Tension
Figure 40-20-5
2 1
1
2 P-76047
Pressure must be released from the grease cylinder to

1 decrease track tension.
P-76325
Install the bleed tool (MEL-1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-20-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-20-5]. Figure 40-20-7
NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-20-5] is used to remove grease. 1
Increase Track Tension
Add grease to the grease fitting (Item 1) [Figure 40-20-5]

until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].
NOTE: Do not remove grease fitting unless pressure P-76837

is released using the bleed fitting. (See
[Figure 40-20-6] on Page 40-20-3)
Tighten the access cover bolt (Item 1) [Figure 40-20-7]
NOTE: If replacement is necessary, always replace to secure the tool.
grease fitting (Item 1) [Figure 40-20-5] with
genuine Bobcat Parts. The fitting is a special Turn the tool 90° counterclockwise and let the grease
fitting designed for high pressure. flow into a container. Release pressure [Figure 40-20-7]
Decrease Track Tension [Figure 40-20-4].
Tighten the bleed fitting. Pivot the access cover closed

WARNING and tighten the access cover bolts.
Raise the loader. Remove the jackstands.

HIGH PRESSURE GREASE CAN
CAUSE SERIOUS INJURY Repeat the procedure for the other track.
• Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2 Dispose of grease in an environmentally safe manner.
turns.
W-2781-0109

MOUNTED) (CONT'D)
Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
DANGER environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 90° turn. This will allow the grease
to flow out faster when lifting the track in the next step.
P-90328
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-20-8]
• Disconnecting or loosening any hydraulic before continuing.
D-1009-0409

1.)
1
WARNING P-85416

the lift arms are secured by an approved lift arm With a chain hoist, lift on the track moving the front idler
support device. Failure to use an approved lift arm assembly toward the rear of the track assembly until all
support device can allow the lift arms or attachment track tension has been released [Figure 40-20-8].
W-2059-0598 Tighten the bleed fitting using the MEL1560 tool (Item 1)
[Figure 40-20-8].
Decrease the track tension. (See Adjusting Tension on
Page 40-20-3.)
NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76 mm (3 in).

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Put the track on the front idler wheel.
MOUNTED) (CONT'D)
Adjust the track to the proper tension. (See Adjusting
Track Removal And Installation (Cont’d) Tension on Page 40-20-3.)
Figure 40-20-9 NOTE: The grease tube must be completely retracted

against the coil spring assembly before
adding grease, to prevent air from being
trapped in the grease tube.
NOTE: Check the alignment of the grease tube (Item

1) [Figure 40-20-19] before adjusting the track.
P-85370
With pry bars, pry the track up and over the front idler
[Figure 40-20-9].
Completely remove the track from the front track

assembly.
Figure 40-20-10
P-85417
With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-20-10].
To install the rubber track:
Completely retract the front idler and track tensioner.
Put the track over the rear drive sprocket lugs.
Put the track over the rear idler.
Slide the track under the rollers.

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation
1 1
1.)
Remove the track. (See Track Removal And Installation

on Page 40-20-4.)
Figure 40-20-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

[Figure 40-20-13] may be inserted to keep the front idler
wheel in place until the track is installed.
1 NOTE: The bolts must be removed before completing

track installation. It will not be possible to
remove the bolts after track tension has been
set.
P-76843
Slide the front idler wheel out of the track housing

[Figure 40-20-11].
NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-20-11] is toward the top of the
track housing for installation.
Figure 40-20-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-20-

12] on the front idler wheel frame engage the holes in the
track tensioner.

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation (Cont’d)
Figure 40-20-14
P-76325
Installation: Track tensioner must be seated properly

1 against the end of the track housing [Figure 40-20-16].
P-85418
Slide the track tensioner (Item 1) [Figure 40-20-14] out

of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-20-14] before sliding it into the track
housing.
Figure 40-20-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-20-15].

MOUNTED) (CONT'D)
Idler (Front) Removal And Installation (Cont'd) CORRECT
Figure 40-20-17
WRONG
2 2
1
1
P-85014A
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
P-85371 against the coil spring assembly (Item 2) [Figure 40-20-
19].
Figure 40-20-18
WRONG
P-85014
Installation: [Figure 40-20-17] and [Figure 40-20-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-20-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

MOUNTED) (CONT'D)
Track Tensioner Disassembly And Assembly
WARNING
4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
AVOID INJURY OR DEATH (Item 3), and wear ring (Item 4) [Figure 40-20-21] from
• Spring loaded components under pressure can the grease tube.
cause serious injury or death.
• Do not disassemble the coil spring assembly. Installation: Apply oil to new O-ring, back-up ring, seal,
W-2617-1004 and wear ring before installation.
Figure 40-20-20 Installation: Apply grease to area between seal and O-

ring before installing.
NOTE: The grease tube must be completely retracted

onto the chrome shaft before replacing the
2 grease fitting and adding grease, to prevent
air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-20-20].

MOUNTED) (CONT'D)
Track Tensioner Disassembly And Assembly (Cont’d) 8
WARNING
1 2 3 4 5 6 7
P-85019
Inspect and replace any damaged parts.

P-62574
The items listed below refer to [Figure 40-20-23].
• Spring loaded components under pressure can 1. Coil Spring Assembly
cause serious injury or death. 2. O-ring
• Do not disassemble the coil spring assembly. 3. Chrome Shaft
W-2617-1004 4. Seal
5. Back-up Ring
6. O-ring
Figure 40-20-22 7. Wear Ring
1 8. Grease Tube
NOTE: The O-ring (Item 2) is used to secure the

chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-20-23] during the
installation of the track tensioner into the
track housing.
P-85372
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 283,5 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

20-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Roller Removal And Installation
MOUNTED) (CONT'D)
Remove the track from the loader. (See Track Removal
Idler (Rear) Removal And Installation And Installation on Page 40-20-4.)
Remove the track. (See Track Removal And Installation Figure 40-20-25
on Page 40-20-4.)
Figure 40-20-24
1
1
1
1
2
2 P-85421
P-76847 Remove the bolts (Item 1) [Figure 40-20-25] from the

roller shaft. (Both ends of the roller shaft.)
Remove the two mount bolts and washers (Item 1) Installation: Tighten the bolts or nuts to 410 - 450 N•m
[Figure 40-20-24]. (300 - 330 ft-lb) torque.
Remove the rear idler from the loader. Remove the roller from the track assembly.
Installation: Align the square sides of the idler shaft with

the notches in the track housing (Item 2) [Figure 40-20-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 407 - 447


MOUNTED) (CONT'D)
Sprocket Removal And Installation
Figure 40-20-26
1
2
P-85407
Remove the six nuts (Item 1) [Figure 40-20-26] and

remove the drive sprocket from the motor.
NOTE: Install three (1/2 in - 13UNC x 3 in) long bolts in

the sprocket holes (Item 2) [Figure 40-20-26]
to aid in the removal of the sprocket.
Installation: Tighten the nuts to 280 - 300 N•m (207 -

222 ft-lb) torque.

MOUNTED) (CONT'D)
Track Housing Removal And Installation
NOTE: Jackstands used when removing the track

must not interfere with track housing removal. 1

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-2.)
Support the track housing.

P-76864
Figure 40-20-27
At the rear of the loader remove the two mount bolts

1 (Item 1) [Figure 40-20-28].
Installation: Tighten the mount bolts to 410 - 450 N•m

Figure 40-20-29
P-85409

from the bottom track housing mount plate. (At the front
and rear of the loader.)

P-85408
At the front of the loader remove the two mount bolts

(Item 1) [Figure 40-20-29].
Remove the track housing from the loader.


TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION)
Description
Figure 40-21-1
P-85368
The track carriage components consist of front and rear

idlers, rollers, leaf springs, the track, track tensioner, the
drive sprocket and the track housing [Figure 40-21-1].

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-21-3
SUSPENSION) (CONT'D)
Checking Tension
Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
prematurely.
NOTE: The wear of track rollers vary with the working

conditions and different types of soil
conditions.
Park the loader on a level surface.
Figure 40-21-2
P-85379A
Figure 40-21-4
Track
13 mm
Roller
(1/2 in)
1
P-85354A
Track
Raise one side of the loader and put jackstands at the B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-21-2].
Lower the loader to the jackstands. Be sure the DO NOT put your fingers into the pinch points between
jackstands do not touch the tracks. the track and the roller. Use a 13 mm (1/2 in) bolt, dowel
or block to check the gap [Figure 40-21-3] and [Figure
Measure the track sag at either middle track roller (Item 40-21-4].
1) [Figure 40-21-2]. The correct gap is 13 mm (0.50 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

Adjusting Tension
Figure 40-21-5
2 1
1
2 P-76047
Pressure must be released from the grease cylinder to

1 decrease track tension.
P-76325
Install the bleed tool (MEL-1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-21-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-21-5]. Figure 40-21-7
NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-21-5] is used to remove grease. 1
Increase Track Tension
Add grease to the grease fitting (Item 1) [Figure 40-21-5]

[Figure 40-21-4].
NOTE: Do not remove grease fitting unless pressure P-76837

is released using the bleed fitting. (See
[Figure 40-21-6] on Page 40-21-3)
Tighten the access cover bolt (Item 1) [Figure 40-21-7]
NOTE: If replacement is necessary, always replace to secure the tool.
grease fitting (Item 1) [Figure 40-21-5] with
genuine Bobcat Parts. The fitting is a special Turn the tool 90° counterclockwise and let the grease
fitting designed for high pressure. flow into a container. Release pressure [Figure 40-21-7]
Decrease Track Tension [Figure 40-21-4].
Tighten the bleed fitting. Pivot the access cover closed

WARNING and tighten the access cover bolts.
Raise the loader. Remove the jackstands.

HIGH PRESSURE GREASE CAN
CAUSE SERIOUS INJURY Repeat the procedure for the other track.
• Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2 Dispose of grease in an environmentally safe manner.
turns.
W-2781-0109

Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
DANGER environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 90° turn. This will allow the grease
to flow out faster when lifting the track in the next step.
P-90328
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-21-7]
• Disconnecting or loosening any hydraulic before continuing.
D-1009-0409

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

WARNING P-85380

the lift arms are secured by an approved lift arm With a chain hoist, lift on the track moving the front idler
support device. Failure to use an approved lift arm assembly toward the rear of the track housing assembly
support device can allow the lift arms or attachment until all track tension has been released [Figure 40-21-
to fall and cause injury or death. 8].
W-2059-0598
Tighten the bleed fitting using the MEL1560 tool (Item 1)
[Figure 40-21-8].
Decrease the track tension. (See Adjusting Tension on
Page 40-21-3.)
NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76 mm (3 in).

Track Removal And Installation (Cont’d)
Figure 40-21-9
P-85369
With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-21-10].
P-85370
Installation: Completely retract the front idler / track
tensioner.
With pry bars, pry the track up and over the front idler
[Figure 40-21-9]. Put the track on the front idler wheel.
Completely remove the track from the front track Put the track over the rear drive sprocket lugs.
assembly.
Slide the track under the rollers.
Put the track over the rear idler.
NOTE: Check the alignment of the grease tube (Item

1) [Figure 40-21-19] before adjusting the track.
Adjust the track to the proper tension. (See Adjusting

Tension on Page 40-21-3.)

Idler (Front) Removal And Installation
1 1
Remove the track. (See Track Removal And Installation
on Page 40-21-4.)
Figure 40-21-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

1 [Figure 40-21-13] may be inserted to keep the front idler
wheel in place until the track is installed.
NOTE: The bolts must be removed before completing

P-76843 track installation. It will not be possible to
remove the bolts after track tension has been
set.
Slide the front idler wheel out of the track housing
[Figure 40-21-11].
NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-21-11] is toward the top of the
track housing for installation.
Figure 40-21-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-21-

12] on the front idler wheel frame engage the holes in the
track tensioner.

Idler (Front) Removal And Installation (Cont’d)
Figure 40-21-14
P-76325
Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-21-16].
P-76844
Slide the track tensioner (Item 1) [Figure 40-21-14] out

of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-21-14] before sliding it into the track
housing.
Figure 40-21-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-21-15].

Idler (Front) Removal And Installation (Cont'd) CORRECT
Figure 40-21-17
WRONG
2 2
1
1
P-85014A
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
P-85371 against the coil spring assembly (Item 2) [Figure 40-21-
19].
Figure 40-21-18
WRONG
P-85014
Installation: [Figure 40-21-17] and [Figure 40-21-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-21-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

Track Tensioner Disassembly And Assembly
WARNING
4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
AVOID INJURY OR DEATH (Item 3), and wear ring (Item 4) [Figure 40-21-21] from
• Spring loaded components under pressure can the grease tube.
cause serious injury or death.
• Do not disassemble the coil spring assembly. Installation: Apply oil to new O-ring, back-up ring, seal,
W-2617-1004 and wear ring before installation.
Figure 40-21-20 Installation: Apply grease to area between seal and O-

ring before installing.
NOTE: The grease tube must be completely retracted

onto the chrome shaft before replacing the
2 grease fitting and adding grease, to prevent
air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-21-20].

Track Tensioner Disassembly And Assembly (Cont’d) 8
WARNING
1 2 3 4 5 6 7
P-85019

P-62574
The items listed below refer to [Figure 40-21-23].
• Spring loaded components under pressure can 1. Coil Spring Assembly
cause serious injury or death. 2. O-ring
• Do not disassemble the coil spring assembly. 3. Chrome Shaft
W-2617-1004 4. Seal
5. Back-up Ring
6. O-ring
Figure 40-21-22 7. Wear Ring
1 8. Grease Tube
NOTE: The O-ring (Item 2) is used to secure the

chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-21-23] during the
installation of the track tensioner into the
track housing.
P-85372
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 283,5 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

21-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Roller Removal And Installation
Idler (Rear) Removal And Installation And Installation on Page 40-21-4.)
Remove the track. (See Track Removal And Installation Figure 40-21-25
on Page 40-21-4.)
Figure 40-21-24
1
1
2
2 P-85374
P-76847 Remove the bolt and washer (Item 1) [Figure 40-21-25]

from the roller shaft. (Both ends of the roller shaft.)
Remove the two mount bolts and washers (Item 1) Remove the roller from the track assembly.
[Figure 40-21-24].
Installation: Support the roller from underneath with a
Remove the rear idler from the loader. hydraulic floor jack and tighten the bolts to 711,5 N•m
(525 ft-lb) torque.
Installation: Align the square sides of the idler shaft with
the notches in the track housing (Item 2) [Figure 40-21-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 711,5 N•m

(525 ft-lb) torque.

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Installation: Tighten the leaf spring bolts (Item 2)
SUSPENSION) (CONT'D) [Figure 40-21-26] and (Item 1) [Figure 40-21-27] to
406,7 N•m (300 ft-lb) torque.
Leaf Spring Removal And Installation
Figure 40-21-28
Figure 40-21-26
1
3
P-76930
Remove the leaf spring assembly [Figure 40-21-28] from

P-85375 the track housing.
NOTE: The leaf spring assembly [Figure 40-21-28] is

Remove the roller bolt and washer (Item 1) [Figure 40- only sold as a complete left-hand or right
21-26] from the roller shaft. (Both ends of the roller hand assembly from Bobcat Parts.
shaft.)
Figure 40-21-29
Remove the roller from the track housing.
Installation: Support the roller from underneath with a

hydraulic floor jack and tighten the bolts to 711,5 N•m
(525 ft-lb) torque.
Remove the leaf spring bolts (Item 2) [Figure 40-21-26]

from the leaf spring mounts. (Both sides of the track
housing.) 1
Figure 40-21-27
P-76027
The upper and lower leaf spring mounts are wider on one
1 side to prevent the leafs from rubbing on the track
housing during operation.
Installation: The leaf springs are installed correctly when

there is a slight gap (Item 1) [Figure 40-21-29] between
P-85377 the leafs and the track housing. (Cutaway view shown for
clarity.) The gap is easily seen at the roller end of the leaf
spring (Item 3) [Figure 40-21-26].
Access the front, inside leaf spring assembly bolts (Item
1) [Figure 40-21-27] from underneath the loader through
an access hole in the track housing.

Sprocket Removal And Installation
Figure 40-21-30
1
2
P-85407
Remove the six nuts (Item 1) [Figure 40-21-30] and

remove the drive sprocket from the motor.
NOTE: Install three (1/2 in - 13UNC x 3 in) long bolts in

the sprocket holes (Item 2) [Figure 40-21-30]
to aid in the removal of the sprocket.
Installation: Tighten the nuts to 280 - 300 N•m (207 -

222 ft-lb) torque.

Track Housing Removal And Installation
NOTE: Jackstands used when removing the track

must not interfere with track housing removal. 1

Remove the hydrostatic motor from the track housing.

Support the track housing.

P-76864
Figure 40-21-31
At the rear of the loader remove the two mount bolts

(Item 1) [Figure 40-21-32].
1
Figure 40-21-33
P-85422

from the bottom track housing mount plate. (At the front
and rear of the loader.)

P-85408
At the front of the loader remove the two mount bolts

(Item 1) [Figure 40-21-33].
Remove the track housing from the loader.
Installation: Tighten the mount bolts to torque.

TRACK MAINTENANCE Driving over sharp objects should be avoided. If this
is impossible, do not make turns while driving over
Track Damage Identification sharp objects.
The following pages show photos and illustrations of Cutting Of Steel Cords
track damage and the probable cause of the damage. It
is intended to be used for identifying the reason for track Figure 40-30-2
damage and how to avoid future track damage.
Track and Sprocket Rotation:
Figure 40-30-1
Move Sprockets to opposite sides of the loader
P-3864
Remove track
Reinstall 180° Figure 40-30-3
P-85440
NOTE: All applications and conditions will cause

wear on the track inbeds and sprocket teeth.
Rotating the tracks and sprockets will extend Steel Cords
their life. The track can be removed and PI-13034
reinstalled 180 degrees. The sprocket can be
removed and installed on the opposite side of
the loader [Figure 40-30-1]. Damage:
Prevention: Embedded steel cords are cut off [Figure 40-30-2]

and [Figure 40-30-3].
The following preventions should be taken to minimize
the risk of this damage:
Recommended track tension should be periodically

checked. (See DRIVE SYSTEM TOC on Page 40-
01.)
Avoiding quick turns on bumpy and rocky fields.
Drive carefully to avoid having stones and other

articles clog the rubber tracks.

TRACK MAINTENANCE (CONT'D) Causes of the damage:
Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 40-30-4
Rubber tracks are driven with an extraordinary heavy
load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
P-3865 Figure 40-30-6
Damage:
Embedded metals will gradually wear away by friction Minimum Wear

[Figure 40-30-4].
Figure 40-30-5
Excessive Wear
PI-13037A
Track Rotation:
Certain applications or conditions can cause wear on the

track inbeds and sprocket teeth. Rotating the tracks 180
degrees will help extend track life [Figure 40-30-6]. (See
PI-13037 Track Damage Identification on Page 40-30-1.)
Remove the track and rotate it 180 degrees on the same

Replacement: side of the loader. (See DRIVE SYSTEM TOC on Page
40-01.)
When track embedded metals are worn
approximately 50% or more, replace the track.
Example of excessive wear is shown in [Figure 40-
30-4] and [Figure 40-30-5].

TRACK MAINTENANCE (CONT'D) Figure 40-30-8
Track Damage Identification (Cont'd)
Separation Of Embedded Metals
Figure 40-30-7
Idler
Rubber
track
PI-13039
Causes of the damage:
Embedded metals are adhered between the steel cords

P-4379 and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:
Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded embedded metals, the embedded metals will
metals cause their separation from the rubber track's eventually peel off [Figure 40-30-8].
body [Figure 40-30-7].
Figure 40-30-9
Replacement:
Even a partial separation of embedded metals

requires replacement of the track.
Guide
PI-13040
When a rubber track is detracked, it becomes stuck

between the guide or the undercarriage frame,
causing the separation of embedded metals [Figure
40-30-9].

Figure 40-30-10
Minimum
wear
Excessive
wear
PI-13041A
Sprocket Rotation:
PI-13041
Certain applications or conditions can cause wear on the
sprockets. Rotating the sprockets to the opposite side of
Excessively worn sprockets, example shown [Figure the loader will help extend sprocket life [Figure 40-30-
40-30-10] will pull embedded metals out of the track. 11]. (See Track Damage Identification on Page 40-30-1.)
Prevention: Remove the sprocket. (See DRIVE SYSTEM TOC on

Page 40-01.)
Similar to the prevention against the cutting of the steel
cords:
Recommended track tension should be periodically

checked. (See DRIVE SYSTEM TOC on Page 40-
01.)
Quick turns on bumpy and rocky fields should be

avoided.

Track Damage Identification (Cont'd) Embedded metal
Separation Of Embedded Metals Due To Corrosion
Figure 40-30-12
Good
Separation of
bonded rubber
cover
PI-13043
Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals
Damage: from the rubber body [Figure 40-30-13].
Due to corrosion of embedded metals, the adhesion Excessively salty fields, like the sea shore
to the rubber body deteriorates, resulting in complete
separation [Figure 40-30-12]. Strong acidic or alkali soil conditions
Replacement: Compost spread grounds
Even a partial separation of embedded metals On tracks that are out of adjustment, the track rollers,
requires a rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
Prevention:
If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.
When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.

Cuts On The Lug Side Rubber Cuts
Figure 40-30-14
PI-13045
When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 40-30-14]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-30-15].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately Machine operators are requested to drive with great
repaired with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-30-16 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.
Figure 40-30-17 Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-30-16] and [Figure 40-30-
17].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.

Track Damage Identification (Cont'd) Lug abrasion is more or less inevitable. Even if lug
abrasion is proceeding, the rubber track can be used.
Lug Abrasion However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
Figure 40-30-18 abraded tracks with new ones when the lug height
becomes less than 5 mm (0.197 in).
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads
Driving up and down hilly paths with slippage
Making frequent turns on paths covered with rocks

P-4381 and wood
Figure 40-30-19
Lug abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-30-18] and [Figure
40-30-19].
Replacement:
No replacement is required.

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-30-20 embedded metal rubber
PI-13051
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
Damage: [Figure 40-30-21].
Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-30-20]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested
Replacement: to avoid driving over stumps and ridges.
Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.

Abrasion Of The Track Roller Side

Track roller
Figure 40-30-22
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
Damage: the side of the rubber track to cause the abrasion [Figure
40-30-23].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-30-22]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

Cuts On The Edges Of Track Roller Side
Figure 40-30-24
PI-13056
This damage is caused by objects on the field or by

P-4384 interference with the machine frame.
In case of damage by objects on the operating ground:

Figure 40-30-25
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
Edge Edge easily occurs [Figure 40-30-26].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-30-24] and
[Figure 40-30-25].
Replacement:
In such case, the rubber track does not have to be

replaced.

TRACK MAINTENANCE (CONT'D)
Cuts On The Edges Of Track Roller Side (Cont’d)
Figure 40-30-27
Cut
Tear
PI-13057
In case of damage by interference with the machine

frame
If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-30-27].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2
CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2

ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

SEAT BAR Figure 50-10-2
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.
The seat bar is located in the operator cab.

1
Figure 50-10-1
P-85652
Remove the seat bar mounting nuts (Item 1) [Figure 50-

1 10-2] (both sides).
Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-

lb) torque.
2 Lower the operator cab. (See Lowering on Page 10-30-

3.)
P-85653 P-85654 Figure 50-10-3
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
1
Lower the seat bar.
P-90021
Remove the seat bar (Item 1) [Figure 50-10-3] from the

operator cab.
Reverse the above procedure to install the seat bar into

the operator cab.

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023
4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
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 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
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) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)
Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
Raise the operator cab (See Raising on Page 10-30-2.)
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Figure 50-20-1
2
1
1 3
P-85652
Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Remove the operator cab gas spring(s). (See Gas Spring
Gas Spring Bracket Disassembly And Assembly
NOTE: Use the hoist connected to the operator cab
Figure 50-20-4 grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.
Figure 50-20-5
1
1
2
1
P-85661
Remove the clevis (Item 1) from both ends, and the outer
P-85663
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4].
Disconnect the cab harness connector screw (Item 1)
Installation: Apply a small amount of thread-locker on [Figure 50-20-5].
the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4]. Installation: Tighten the connector screw to 3,39 - 3,96
WARNING
AVOID INJURY
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Remove the throttle cable from the cab. (See Cable


OPERATOR CAB (CONT’D)
Figure 50-20-6
P-85658
Remove the two cab mount bolts and nuts (Item 1)

[Figure 50-20-6] from both sides of the cab.
Installation: Tighten the cab mount bolts and nuts to

24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
Figure 50-20-7
P-85662
Using a strap and a hoist remove the cab from the loader.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-30-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure
Remove the four seat mounting nuts (Item 1) [Figure 50- 50-30-2].
30-1] and washers from the operator seat mounting
studs. Figure 50-30-3

3.)
Remove the seat. 2
NOTE: With the seat removed, the cab may raise.
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-30-3].
Remove the slide rail (Item 2) [Figure 50-30-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-30-6
Figure 50-30-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-30-6].
Remove the nut (Item 1) [Figure 50-30-4] from the seat
belt mount.
Figure 50-30-5
P-85772
Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-30-9
Figure 50-30-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
30-7]. the seat back to the upright position.
Figure 50-30-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-30-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-30-10
Figure 50-30-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) Remove the mounting nut (Item 1) [Figure 50-30-11].
Remove the seat shock clips (Item 1) [Figure 50-30-10]. Remove the end release buckle (Item 2) [Figure 50-30-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-30-10]. Figure 50-30-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-30-12].
Remove the seat belt retractor (Item 2) [Figure 50-30-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-30-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-30-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-30-15].
13].
Figure 50-30-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].

BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
The Bob-Tach is located on the front of the loader

connected to the loader lift arms.
Figure 50-40-1 P-85649
P-85554
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.


40 ft-lb) torque.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5
Figure 50-40-3
1 P-31405
Inspect and replace O-ring (Item 1) [Figure 50-40-5] on

P-31402 the grease plug.
Figure 50-40-6
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)
torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 Figure 50-40-10
ft-lb) torque.
Figure 50-40-8
2
P-85665
1
P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
With a 0,875 mm (7/8 in) punch (Item 1) [Figure 50-40-8]

and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd) 4
Figure 50-40-11
1 3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.
Remove the bolt and replace the damaged parts as

Use a punch and hammer to remove the roll pin (Item 1) needed.
[Figure 50-40-11] from the Bob-Tach wedge and spring
clevis. Assembly: Clean threads and apply Loctite® 242 to the
bolt (Item 1) [Figure 50-40-13] torque to 88 - 95 N•m (95
Remove the spring clevis assembly (Item 2) [Figure 50- - 70 ft-lb).
40-11].
Figure 50-40-12
P-85667
Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach.
Always replace bent or broken wedges.

BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-14
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)
Use a seal pick to remove seal (Item 1) [Figure 50-40-

14] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-14]

with a driver tool and hammer.
Figure 50-40-15
3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-40-15].

BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
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 P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. 2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].
Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

40 ft-lb) torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649

BOB-TACH (POWER) (CONT’D) Figure 50-41-8
Figure 50-41-6
P-31406
1
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Inspect and replace the O-ring (Item 1) [Figure 50-41-6] [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
on the grease plug. ft-lb) torque.
1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 0,875 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.

BOB-TACH (POWER) (CONT'D) Figure 50-41-12
Lever And Wedge Disassembly And Assembly
Figure 50-41-10
1 1 2
P-85665
Remove the washer and spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-12].
Figure 50-41-13
Remove the washers and bolts (Item 1) [Figure 50-41-
10] from the cylinder (both ends).
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

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

1
Figure 50-41-11
P-85666
1 Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-41-13] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

11].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.

BOB-TACH (POWER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14
2 1
P-85669
P-85667 Remove the Power Bob-Tach. (See Removal And

Remove the wedge (Item 1) [Figure 50-41-14] out the Use a seal pick to remove seal (Item 1) [Figure 50-41-
bottom of the Bob-Tach. 16] from the Bob-Tach.
Always replace bent or broken wedges. Remove and replace bushing (Item 2) [Figure 50-41-16]
with a driver tool and hammer.
Figure 50-41-15
Figure 50-41-17
4 3
1 2
3 2
P-85668 1
NA5472
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-15] are damaged, put the Installation: The seal (Item 1) needs to be seated in the
assembly in a vise. Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-41-17].
Remove the bolt and replace the damaged parts as
needed.
Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-41-15] torque to 88 - 95 N•m (95
- 70 ft-lb).

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4
P-90592A
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].
Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT'D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1
P-90611

P-85692 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being
removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.

REAR GRILLE Figure 50-60-3
Figure 50-60-1
1
P100807
Align the tabs of the two side covers into the slots in the
P100808 loader frame and lower [Figure 50-60-3].
Figure 50-60-4
Flip the lockable handle (Item 1) [Figure 50-60-1] up and
turn the handle 90° counterclockwise. Lift and pull the
rear grille backward to remove from the loader.
Figure 50-60-2
P-85604
Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
P100809
Turn the lockable handle 90° clockwise and fold the
handle down.
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].

REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
3
2
P-85695
1
Remove the top and bottom door hinge mounting bolts

P-85697 and nuts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].
Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
1 1
P-90585
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation

1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-85698A
Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].
Remove the striker assembly from the loader.
Striker Disassembly And Assembly

P-85698A
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320A
Tighten both striker mount bolts (Item 1) [Figure 50-70-
6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].
Check the parts for wear and replace as needed.
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.
Remove the bolt and nut (Item 2) [Figure 50-70-7] from

the latch.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

FUEL TANK Figure 50-80-3

1.)
Remove the engine / hydrostatic pump assembly from 1

2
Page 70-10-7.)
Figure 50-80-1
P-85707
Disconnect the fuel vent hose (Item 1) and remove the

two bolts (Item 2) [Figure 50-80-3].
1 Figure 50-80-4
1 4
P-85714
2 3
Remove the three mount bolts (Item 1) [Figure 50-80-1]
from the access cover at the rear of the loader frame.
Remove the access cover.
Figure 50-80-2
1
P-85708
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].

1
50-80-4] from the fuel level sender.
Remove the two mounting bolts (Item 3) and remove the

bracket (Item 4) [Figure 50-80-4].
P-85713
Drain the fuel into a container.

FUEL TANK (CONT'D) Figure 50-80-7
Figure 50-80-5
1
1
1 1
P-85711
At the right side of the loader, remove the two main frame
P-85710 mount bolts and nuts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount bolts to 542 -

Remove the bolts (Item 1) [Figure 50-80-5] from the 583 N•m (400 - 430 ft-lb) torque.
battery hold down plate.
Figure 50-80-8
Remove the hold down plate from the loader.
Figure 50-80-6
1 1 1
P-85712
2
P-85709 At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].
Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount bolts to 542 -
(Item 2) [Figure 50-80-6]. 583 N•m (400 - 430 ft-lb) torque.
Lift the fuel tank and remove it from the loader frame.
NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
damage.

FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-11
Figure 50-80-9
1
1
P-85707
P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
50-80-9] from the fuel level sender. Figure 50-80-12
Remove the fuel level sender.
Figure 50-80-10
P-85715
Remove the fuel fill screen (Item 1) [Figure 50-80-12].

P-85716
Inspect and replace as needed.
Inspect the fuel level sender and replace if worn or

damaged.

CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
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-85675
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Check the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-90-2
support device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the bolt and nut (Item 1) [Figure 50-90-3] to 90-6].
disconnect the lift pedal linkage from the crossbar.
Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Check the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) The pedals should be positioned at a comfortable angle
so full movement of the pedal can be reached easily
Linkage Removal And Installation (Cont’d) while properly sitting in the loader seat.
1
1
2
P-85675 P-85676
Remove the bolt (Item 1) [Figure 50-90-7] and nut from Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
the pedal linkage. from the pedal mounting bracket.
Remove the linkage (Item 2) [Figure 50-90-7]. Figure 50-90-10
Figure 50-90-8
1
1
2
P-85675
P-85675A
Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage. Check the bushing in the pedal for wear and replace as
needed.
Remove the linkage (Item 2) [Figure 50-90-8].
Tilt the pedal back and forth until an acceptable “neutral”
Pedal (Adjusting) angle is achieved on the pedal.
After installing the pedal, adjust the pedal angle so that Tighten the two nuts (Item 2) and pivot bolt (Item 1)
there is clearance under the rear of the pedal. The valve [Figure 50-90-10] on the pedal assembly to standard
spool must travel full stroke without the pedal hitting the torque.
floor panel.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11
1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors 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 and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Check the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.
to fall and cause injury or death. Figure 50-91-2
W-2059-0598

support device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
spool must travel full stroke without the pedal hitting the
Figure 50-91-3 floor panel.
The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
1 while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.
P-85676
Figure 50-91-4
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]
from the pedal mounting bracket.
Figure 50-91-6
1 1
2
P-90981
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot. P-85675
Repeat for other side.

Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Check the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7
1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].

CONTROL PANEL
Description
Figure 50-100-1
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
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. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-100-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-100-3

D-1009-0409
1
WARNING
P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598
the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)

CONTROL PANEL (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Figure 50-100-4
Figure 50-100-6
2
1
1 1
2
2 2
P-90612
1 1
P-85864
Scribe a mark across the top of the steering linkage bars

(Item 1) [Figure 50-100-4] which are connected to the Remove the nuts (Item 1) and the steering stabilizers
steering shaft on the control panel. (Item 2) [Figure 50-100-6].
Remove the four steering linkage mounting bolts, nuts

and rubber isolators (Item 2) [Figure 50-100-4].
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-100-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Figure 50-100-7 2
2 2
1
3 1 3 3 P-85867
3
Remove the four bolts (Item 1) [Figure 50-100-9] from

P-85865 the control panel.
Remove the control handle assembly (Item 2) [Figure

Figure 50-100-8 50-100-9].
Figure 50-100-10
4
3
2
1
1
P-85861
P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50-
100-8]. Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8]. Remove the control handle (Item 4) [Figure 50-100-10].

CONTROL PANEL (CONT'D) Linkage Removal And Installation

W-2059-0598
1 2 1
WARNING
P-85872
Remove the two bolts (Item 1) from the bellcrank (Item 2) fall or move and cause injury or death.
[Figure 50-100-11]. W-2017-0286
Remove the bellcrank from the bracket [Figure 50-100- Lift and block the loader. (See Procedure on Page 10-10-
11]. 1.)
Figure 50-100-12 Raise the lift arms and install an approved lift arm

2
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-11] for wear and
replace as need.
Repeat the procedure for the other control handle

assembly.

Linkage Removal And Installation (Cont’d)

1
Figure 50-100-13
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-100-14].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-13] which are connected to the Installation: Tighten the centering spring bolt and a
steering shaft on the control panel. NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-100-15
and rubber isolators (Item 2) [Figure 50-100-13].

1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-10.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-15] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-100-16
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Check the wear on the centering blocks (Item 1) [Figure
P-48630 50-100-17].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-100-17]. Remove the centering
of the following parts: blocks.
ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -

54,2 N•m (35 - 40 ft-lb) torque.
1 Bolt
2 Bushings NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer NOTE: If the centering blocks are worn, they can be
5 Spring removed and rotated 180 degrees and
6 Lock Nut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-100-18
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-20].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-20].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-21
18] from the pintle.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Figure 50-100-19 2
1 3
1
2 P-48659
4 NOTE: When installing the pintle base (Item 1) onto

3
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-100-21].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-100-21]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the bolt and nut (Item 1) [Figure 50-100-19].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the linkage neutral
steering control lever (Item 4) for damage and replace as adjusting procedure must be performed. (See
needed [Figure 50-100-19]. Linkage Neutral (Adjusting) on Page 50-100-
10.)
NOTE: The washers (Item 2) [Figure 50-100-19] are
hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (CONT'D) NOTE: Anti-sieze should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-22 Figure 50-100-24
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) to catch the
for damage [Figure 50-100-22]. torsion bushing [Figure 50-100-24].
Inspect the torsion bushing (Item 4) [Figure 50-100-22] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-24] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-23 arm should be the same.
4
2
P-54626
Remove the base pintle (Item 1) [Figure 50-100-23] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) from the base pintle
[Figure 50-100-23].
Inspect parts for wear and damage, replace as needed

[Figure 50-100-23].

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
Kit - 6689778 Remote Start Tool (Service Tool) or 1

MEL1563 Remote Start Tool.
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT-MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10- P-85845
1.)
Figure 50-100-25 Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing.
3
Figure 50-100-27
2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
100-25].
To make this tool use a locking grip C-Clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-100-27].
[Figure 50-100-25] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-100-25] is torsion bushing (Item 2) [Figure 50-100-27] to
also needed. The centering block can be placed as turn freely between the torsion bushing and
shown and welded to the C-clamp if desired. the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-28
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT-MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-100-28] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-29
Tighten bolts (Item 3) [Figure 50-100-29] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-28] and [Figure
50-100-29].
1
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-25] 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-
29] around both centering blocks.
Lock the C-Clamp in place.

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 50-100-31]
the left pump before adjusting the right pump. counterclockwise until forward creep is seen.
Figure 50-100-30 Turn the adjustment screw (Item 1) [Figure 50-100-31] 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.
P-48632
Loosen the left pump pintle adjustment lock bolts

(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-30].) Loosen the bolts enough to
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 50-100-31
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-32
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-32] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre-applied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-14.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting 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.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-34
1
WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-34].
Pre-load tension in the torsion bushings must be The bolts must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-34] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-35
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-37].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-35] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-36 Figure 50-100-38
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-100-36]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-38].
Verify the cam mounting nuts (Item 4) [Figure 50-100-36]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-39
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-100-41].

P-85844
Figure 50-100-42
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
39] on each steering linkage bar. 2
Figure 50-100-40
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-42].
P-90615
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-
40]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-43 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,0 m (10

ft) of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in.
Tighten the two bolts and nuts (Items 1) [Figure 50-100- If the drift is excessive to the right, turn the left
43] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-44 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-46
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-100-46]

from the end of the shocks connected to the steering
linkages.
Remove the mounting nuts (Item 2) [Figure 50-100-46]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm support
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-101-1]

DANGER that secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-

101-2].
WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-101-2].
Never work on a machine with the lift arms up unless Remove the control panel (Item 3) [Figure 50-101-2].
W-2059-0598

CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-110-1
2
3
P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-110-2
P-85883A
Remove the rubber boot (Item 1) [Figure 50-110-2].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-111-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector.[Figure 50-111-3].
Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.
Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)

torque.
Figure 50-111-8
7
8
1
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 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 neutral and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2 [Figure 50-111-10] as shown away from stop
P-21882
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Check the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-13] from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
P16534 111-14] from the handle assembly.
Installation: Tighten the allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Check all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-16] that

connects the handle to the handle sensor unit for wear,
replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A
Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC)
Description
The control panel has two electronic handles that control

the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.
Joystick Testing
See Bobcat Advanced Troubleshooting System

(B.A.T.S.) or connect to service analyzer to check
function.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-3
Joystick Removal And Installation
device. (See Installing on Page 10-20-1.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890
Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 47,5 - 54,2 N•m


ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item
2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer (Item [Figure 50-120-2] from the front access panel.
2), and remove the left access panel (Item 3) [Figure 50-
120-1]. Remove the front access panel from the loader.
Remove the front access panel from the loader.

ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
2 1
1
2
P-90587
P-85887
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1]. Figure 50-121-4
Figure 50-121-2
2
3 2
1 2
1
1
2
P-90588
P-85884
Remove the bolt and throttle pedal (Item 1), and remove
the mounting screws (Item 2) [Figure 50-121-4].
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Remove the right inside access panel (Item 3) [Figure
50-121-4].

WINDOW (REAR) Disassembly And Assembly
WARNING
1
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P-85705
Figure 50-130-1
Remove the screw (Item 1) from the latch [Figure 50-

130-2].
Installation: Tighten the screw (Item 1) [Figure 50-130-

2] to 21 - 23 N•m (180 - 200 in-lb) torque.
1 1
Figure 50-130-3
7
6
1
P-85706
5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] in until they disengage
from the window frame. 2
3
Push the rear window out the rear of the operator cab. 4
P-85704
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. Inspect and replace any damaged parts.
Clean the area before installing the rear window The items listed below refer to [Figure 50-130-3].
assembly.
1. Latch
Reverse the procedure to install the rear window. 2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal

WINDOW (TOP)
Figure 50-131-1
1 1
P-85807
Install the bolts (Item 1) [Figure 50-131-1] through the

window grommets and through the cab holes.
Figure 50-131-2
1 1
1 1
P-85808
From inside the operator cab, install and tighten the four
nuts (Item 1) [Figure 50-131-2] on the window bolts.
Tighten the nuts (Item 1) [Figure 50-131-2] to 9 - 10 N•m


WINDOW (SIDE) Figure 50-132-3
1 1
Figure 50-132-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.
Figure 50-132-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.

CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

installed kit. 1
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
2
P-85781A
2 1
Open the cab door.
Disconnect electrical connector (Item 2) and washer fluid

Figure 50-140-2
2
3
2 1
1
P-85837
P-85588A P-85589A
Remove the four bolts and nuts (Item 2) [Figure 50-140-

Rotate and pull the clip (Item 1) out of the gas spring 4] from the cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. Remove the hinges (Item 1) [Figure 50-140-4] from the
cab.
Installation: Install the hinges (Item 1) on the cab and

use the bolts and nuts (Item 2) [Figure 50-140-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].
2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-140-

4.)
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
1
1
P-85413
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P-85831
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837
Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.
P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

ARMREST (CONT’D) Figure 50-150-7
Remove the Joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8
1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

ARMREST (CONT’D) (SN A3P012658 & Above And A3P111414 & Above)
Disassembly And Assembly (Cont’d) Figure 50-150-11
(SN A3P012657 & Below And A3P111413 & Below)
Figure 50-150-9
1
3
2
P100825
1
Figure 50-150-12
P-90842
Figure 50-150-10
7 4
6 3
5 2
3
6 1
5 2 P100824
4 1
Remove the nut (Item 1), washer (Item 2), spring (Item 3)
P-90843 [Figure 50-150-11] and [Figure 50-150-12].
Remove the spacer (Item 4), washer (Item 5), plastic

Remove the nut (Item 1), washer (Item 2), and the plastic washer (Item 6) and the bolt (Item 7) [Figure 50-150-12].
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10]. Installation: Tighten the nut to 21 - 23 N•m (80 - 200 in-
lb) torque.
Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

ARMREST (CONT’D)
Figure 50-150-13
1 1
2
P-90844
Remove the two nuts and bolts (Item 1) and the slide rail
(Item 2) [Figure 50-150-13] from the arm rest mount.
Repeat for the other side.

LEFT SIDE LOWER PANEL Figure 50-160-3
Raise the operator’s cab.
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)
1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1
30-4.)
Lower the operator’s cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].
Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.
Figure 50-160-13
P-90864

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operator’s cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4
Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new when it has been removed.
side of the cab far enough to access the wire
harness. Figure 50-170-8
Figure 50-170-6
2 1
1
P-90877
2
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove
the radio from the right side lower panel.
Disconnect the wire harnesses (Item 1) and the antenna
(Item 2) [Figure 50-170-6] (if equipped with radio). Installation: Insert a screwdriver into the slot (Item 2)
[Figure 50-170-8] to lock the tab into place.
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.
Remove the input from the right side lower panel.
Figure 50-170-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.

HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if
P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation on Page 60-60-2.)
2) [Figure 50-180-1] (if equipped).
Figure 50-180-4
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
1
1
Figure 50-180-2
1
1
2
1 P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
Installation: Route the cab light wire harness in the

P-90894 grove on the topside of the headliner (if equipped with
HVAC).
Remove the air duct (Item 1) [Figure 50-180-2] (if NOTE: Replace the retainers if needed.
equipped).

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . 60-50-10
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1


CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 FC1 FUSE CENTER 1 3
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 FC2 FUSE CENTER 2 3
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 T1 BATT GROUND 4
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T2 BUZZER GROUND 8
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 T3 FLASHER 13
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7 T6 BATT GROUND 4
C126 HORN 2 13 C441 TWO SPEED 2 7 T8 BATT GROUND 4
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 T13 BUZZER POWER 8
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5 T14 PRE HEATER 6
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C250 DOOR SENSOR 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C251 WIPER 5 9 C480 LEFT PANEL(GRAY) 12 8 T17 LEFT REAR WORK LIGHT (+) 11
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 T18 LEFT REAR WORK LIGHT (-) 11
C277 AIR RIDE SEAT 6 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C278 RIGHT SPEAKER 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C279 LEFT SPEAKER 2 9 C489 ACCESSORY 2 3,4
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8
C362 REAR AUX SOLENOID 8 7 C602 LEFT REAR TAIL LIGHT 2 11
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB CONNECTOR 48 3-5, 8-13 C611 BLOWER MOTOR 4 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW1 BRAKE SWITCH 9
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW2 BEACON SWITCH 13
C411 LEFT HANDLE 5 WAY 5 10,13 C667 DOOR KIT 6 9 SW3 HAZARD SWITCH 13
C412 HANDLE(HORN) 2 10,13 C670 EXTERIOR BEACON 6 13 SW4 HAND/FOOT, H/ISO SWITCH 9
C413 REAR ROD 2 7 C676 RADIO 6 9 SW5 POWER BOBTACH SWITCH 13
C414 REAR BASE 2 7 SW6 BUCKET POSITION SWITCH 13
C415 HIGH FLOW SOLENOID 2 7 SW8 FRONT WIPER SWITCH 9
C416 DIVERTER SOLENOID 2 7 SW9 TRAVEL CONTROL SWITCH 8
C417 REAR AUX RELIEF 2 7 J1A GATEWAY COTROLLER 34 SW10 BLOWER SWITCH 12
C418 FRONT ROD 2 7 J1B GATEWAY CONTOLLER 26 SW11 AC SWITCH 12
C419 FRONT BASE 2 7 J2A AUX CONTROLLER 34
C420 HYD LOCK 2 7 J2B AUX CONTROLLER 26
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 WIRING SCHEMATIC
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT (STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 1 of 13
(PRINTED MARCH 2011)
Printed In U.S.A. 7175752
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE)
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP A-32
A-33 SPARE ANALOG A-33
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE
HARNESS PART NUMBER

MAIN FRAME 7174782
STD CAB 7165991
DLX CAB 7176098
DLX FUEL 7175293
STD FUEL 7149219
DOOR 7155024
S/R 6733370
TAILGATE DOM 7175271
TAILGATE EUR 7175287
2 SPD ADP 7159366
BACKUP ALARM 7175017
BRAKE ADAPTER 7165061
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 2 of 13
POWER
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATTERY MEGAFUSE
FC1 FUSE 2
100.0 Amps 1180/RED/WHT
BATT_CABLE 25 A J2B 2
1025/RED 1160/RED/WHT 1150/RED/WHT
J2B 3
1240/RED/WHT
FC1 FUSE 1 SHEET 8
1400/RED/WHT
25 A C408 17 SHEET 9
1070/RED 1120/RED/WHT 1450/RED/WHT 1450/RED/WHT 1420/RED/WHT
SHEET 8
1110/RED/WHT 1440/RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130/RED/WHT
15 A J1B 3
1290/RED 1370/RED/WHT
SHEET 9
FC2 FUSE 2 1460/RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
1190/RED 25 A 1165/RED/WHT
SHEET 5
1010/RED
FRC 1 FUSE 6
1310/RED 30 A 1360/RED/WHT
SHEET 7
1050/RED FRC1 FUSE 5
30 A 1350/RED/WHT
SHEET 6
FRC1 FUSE 11
25 A
SHEET 12
FRC1 FUSE 10
1340/RED 20 A 1330/RED/WHT
SHEET 11
1620/RNG/WHT
FRC1 FUSE 9 SHEET 8
1940/RNG/WHT
15 A SHEET 8
1320/RED/WHT 1930/RNG/WHT
SHEET 11 SHEET 8
1060/RED 1775/RNG/WHT
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785/RNG/WHT
SHEET 9
1950/RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
5A SHEET 8
1570/RNG/WHT
SHEET 10
FRC1 FUSE 2
1760/RNG/WHT 25 A 1850/RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A 1550/RNG/WHT
SHEET 13
FRC1 FUSE1
25 A 1750/RNG/WHT 1780/RNG/WHT Printable Version Click Here
C489 A
SWITCHED
POWER
1720/RNG/WHT
C404 B WIRING SCHEMATIC
1050/RED 30
87
1765/RNG/WHT 1790/RNG/WHT
SHEET 12 (STANDARD MACHINE)
SHEET 6
2055/BLK
2030/BLK
85 86
1795/RNG/WHT
FRC1 FUSE 7
25 A 1730/RNG/WHT
T650 (S/N A3P011001 - A3P012213)
SHEET 12 SHEET 5
FRC1 FUSE 8
25 A
(S/N A3P111001 - A3P111241)
1580/RNG/WHT
8000/TAN
1920/RNG/WHT
J1A 4
SHEET 9
Sheet 3 of 13
SHEET 5
1830/RNG/WHT
C408 6 SHEET 5
GROUND
2080/BLK
SHEET 5
2070/BLK
SHEET 5 C408 32
2940/BLK 2950/BLK 2950/BLK
SHEET 8
2960/BLK 2510/BLK
SHEET 8 J1B 16
2920/BLK 2500/BLK 2110/BLK T6
SHEET 8 J1B 15 BATT GND
2250/BLK 2540/BLK
SHEET 8 J2B 16
2550/BLK 2090/BLK
J2B 15
2765/BLK
SHEET 11
2745/BLK
SHEET 12
2790/BLK T8
SHEET 9 BATT GND
2780/BLK
SHEET 13
2730/BLK
SHEET 9
2620/BLK
SHEET 11
2630/BLK 2720/BLK
SHEET 11 C103 B C489 B
2650/BLK 2600/BLK 2600/BLK
SHEET 10
2640/BLK 2810/BLK 2390/BLK
SHEET 11 SHEET6
2610/BLK
SHEET 11
2200/BLK
SHEET 7
2751/BLK OR 2770/BLK
SHEET 13
2450/BLK
SHEET 7
2741/BLK
SHEET 13
2785/BLK 2710/BLK 2300/BLK T1
SHEET 13 SHEET 5 BATT GND
2930/BLK 2480/BLK
SHEET 9 C408 42 SHEET 7
2830/BLK 2900/BLK 2900/BLK
SHEET 13
2700/BLK 2000/BLK
SHEET 8 SHEET 11
3530/LBL
SHEET 7
3800/LBL
SHEET 6
2370/BRN OR 3910/LBL
SHEET 9
3310/LBL OR 2180/BRN 3010/LBL
SHEET 7 J1B 17
3410/LBL
SHEET 7
3110/LBL OR 2180/BRN
SHEET 6
3510/LBL
SHEET 6 Printable Version Click Here
3710/LBL
SHEET 6
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 4 of 13
CAN BUS
9160/PUR/WHT
C503 2
9260/PUR RH DLX PANEL
C503 4
9200/PUR 9270/PUR 9230/PUR C408 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR
GWY CTRLR J1B 8 C479 4
9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
1830/RNG/WHT 1
#
SHEET 3
2070/BLK 2
SHEET 4 RIGHT
9560/PUR/WHT 3
JOYSTICK
9660/PUR 4
9220/PUR
J2B 8 AUX CTRLR C449
9120/PUR/WHT
J2B 9 1840/RNG/WHT 1 #
SHEET 3
2080/BLK 2
SHEET 4
9540/PUR/WHT 3 LEFT
9640/PUR 4 JOYSTICK
C426
9500/PUR/WHT A
J1B 14
9600/PUR B
J1B 20
9400/PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730/RNG/WHT E
SHEET 3
1165/RED/WHT F
SHEET 3
2710/BLK G
SHEET 4
# CONNECTOR DOES NOT EXIST IN 7165991
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 5 of 13
ENGINE
STARTER
STARTER C109
1030/RED 30 J1A 22
8250/TAN B 8250/TAN R M
B SHEET 3
SHEET 3 87 8200/TAN A 8200/TAN S 1015/RED
C110
2005/BLK 85 86 8210/TAN B
SHEET 12 J1A 7 S 1020/RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800/RNG/WHT 1815/RNG/WHT
SHEET 12
EXCITATION
2015/BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120/TAN D5 8100/TAN B 8100 TAN PULL 24.5 OHM
1350/RED/WHT 30 0.33 OHM
SHEET 3 87 8150/TAN J1B 4 8800/TAN A 8800 TAN HOLD
J1A 30
2810/BLK 2800/BLK C 2800 BLK
85 86 SHEET4
2025/BLK 8110/TAN
SHEET 7 J1A 3
C106 GLOW
3600/LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550/TAN
3610/LBL B GND 1060/RED J1A 14
SHEET 3 87 8500/TAN
3800/LBL T14 PRE HEATER
SHEET 4
3210/LBL B SIG 85 86
ENGINE COOLANT 2016/BLK 8510/TAN
3200/LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055/BLK
SHEET 3
C104
C107
3500/LBL B +5V PWR
SHEET 9
3520/LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510/LBL A GND SENDER (0.5 ~ 4.5V)
SHEET 4
C355 C
C406 Printable Version Click Here
3100/LBL OR 3180/LBL 3100/LBL OR 3180/LBL A SIG FUEL
J1B 12 SENDER
3110/LBL OR 2180/BRN 3110/LBL OR 2180/BRN B GND
SHEET 4
C355 D
WIRING SCHEMATIC
3710/LBL
C405
B GND
(STANDARD MACHINE)
SHEET 4 AIR FILTER
3700/LBL A SIG
J1A 16 SWITCH T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 6 of 13
HYDRAULICS
TRACTION
LOCK C425 TRACK MACHINES
30 4150/LGN
1360 RED/WHT J1A 13
SHEET 3 87 4100/LGN B C308
BRAKE
2025 BLK 4200/LGN A 4200/RED A SOLENOID
SHEET 6 85 86 J1B 6
2035/BLK 4110/LGN 2200/BLK C 2200/BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C
C362 C414
OPTIONAL REAR AUX
4440/LGN A 4440/LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440/BLK B 2440/BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410/BLK B
4430/LGN C 4430/LGN 1 SIG OPTIONAL REAR AUX J1A 1 HYD LOCK SOLENOID
J2B 7 4410/LGN A
2430/BLK D 2430/BLK 2 GND DIRECTIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER
7.5 OHM 12V C105
C416 HYDRAULIC
3410/LBL B CHARGE
4450/LGN E 4450/LGN 1 SIG OPTIONAL REAR AUX 3420/LBL C
J2B 4 J1B 1 PRESSURE
2450/BLK F 2450/BLK 2 GND BLEED / LOCK VALVE
SHEET 4 3400/LBL A 0.5-7.5V
SOLENOID MALE COUPLER J1B 23
7.5 OHM 12 V +8V
C417 C108
4480/LGN G 4480/LGN 1 SIG OPTIONAL REAR AUX
HYDRAULIC
J2B 6 3310/LBL OR 2180/BRN B TEMPERATURE
2480/BLK H 2480/BLK 2 GND BLEED / LOCK VALVE SHEET 4
SHEET 4 3300/LBL A
SOLENOID FEMALE COUPLER J1A 32 SENDER
500 - 3000 OHM
C112
C415
OPTIONAL HIGH FLOW 3430/LBL A HYDRAULIC
2460/BLK B GND J1A 34
J2A 26 SOLENOID 3530/LBL B FILTER SWITCH
4460/LGN A SIG SHEET 4
J2B 26 7.5 OHM
12 V
C418
2330/BLK 2 GND FRONT ROD SOLENOID (MALE)
J2A 18
4330/LGN 1 SIG 3.3 OHM PWM
J2B 19
C419
2340/BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
J2B 13
C437
2360/BLK 2 GND
J1A 27 TWO SPEED Printable Version Click Here
4360/LGN 1 SIG MAKEUP SOLENOID
J1B 25
2350/BLK
C441
2 GND
WIRING SCHEMATIC
J1A 26
4350/LGN 1 SIG TWO SPEED SOLENOID
J1B 26 (STANDARD MACHINE)
C446
J1A 18
2910/BLK
4010/LGN
2
1
GND HYDRAULIC
FAN SOLENOID T650 (S/N A3P011001 - A3P012213)
SIG
J1B 19 7.2 OHM
12 V (S/N A3P111001 - A3P111241)
Sheet 7 of 13
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3
T2
BUZZER (-)
C500
LEFT PANEL (BLACK) C408 4 RH KEY SWITCH
9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 2
J1A 24 START
9320/PUR OR 7040/WHT C479 10 9350/PUR OR 3040/LBL 9350/PUR OR 3040/LBL 4
BUZZER J1B 22 RUN/ENTER SW
2920/BLK C479 2 C408 40
SHEET 4 GROUND 1950/RNG/WHT 5
SHEET 3 Switched Power
1440/RED/WHT C479 1 1420/RED/WHT 1
SHEET 3 Battery (+) SHEET 3 Battery (+)
2960/BLK 3
1960/RNG/WHT 1620/RNG/WHT C479 5 SHEET 4 GROUND
SHEET 3 SHEET 3 Switched Power 6
SW9 6450/PNK C479 11
SHEET 13 Left Blinker Input
TRAVEL CONTROL C479 8
SWITCH (OPTIONAL) 6550/PNK
SHEET 13 Right Blinker Input
5 6 4500/LGN OR 3600/LBL C479 9

SHEET 9 Park Break Input
4 C479 7
2700/BLK 2 3 4730/LGN
SHEET 4 Travel Control Input RH DLX PANEL
1
1590/RNG/WHT C503 5
C480 SHEET 3 Switched Power
LEFT PANEL (GRAY) C503 1
1240/RED/WHT
4750/LGN 12 SHEET 3 Battery (+)
SHEET 9 Reserved Output 5 C503 3
9310/PUR OR 3610/LBL 2 2250/BLK
SHEET 9 Park Break Output SHEET 4 GROUND
PTOL
C499 (Press To Operate Loader)
C408 1
9380/PUR OR 3030/LBL 9380/PUR OR 3030/LBL 2
J1A 20 PTOL OUTPUT
9370/PUR OR 2380/BRN 9370/PUR OR 2380/BRN 4
J1A 19 PTOL LED
C408 37
1930/RNG/WHT 1
SHEET 3 SWITCH POWER
2940/BLK 3
SHEET 4 GROUND
WIRING SCHEMATIC
(STANDARD MACHINE)
CAB DISPLAY T650 (S/N A3P011001 - A3P012213)

(S/N A3P111001 - A3P111241)
Sheet 8 of 13
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550/LGN C408 5
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1 4275/LGN C408 3
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060/BLK 5 6 4235/LGN C408 2
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 4
C212
2795/BLK 1
+ POWER SOCKET
1375/RED/WHT 2
-
C209
2790/BLK C408 24 2790/BLK 2010/BLK B
C408 23 SHEET 4
1370/RED/WHT 1370/RED/WHT 1390/RED/WHT A DOME LIGHT
SHEET 3
4760/LGN C
*
C676
1885/RNG/WHT 1
2885/BLK 2
C129 C279
1210/RED/WHT A
SHEET 3
1580/RNG/WHT C408 16 1580/RNG/WHT * 1865/RNG/WHT B LEFT SPEAKER
1
2
+ 7820/WHT
7830/WHT
3
4 RADIO CONN
2820/BLK C -
ACCESSORY
CONN C278
2 - 7810/WHT 6
RIGHT SPEAKER 1 7800/WHT 5
+
2730/BLK C408 33 2730/BLK
SHEET 4
C277
1510/RNG/WHT 4
2210/BLK 5 AIR RIDE
SEAT SOLENOID
C482 SEATBAR
SENSOR C667 C250 SENSOR SHOWN
2370/BRN OR 3910/LBL C408 45 2370/BRN OR 3910/LBL A GND
SHEET 4 4750/LGN 4740/LGN 4 4740/LGN 1 WITH DOOR OPEN
SHEET 8 DOOR SENSOR
1400 RED/WHT 5 1400/RED/WHT 2 C251
3920/LBL OR 3370/LBL C408 46 3920/LBL OR 3370/LBL B SIG SHEET 3
J1B 11 1860/RNG/WHT D SW PWR
6 7330/WHT C PARK WIPER
3930/LBL 3900/LBL OR 5370/YEL 3900/LBL OR 5370/YEL C PWR
J1B 24 1570/RNG/WHT 7300/WHT A LOW MOTOR
3500/LBL
+5V SHEET 6 C408 44 B GND
1850/RNG/WHT 1850/RNG/WHT 1 1850/RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310/WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN OR 3600/LBL 3 2 FRONT WIPER
SHEET 8 1 2840/BLK 2 2840/BLK SWITCH C252
9310/PUR OR 3610/LBL 4 5
SHEET 8 7310/WHT L
1775/RNG/WHT 6
SHEET 3 WASHER
2930/BLK
SHEET 4 2845/BLK X MOTOR
WIRING SCHEMATIC
(STANDARD MACHINE)
7165991Standard Cab Harness T650 (S/N A3P011001 - A3P012213)
7176098 Deluxe Cab Harness (S/N A3P111001 - A3P111241)
Sheet 9 of 13
Printed In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7175752
MANUAL
CONTROLS
C409
K
G RIGHT HANDLE
1590/RNG/WHT A
4940/LGN H
J2A 30
4930/LGN J SKI CTRL
J2A 31
4920/LGN E DETENT FLOW
J2B 21
4910/LGN F
J2A 13 TWO SPD
4310/LGN C -
J2B 17
4320/LGN D
J2B 18 PWM
4300/LGN B +
J2B 23
C410
K
D LEFT HANDLE
4840/LGN C
J2A 28
4830/LGN B SKI CTRL
J2A 22
4820/LGN G
J2A 12
4810/LGN F SIDE SHIFT
J2A 11
1570/RNG/WHT 1710/RNG/WHT A
SHEET 3
1560/RNG/WHT J
J2B 22
H
E
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A C103 C T19 1
7100/WHT 7100/WHT B
+ BACKUP ALARM
2650/BLK 7001923 A HORN
SHEET 4 -
T20 1
C421 Printable Version Click Here

2370/BLK 3
J1A 10
J1B 7
4370/LGN 1
2
TILT SPOOL LOCK SOLENOID
WIRING SCHEMATIC
C422 (STANDARD MACHINE)
2380/BLK 3
J1A 2
J1B 5
4380/LGN 1
2
LIFT SPOOL LOCK SOLENOID T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 10 of 13
(PRINTEDMARCH 2011)
LIGHTS
C434-1
2735/BLK B LEFT FRONT
6100/PNK A WORK LIGHT
37.00 Watts
C434-2
2765/BLK C408 28 2765/BLK 2750/BLK B
SHEET 4 LEFT FRONT
50.00 Watts
C435-1
6000/PNK C408 25 6000/PNK 6120/PNK A RIGHT FRONT
2760/BLK B WORK LIGHT
37.00 Watts
C435-2
6130/PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610/BLK 2
1330/RED/WHT 30 C103 A 6310/PNK RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK 6320/PNK 1 TAIL LIGHT
2000/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 LEFT REAR
6320/PNK 2640/BLK 2 TAIL LIGHT
J1A 5 SHEET 4
6330/PNK
J1A 31
2620/BLK T16 1
SHEET 4 RIGHT REAR
6210/PNK WORK LIGHT
REAR
LIGHT T15 1
1320/RED/WHT 30 C103 H
SHEET 3 6200/PNK 6200/PNK T17 1
87
2630/BLK LEFT REAR
85 86 SHEET 4 WORK LIGHT
2045/BLK T18 1
2035/BLK
SHEET 7
6210/PNK
J1A 17
6230/PNK
J1A 28
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 11 of 13
HVAC
C630
7021/WHT 7020/WHT C408 34 7020/WHT B
J1A 11
7023/WHT 2570/BLK C
3320/LBL A
THERMOSTAT
C350
B C483
7024/WHT A EVAPORATOR 2560/BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980/RNG/WHT A DBL
C486 7220/WHT B WHT (TEMP CONTROL
C355 A SWITCH)
7024/WHT 7025/WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290/BLK 2280/BLK D SIG
SHEET 13
D4 2130/BLK C GND HEATER
1900/RNG/WHT 1910/RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT C408 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3 6 C611
2005/BLK
SHEET 6 3 1970/RNG/WHT A 14.00 Amps High
1790/RNG/WHT
SHEET 3 1520/RNG/WHT B 7.50 Amps Med BLOWER
1815/RNG/WHT
SHEET 6 7320/WHT C 5.00 Amps Low MOTOR
8020/TAN
J1A 21 2580/BLK D
2745/BLK 2745/BLK
SHEET 4
C408 22
7040/WHT
SW11
AC SWITCH
1 C
2100/BLK
3
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 12 of 13
OPTIONS
SW5
POWER
BOBTACH
SWITCH
C411 1410 RED/WHT C408 26 1410/RED/WHT 1380/RED/WHT 2 1 7000/WHT OR 4480/LGN C408 97000/WHT OR 4480/LGN
C408 15 SHEET 3
B 6010/PNK 6010/PNK 1430/RED/WHT 1200/RED/WHT 3 C408 10
C 6550/PNK 5 4 7010/WHT OR 4470/LGN 7010/WHT OR 4470/LGN
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515/PNK 6500/PNK 6500/PNK 6530/PNK FLASHER CONN SW2
5 PIN E 6540/PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415/PNK 6400/PNK 6400/PNK 6430/PNK 6570/PNK
2725/BLK C607
6450/PNK 6 C355 E
SHEET 8 5 A 7010/WHT OR 4470/LGN
SW3 1 4
C103 E HAZARD SWITCH 2 C670 STROBE 1 2 B 2770 BLK OR 2470/BLK 2751/BLK OR 2770/BLK
6410/PNK (PINS 3 & 6 3 BEACON
4 6700/PNK E 3 2751/BLK OR 2770/BLK
6510/PNK INTERNALLY 5 SHEET 12 2290/BLK SHEET 4
2850/BLK 2420/BLK D C355 B
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK OR 2480/BLK
F
2780/BLK C408 30 2780/BLK A 7000/WHT C355 F
SHEET 4 B
6440/PNK
6540/PNK RIGHT PWR BOB OPEN
BLINKER
1550/RNG/WHT C408 13 1550/RNG/WHT

SHEET 3
SW6
3 2 BUCKET
7022/WHT 1 POSITION
C126
SHEET 4 SHEET 4 4 SWITCH
C412 2785/BLK B 2830/BLK 5
B 7210/WHT C408 38 7210/WHT A C423
LEFT HANDLE 6 OPTIONAL
C408 35 D3 A
2 PIN A 1460/RED/WHT 7022/WHT 7030/WHT BUCKET
SHEET 3
POSITION
2741/BLK 2740/BLK B SOLENOID
SHEET 4 9.8 OHM
WIRING SCHEMATIC
(STANDARD MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 13 of 13
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C423 BUCKET POSITION 2 13 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C425 BRAKE SOLENOID 3 7 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C434-1 LEFT WORKLIGHT 1 2 11
C106 ENGINE SPEED SENSOR 2 6 C434-2 LEFT WORKLIGHT 2 2 11 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C435-1 RIGHT WORKLIGHT 1 2 11 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C435-2 RIGHT WORKLIGHT 2 2 11 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C437 TWO SPEED MAKEUP 2 13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C110 ALTERNATOR 2 6 C441 TWO SPEED 2 13
C112 HYD OIL FILTER SWITCH 2 7 C446 HYDRAULIC FAN 2 7 SW1 BRAKE SWITCH 6 8
C126 HORN 2 13 C449 LEFT JOYSTICK (CAB HARN) 4 5 SW2 BEACON SWITCH 6 13
C129 CAB ACCESSORY 3 9 C450 RIGHT JOYSTICK (CAB HARN) 4 5 SW3 HAZARD SWITCH 6 13
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW6 BUCKET POSITION SWITCH 6 13
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW9 TRAVEL CONTROL SWITCH 6 8
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW10 BLOWER SWITCH 5 12
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW11 AC SWITCH 3 12
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8 T1 BATT GROUND 1 4
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8 T2 BUZZER GROUND 1 8
C404 BU ALARM-MFR HARN 2 3,10 C602 LEFT REAR TAIL LIGHT 2 11 T3 FLASHER 2 13
C405 AIR FILTER SWITCH 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 T6 BATT GROUND 1 4
C406 FUEL SENDER 2 6 C606 POWER BOBTACH OPEN 2 13 T8 BATT GROUND 1 4
C408 CAB - MFR HARN CONNECTOR 48 3-5,8,9,11-13 C607 POWER BOBTACH CLOSE 2 13 T13 BUZZER POWER 1 8
C409 RIGHT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T14 PRE HEATER 1 6
C410 LEFT HANDLE 10 10 C611 BLOWER MOTOR 4 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C630 THERMOSTAT 3 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C635 HEATER VALVE 6 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C415 HIGH FLOW SOLENOID 2 13 C667 DOOR 6 9 T18 LEFT REAR WORK LIGHT (-) 1 11
C418 FRONT ROD (MALE) 2 7 C670 EXTERIOR BEACON 6 13 T19 BACKUP ALARM 1 10
C419 FRONT BASE (FEMALE) 2 7 C676 RADIO 6 13 T20 BACKUP ALARM (GND) 1 10
C420 HYD LOCK 2 7
C421 TILT SPOOL LOCK 3 10
C422 TILT SPOOL LCOK 3 10

BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 Printable Version Click Here
BATTERY GROUND
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
WIRING SCHEMATIC
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
(STANDARD MACHINE)
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
Sheet 1 of 13
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 B-5 REAR AUX (F)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-12 B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25
A-27 SPARE A-27
A-29 A-29
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

EXMF 7199263
MAINFRAME
LF 7196823
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TRK BRAKE ADP 7165061
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 2 of 13
1240/RED/WHT WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SHEET 8 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1400/RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB-MFR HARN SHEET 9
C667 DOOR HARNESS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1450/RED/WHT 17 1450/RED/WHT 1420/RED/WHT BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
SHEET 8
C500 RH KEY SWITCH CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
FC1 FUSE CENTER 1440/RED/WHT MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
2 SHEET 8
FUSE 1 25 A 1110/RED/WHT J1B HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C479 LH PANEL
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
+12V 1025/RED
FUSE 2 25 A
1160/RED/WHT 1150/RED/WHT 3
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
100.0 Amps FUSE 3 OPEN COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATT_CABLE
LEGEND
SCHEMATIC INDEX
FUSE 4 OPEN PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
1010/RED
SHEET 6 CAN BUS PAGE 5
STARTER FC2 FUSE CENTER ENGINE PAGE 6
CONNECTOR
FUSE 1 25 A HYDRAULICS PAGE 7
1190/RED 1165/RED/WHT CAB DISPLAY PAGE 8
SHEET 5
C426 REMOTE RUN, ACD CAB PAGE 9
FUSE 2 25 A MANUAL CONTROLS PAGE 10
1040/RED 1490/RED/WHT 1410/RED/WHT WIRE BREAK
SHEET 13
(TWO WIRE BREAKS LIGHTS PAGE 11
C408 CAB-MFR CONN (OPTIONS)
FUSE 3 OPEN JOIN ONE WIRE) HVAC PAGE 12
1460/RED/WHT
SHEET 13 SHEET # OPTIONS PAGE 13
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
SHEET 9 SJC PAGE 15
C408 CAB-MFR CONN (ACCESSORIES)
FRC1 FUSE RELAY CENTER

1050/RED
FUSE 5 30 A
1350/RED/WHT
SHEET 6
SHEET 6 1060/RED FRC1 FUEL SHUTOFF RELAY
FUSE 6 30 A
FRC1 PRE HEATER RELAY 1310/RED 1360/RED/WHT
SHEET 7
1030/RED FRC1 TRACTION LOCK RELAY
SHEET 6
FUSE 9 15 A 1320/RED/WHT
FRC1 STARTER RELAY
SHEET 11
FRC1 REAR LIGH RELAY
1340/RED SHEET 11
FRC1 FRONT LIGHT RELAY
C404
FUSE 11 25 A BU ALARM-MFR HARN 1620/RNG/WHT
1300/RED 1140/RED/WHT 1720/RNG/WHT B SHEET 8
SHEET 12 (SEE ADDITIONAL C479 LH PANEL
FUSE1 25 A FRC1 HVAC RELAY OPTIONS SHEET)
SHEET 8
A T13 LH PANEL BUZZER
FUSE 2 25 A 1780/RNG/WHT C489
1760/RNG/WHT 1850/RNG/WHT SHEET 9 1930/RNG/WHT
MFR ACCESSORY SHEET 8
C408 CAB-MFR CONN (FR WIPER) C499 RH PANEL PTOL
FUSE 3 15 A
1550/RNG/WHT C408
SHEET 13 1775/RNG/WHT
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
FUSE4 5 A 1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
43
SHEET 8
1530/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
C410 LEFT HANDLE
SHEET 10 SHEET 8
C409 RIGHT HANDLE J2B C500 RH PANEL KEY SWITCH
FUSE 7 25 A 1560/RNG/WHT 22
1795/RNG/WHT 1730/RNG/WHT AUX CTRLR
SHEET 9
C426 REMOTE RUN, ACD SW4 H/ISO SWITCH
FUSE 8 25 A 1580/RNG/WHT
FRC1 SHEET 9 1960/RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050/RED 30 J1A C110 ALT EXCITATION
87 GWY CTRLR 1790/RNG/WHT
SHEET 12 WIRING SCHEMATIC
2055/BLK 85 86 3380/LBL 4 C408 FRC1 HVAC RELAY
SHEET 6
SHEET 12
2030/BLK
1920/RNG/WHT
CAB-MFR HARN
6 1840/RNG/WHT
(STANDARD MACHINE)
1920/RNG/WHT
SHEET 5
1830/RNG/WHT
C449 LH JOYSTICK T650 (S/N A3P012214 AND ABOVE)
SHEET 5
C450 RH JOYSTICK
Sheet 3 of 13
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
ACS PAGE 14
SJC PAGE 15
2080/BLK
SHEET 5
C449 LH JOYSTICK
2070/BLK
SHEET 5
C450 RH JOYSTICK
2920/BLK C408
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940/BLK 2950/BLK 32 2950/BLK
SHEET 8
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8 2765/BLK
C503 RH DELUXE PANEL SHEET 11
16 2540/BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745/BLK BATT GND
2550/BLK 2090/BLK SHEET 12
2930/BLK AUX CTRLR
SHEET 8 C408 CAB-MFR CONN (HVAC)
SW1 BRAKE SWITCH 2790/BLK
2830/BLK 2900/BLK 42 2900/BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SW6 BKT POSITION SWITCH
2780/BLK
SHEET 8 2700/BLK SHEET 13
SW9 TRAVEL CONTROL SWITCH C408 CAB-MFR CONN (OPTIONS)
2785/BLK 2730/BLK
SHEET 13 SHEET 9
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
SHEET 11 2105/BLK
2620/BLK
SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630/BLK C489
SHEET 11 TAILGATE HARN B 2720/BLK
T18 LH REAR LIGHT MFR ACCESSORY
2650/BLK 2600/BLK B 2600/BLK
SHEET 10
T20 BU ALARM 2400/BLK 2390/BLK
SHEET 6
2640/BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200/BLK
C602 LH REAR LIGHT SHEET 7
2610/BLK C425 BRAKE
SHEET 11 2770/BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455/BLK
2170/BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710/BLK 2300/BLK
2160/BRN SHEET 5
SHEET 6 C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320/BRN
SHEET 7
C112 HYD OIL FILTER SWITCH
SHEET 9
2370/BRN J1B Printable Version Click Here
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR
SHEET 7
2220/BRN
C108 HYD TEMP SENDER
2230/BRN 17
WIRING SCHEMATIC
SHEET 7 2190/BRN
C105 HYD CHG PRESSURE SENDER
(STANDARD MACHINE)
SHEET 6
2180/BRN T650 (S/N A3P012214 AND ABOVE)
C355 FUEL HARN (FUEL SENDER)
SHEET 6
2140/BRN (S/N A3P111242 AND ABOVE)
C107 ENG OIL PRESS SENDER
2150/BRN
Sheet 4 of 13
SHEET 6
C405 AIR FILTER SWITCH (PRINTED MARCH 2011)
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 PARTIAL CONNECTOR
CAN BUS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7 CONNECTOR
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK
(TWO WIRE BREAKS
* DLX CAB HARN 7196753 ONLY
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
(NOT IN STD CAB HARN 7165991)
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200/PUR 9270/PUR 9230/PUR 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4

CAN LO C479
9 9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 7 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426 9260/PUR 4
Remote Run Tool, ACD C503
9160/PUR/WHT 2 RIGHT DELUXE PANEL
14 9500/PUR/WHT A
CAN HI
20 9600/PUR B
CAN LO
21 3090/LBL D REMOTE RUN KEY 1830/RNG/WHT 1
C SHEET 3
SHEET 3
1730/RNG/WHT E SWITCHED POWER SHEET 4
2070/BLK
9560/PUR/WHT
2
3
* C450
RIGHT JOYSTICK
1165/RED/WHT F (SJC/AWS ONLY)
SHEET 3 UNSWITCHED POWER 9660/PUR 4
2710/BLK G GROUND 9220/PUR 8
SHEET 4 J2B
9120/PUR/WHT 9
AUX CTRLR
1840/RNG/WHT 1
SHEET 3
SHEET 4
2080/BLK
9540/PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640/PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 5 of 13
ENGINE
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
ACS PAGE 14
SJC PAGE 15
FRC1
STARTER RELAY C109
30 S/R ADAPTER STARTER
1030/RED A
SHEET 3 87 8200/TAN TAN S M
B SHEET 3
3560/LBL B TAN R
85 86 8210/TAN 1015/RED
SHEET 12 2005/BLK
C110
B S 1020/RED
ALTERNATOR G
L 1800/RNG/WHT
SHEET 3
EXCITATION
2015/BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100/TAN B
1350/RED/WHT 30 8120/TAN PULL 0.33 OHM
SHEET 3 87 3410/LBL
2400/BLK 2800/BLK C GND
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 8800/TAN A HOLD
24.5 OHM
FRC1 T14
GLOW PLUG PRE HEATER
RELAY 8500/TAN
1060/RED 30
SHEET 3 87
2016/BLK 85 86
2055/BLK
SHEET 3
6 8510/TAN
14 3420/LBL
3 8110/TAN
30 3410/LBL
7 8210/TAN
22 3560/LBL
C107
5140/YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140/LBL C SIG ENGINE OIL PRESSURE
2140/BRN A GND SENDER (0.5-4.5V)
SHEET 4
C405
2150/BRN B GND
SHEET 4 AIR FILTER
16 3150/LBL A SIG Printable Version Click Here
SWITCH (NC)
C106
15 3160/LBL
2160/BRN
A
B
SIG
GND
ENGINE SPEED SENSOR WIRING SCHEMATIC
SHEET 4 (163 OHM)
C104
(STANDARD MACHINE)
2170/BRN B GND ENGINE COOLANT
18
SHEET 4
3170/LBL A SIG
SENSOR (500-3000 OHM)
(8 VOLT)
4 8800/TAN
J1B C355
GWY CTRLR FUEL HARN
C406 Sheet 6 of 13
12 3180/LBL C 3180/LBL OR 3100, LBL A SIG
FUEL SENDER
SHEET 4
2180/BRN D 2180/BRN OR 3110, LBL B GND (30 - 270 OHM)
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
HYDRAULICS
GROUND PAGE 4
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CAB PAGE 9
MANUAL CONTROLS PAGE 10
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100/LGN 4200/LGN A 4200/LGN A SOLENOID
RELAY TRACK 2 SPEED
2200/BLK C 2200/BLK B 9.8 OHM ADAPTER (SEE
1360/RED/WHT 30 SHEET 4
SHEET 3 3430/LBL 12 V ADDITIONAL
87
2025/BLK WHEEL 2 SPD ADAPTER HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035/BLK 4110/LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
C WHEEL SINGLE SPEED
8
TRACTION LOCK
13
C108
2220/BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 4
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND HYDRAULIC
SHEET 4
3190/LBL C SIG CHARGE
5190/YEL A +8V PWR PRESSURE
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A 18 2330/BRN 2 GND FRONT ROD
AUX CTRLR
4330/LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
WIRING SCHEMATIC
1 2340/BRN
C419
2 GND
(STANDARD MACHINE)
FRONT BASE
4340/LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM T650 (S/N A3P012214 AND ABOVE)
19 13
J2B
Sheet 7 of 13
AUX CTRLR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CAN BUS PAGE 5
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CONNECTOR
CAB DISPLAY PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
WIRE BREAK
(TWO WIRE BREAKS
PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 SHEET #
SJC PAGE 15
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3 C499
LEFT PANEL
Press To Operate Loader
7040/WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930/RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940/BLK 3
7040/WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920/BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960/RNG/WHT 1440/RED/WHT 1 20 3030/LBL 1 3030/LBL OR 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
*
SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5 SWITCHED POWER
J1A
19 2380/BRN 37 2380/BRN OR 9370, PUR 4
PTOL LED
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT
SHEET 13 GWY CTRLR
C500
5 6 3500/LBL 8
SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
4
2700/BLK 2 3 3650/LBL 7 24 8130/TAN 4 8130/TAN OR 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
3600/LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040/LBL 40 4
3040/LBL OR 9350, PUR RUN/ENTER SWITCH
3610/LBL OR 9310, PUR 4 5 GWY CTRLR
SHEET 3 1775/RNG/WHT 6
1950/RNG/WHT 5
SHEET 4 2930/BLK C480 SHEET 3 SWITCHED POWER
LEFT PANEL (GRAY) 1420/RED/WHT 1
SHEET 3 UNSWITCHED POWER
3620/LBL 12 2960/BLK 3
SHEET 9 DOOR SIGNAL SHEET 4 GROUND
11
10
9 C503
3610/LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590/RNG/WHT 5
7 SHEET 3 SWITCHED POWER
6 1240/RED/WHT 1
5 2250/BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 8 of 13
Printed In U.S.A. 7197683 Printable Version Click Here
PAGE 1,2 LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3 PARTIAL CONNECTOR
CAB
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 CONNECTOR
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
ENGINE 8000 THROUGH 8999 TAN TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
(TWO WIRE BREAKS
JOIN ONE WIRE)
ACS PAGE 14 SHEET #
SJC PAGE 15
*
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 3 3
SHEET 9 2060/BLK 5 6
4
C408
CAB-MFR HARN
2
3
4235/LGN
4275/LGN
*C212
POWER
SOCKET
5 4550/LGN 2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
2790/BLK 24 2790/BLK 2790/BLK 2010/BLK

* C209
B GND
SHEET 4
1370/RED/WHT 23 1370/RED/WHT 1390/RED/WHT A +12V PWR DOME
SHEET 3
3640/LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210/RED/WHT A +12V BATT PWR
1580/RNG/WHT 16 1580/RNG/WHT 1865/RNG/WHT B +12V SW PWR
SHEET 3
2820/BLK C GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT SHEET 13
2210/BLK SHEET 13
2885/BLK SHEET 13
2060/BLK
SHEET 4
2730/BLK 33 2730/BLK
SHEET 9
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620/LBL 3630/LBL 4
SHEET 8 DOOR SIGNAL
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
6
1850/RNG/WHT 27 1850/RNG/WHT 1850/RNG/WHT 1

SHEET 3 WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
2370/BRN 45 2370/BRN OR 3910, LBL A GND SENSOR 7310/WHT 3
WASHER SIGNAL
11 3370/LBL 46 3370/LBL OR 3920, LBL B SIG * C252

L SIG
WASHER
+5V
24 5100/YEL 5370/YEL 44 5370/YEL OR 3900, LBL C +5V PWR
2845/BLK X GND MOTOR WIRING SCHEMATIC
SHEET 6 5140/YEL
(STANDARD MACHINE)
Sheet 9 of 13

POWER PAGE 3
MANUAL
CAB DISPLAY PAGE 8
CONTROLS
LIGHTS PAGE 11 WIRE BREAK
HVAC PAGE 12 (TWO WIRE BREAKS
OPTIONS PAGE 13
ACS PAGE 14 SHEET #
SJC PAGE 15
C409
RIGHT HANDLE
J2A
K
AUX CTRLR G
1520/RNG/WHT A
SHEET 3
30 4940/LGN H
C404 31 4930/LGN J SKI CTRL
C103
BU ALARM-MFR HARN 4920/LGN E
TAILGATE HARN DETENT FLOW
T19 TERMINAL (+) 13 4910/LGN F
(SEE ADDITIONAL A 7100/WHT C 7100/WHT TWO SPD
OPTIONS SHEET) 4310/LGN C
BACK UP
4320/LGN D PWM
2650/BLK ALARM
SHEET 4 4300/LGN B (8 VOLT)
T20 TERMINAL (-)
21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670/BRN 3 GND D
GWY CTRLR 4670/LGN 1 SIG TILT SPOOL LOCK 28 4840/LGN C
2 7.8 OHM 12V 22 4830/LGN B SKI CTRL
12 4820/LGN G
C422 11 4810/LGN F SIDE SHIFT
2 2680/BRN 3 GND 1530/RNG/WHT A
LIFT SPOOL LOCK SHEET 3
4680/LGN 1 SIG J
7.8 OHM 12V
2 H
E
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 10 of 13
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 JOIN ONE WIRE)
ACS PAGE 14
SJC PAGE 15 C434-1
2735/BLK B GND LEFT FRONT
6100/PNK A SIG WORK LIGHT
C408
37.00 Watts
CAB-MFR HARN
C434-2
2765/BLK 28 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000/PNK 25 6000/PNK 6120/PNK A SIG RIGHT FRONT
2760/BLK B GND WORK LIGHT
37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
2610/BLK 2 GND
1330/RED/WHT 30 SHEET 4 RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 SIG
2640/BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 4 RIGHT REAR
6210/PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
RELAY
1320/RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200/PNK H 6200/PNK SIG LEFT REAR
2630/BLK GND WORK LIGHT
2045/BLK 85 86 SHEET 4
2035/BLK T18 TERMINAL (-)
SHEET 7
WIRING SCHEMATIC
(STANDARD MACHINE)
Sheet 11 of 13
HVAC
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
(TWO WIRE BREAKS
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
ACS PAGE 14
SJC PAGE 15
2440/BLK * C610
2 GND
#
DLX FUEL HARN 7184255 ONLY
HVAC DUCT
7440/WHT 1 SIG FAN (NOT IN STD FUEL HARN 7149219)
C483
2560/BLK * C BLK
7420/WHT A DBL POTENTIOMETER
7425/WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130/BLK C GND HEATER
7430/WHT A +12V PWR VALVE
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3 6
SHEET 6
2005/BLK
1790/RNG/WHT 3 7530/WHT * C611
1 14.00 Amps High
SHEET 3 7410/WHT 7520/WHT 2 7.50 Amps Med BLOWER
SW11 7510/WHT 3 5.00 Amps Low MOTOR
21 3450/LBL
SHEET 4
2745/BLK 22 2745/BLK *
AC SWITCH 2580/BLK 4
J1A 7015/WHT 1 C 7400/WHT

GWY CTRLR 2100/BLK
3
11 7021/WHT 7020/WHT 34
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570/BLK 2

SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C355
#
FUEL HARN
A 7024/WHT 7025/WHT
C486
1 SIG
WIRING SCHEMATIC
2 MAGNET CLUTCH
GND
SHEET 13
2290/BLK 2280/BLK
(COMPRESSOR)
(STANDARD MACHINE)
D4
Sheet 12 of 13
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 WIRE BREAK * DLX CAB HARN 7196753 ONLY
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
# C607
C355
FUEL HARN
C408
#
POWER 10 CAB-MFR HARN
BOB-TACH
SIG
GND
1
2
4470/LGN OR 7010, WHT
2470/OR 2770, BLK 2770/OR 2751, BLK
E
B
4470/LGN
2770/BLK
4470/LGN
4480/LGN
(NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 4
2290/BLK
SHEET 12
#
*POWER
SW5 2 1
3
C606 BOBTACH
POWER 5 4
SIG 2 2480/OR 2775, BLK SWITCH 6
BOB-TACH 1 4480/LGN OR 7000, WHT 4480/LGN
GND F 9
OPEN
1380/RED/WHT
1410/RED/WHT 26 1410/RED/WHT 1200/RED/WHT
SHEET 3
X T3
C411
B 6010/PNK 15
1430/RED/WHT
6010/PNK L
* FLASHER CONN
C 3500/LBL
SHEET 8 D1
LEFT HANDLE A 6515/PNK 6500/PNK 36 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
(BLINKER / FLASHER) E 6540/PNK
5 PIN D2 SWITCH
D 6415/PNK 6400/PNK 29 6400/PNK 6430/PNK
3400/LBL 2725/BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
2850/BLK
INSULATED) 6
E 6410/PNK
EURO TAIL LIGHTS
(SEE ADDITIONAL D 6510/PNK * C670
E
OPTIONS SHEET) 2780/BLK 30 D
2780/BLK 2420/BLK BEACON/FLASHER
SHEET 4
6440/PNK F EXTERIOR HARNESS
6540/PNK B (SEE ADDITIONAL
1550/RNG/WHT 13 1550/RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820/WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450/LGN D3 4455/LGN 35 4455/LGN 1
4
2 *
SW6
BUCKET
SPEAKER
-
2 7830/WHT 4
2830/BLK 5 POSITION C278 RADIO CONN
SOLENOID GND B 2450/BLK 2455/BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6 2 7810/WHT 6
RIGHT -
C126 SPEAKER 1 7800/WHT 5
SHEET 4 2785/BLK + 1885/RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885/BLK 2
LEFT HANDLE B 7210/WHT 38 7210/WHT A SIG SHEET 9 GND
HORN
(HORN) A 1460/RED/WHT
2 PIN
SHEET 3 C277
* 1
2
3
C415 1510/RNG/WHT 4 PWR
J2A HIGH FLOW SHEET 9 AIR RIDE
26 2460/BRN B GND 2210/BLK 5 GND
AUX CTRLR SOLENOID SHEET 9 SEAT
4460/LGN A SIG 6
7.5 OHM 12 V
J2B
26
AUX CTRLR
C437 WIRING SCHEMATIC

27 2360/BRN 2 GND TWO SPEED
J1A
4360/LGN 1 SIG
MAKEUP SOLENOID
8.8 OHM 12V TRACK 2 SPEED
(STANDARD MACHINE)
ADAPTER (SEE
GWY CTRLR
26 2350/BRN
C441
2 GND TWO SPEED
ADDITIONAL
OPTIONS SHEET)
SOLENOID
4350/LGN 1 SIG
5.1 OHM 12 V (S/N A3P111242 AND ABOVE)
25 26
J1B
Sheet 13 of 13
GWY CTRLR
CONNECTOR ASSIGNMENTS CONNECTOR ASSIGNMENTS (ACS)
NUM OF NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 J1A GATEWAY COTROLLER 34 C428 TILT ACTUATOR 8 14
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26 C429 LIFT ACTUATOR 8 14
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 J2A AUX CONTROLLER 34 C467 LIFT PEDAL LOCK 3 14
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7 J2B AUX CONTROLLER 26 C468 TILT PEDAL LOCK 3 14
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 J1-ACS ACS CONTROLLER 8 C469 TILT HANDLE 3 14
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11 J2-ACS ACS CONTROLLER 10 C470 TILT PEDAL 3 14
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 J3-ACS ACS CONTROLLER 10 C471 LIFT PEDAL 3 14
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 J5 DRIVE CONTROLLER 50 C472 LIFT HANDLE 3 14
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7
C126 HORN 2 13 C441 TWO SPEED 2 7 FC1 FUSE CENTER 1 3
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 FC2 FUSE CENTER 2 3
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5,15 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5,15
C250 DOOR SENSOR 2 9 C459 LEFT JOYSTICK 4 15
C251 WIPER 5 9 C460 RIGHT JOYSTICK 4 15 T1 BATT GROUND 4
C252 WASHER 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T2 BUZZER GROUND 8
C277 AIR RIDE SEAT 6 9 C480 LEFT PANEL(GRAY) 12 8 T3 FLASHER 13
C278 RIGHT SPEAKER 2 9 C482 SEATBAR SENSOR 3 9 T6 BATT GROUND 4
C279 LEFT SPEAKER 2 9 C483 TEMP CONTROL SWITCH 3 12 T8 BATT GROUND 4 CONNECTOR ASSIGNMENTS (SJC)
C308 BRAKE SOLENOID 2 7 C486 AC COMPRESSOR 2 12 T13 BUZZER POWER 8 NUM OF
CONN DESCRIPTION SHEET
C350 AC EVAPORATOR SWITCH 2 12 C489 ACCESSORY 2 3,4 T14 PRE HEATER 6 PINS
C355 DLX or STD FUEL HARNESS 6 6,12,13 C492 ACS/SJC/AWS 1 8 3,5,9,14,15 RIGHT REAR WORK LIGHT(+) C536 RIGHT SWASHPLATE 4 15
T15 11
C362 REAR AUX SOLENOID 8 7 C493 ACS/SJC/AWS 2 4 3,4,14,15 T16 RIGHT REAR WORK LIGHT(-) 11 C537 LEFT SWASHPLATE 4 15
C404 BACKUP ALARM 2 3,10 C497 SJC HORN/BLINKER 3 13 LEFT REAR WORK LIGHT (+) 11 C428 TILT ACTUATOR 8 15
T17
C405 AIR FILTER SWITCH 2 6 C499 PTOL 4 8 T18 LEFT REAR WORK LIGHT (-) 11 C429 LIFT ACTUATOR 8 15
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8 10 C453 RIGHT QUAD A DRIVE 4 15
T19 BACKUP ALARM
C408 CAB CONNECTOR 48 3-5, 8-13 C503 RH DLX PANEL 6 5,8 T20 BACKUP ALARM (GND) 10 C454 LEFT QUAD DIRVE 4 15
C409 RIGHT HANDLE 10 10 C602 LEFT REAR TAIL LIGHT 2 11 C474 BRAKE LIGHT 1 15
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11
C411 LEFT HANDLE 5 WAY 5 10,13 C606 POWER BOBTACH OPEN 2 13 SW1 BRAKE SWITCH 9 C501 A22 PUMP HARNESS 8 15
C412 HANDLE(HORN) 2 10,13 C607 POWER BOBTACH CLOSE 2 13 SW2 BEACON SWITCH 13 C544 LEFT FORWARD DRIVE 2 15
C413 REAR ROD 2 7 C611 BLOWER MOTOR 4 12 SW3 HAZARD SWITCH 13 C545 LEFT REVERSE DRIVE 2 15
C414 REAR BASE 2 7 C630 THERMOSTAT 3 12 SW4 HAND/FOOT, H/ISO SWITCH 9 C546 RIGHT FORWARD DRIVE 2 15
C415 HIGH FLOW SOLENOID 2 7 C635 HEATER VALVE 6 12 SW5 POWER BOBTACH SWITCH 13 C547 RIGHT REVERSE DRIVE 2 15
C416 DIVERTER SOLENOID 2 7 C667 DOOR KIT 6 9 SW6 BUCKET POSITION SWITCH 13 C542 LEFT SWASHPLATE 3 15
C417 REAR AUX RELIEF 2 7 C670 EXTERIOR BEACON 6 13 SW8 FRONT WIPER SWITCH 9 C543 RIGHT SWASHPLATE 3 15
C418 FRONT ROD 2 7 C676 RADIO 6 9 SW9 TRAVEL CONTROL SWITCH 8 C707 OBW STOP BRAKE LIGHT 3 15
C419 FRONT BASE 2 7 SW10 BLOWER SWITCH 12
C420 HYD LOCK 2 7 SW11 AC SWITCH 12

LIGHTS
ACCESSORIES
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRING SCHEMATIC
(ACS & SJC MACHINE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 1 of 15
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) J5 DRIVE CONTROLLER
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1 1 SAFETY IN
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT 2 TWO SPEED SWITCH
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT 3 SPARE DIGITAL INPUT 2
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID 4 H PAT SWITCH
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F) 5 ISO PAT SWITCH
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID 6 ISO LITE
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M) 7 L SWASH PLATE ANGLE
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1 8 R SWASH PLATE ANGLE
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1 9 SPARE ANALOG 4
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10 10 SPARE ANALOG 5
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11 11 L FWD RETURN
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12 12 CAN HIGH
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F) 13 LF ANGLE
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2 14 RF ANGLE
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND 15 LR ANGLE
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND 16 H PAT LITE
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND 17 RR ANGLE
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL 18 L JOYSTICK X
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M) 19 L JOYSTICK Y
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2 20 R JOYSTICK X
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER 21 L FWD DRIVE
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER 22 CAN LOW
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER 23 R QUAD A DRIVE
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24 24 R QUAD B DRIVE
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE) 25 TWO SPEED 1
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW 26 BRAKE LIGHT OUTPUT
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN 27 GROUND
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON 28 GROUND
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN 29 SENSOR GROUND
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP 30 SENSOR SUPPLY 2 +5V
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN 31 L REV DRIVE
A-32 HYD OIL TEMP A-32 32 CAN SHIELD
A-33 SPARE ANALOG A-33 33 L QUAD A DRIVE
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE 34 L QUAD B DRIVE
35 SAFETY OUT
36 BACKUP ALARM
ACS CONTROLLER HARNESS PART NUMBER HARNESS PART NUMBER
MAINFRAME 7175625 37 R JOYSTICK Y
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS SJC TRACK 7159458
PIN FUNCTION PIN FUNCTION PIN FUNCTION STD CAB 7165991 A22 PUMP 7169309 38 SPARE ANALOG 1
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 DLX CAB 7176098 SUSP JSTK 7163706 39 SPARE PWM COIL 7
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER DLX FUEL 7175293 BACKUP ALARM 7175017 40 SENSOR SUPPLY 1 +5V
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER STD FUEL 7149219 BRAKE ADAPTER 7165061 41 L REV RETURN
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 DOOR 7155024 42 R FWD RETURN
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE S/R 6733370 43 R FWD DRIVE
F F LIFT HANDLE F LIFT MOTOR 1 TAILGATE DOM 7175271 44 R REV DRIVE
G GROUND G TILT HANDLE G PEDAL ENABLE TAILGATE EUR 7175287 45 R REV RETURN
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 2 SPD ADP 7159366 46 TWO SPEED 2
J LIFT PEDAL J GROUND ACS 7164144 47 UNSWITCHED BATTERY
K TILT PEDAL K TILT MOTOR 2 SJC WHEEL 7159325 48 UNSWITCHED BATTERY
49 SPARE PWN COIL 6
50 SWITCHED BATTERY
WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 2 of 15
POWER
FC1 FUSE 3 ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
25 A COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
C493 1 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
FC1 FUSE 4 SJC CONTROL PAGE 15
1280/RED 25 A 1235/RED/WHT
BATTERY MEGAFUSE
FC1 FUSE 2
C493 2
100.0 Amps 1180/RED/WHT
BATT_CABLE 25 A J2B 2
J2B 3
1240/RED/WHT
FC1 FUSE 1 SHEET 8
1400/RED/WHT
25 A C408 17 SHEET 9
1070/RED 1120/RED/WHT 1450/RED/WHT 1450/RED/WHT 1420/RED/WHT
SHEET 8
1110/RED/WHT 1440/RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130/RED/WHT
15 A J1B 3
SHEET 9
FC2 FUSE 2 1460/RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
1190/RED 25 A 1165/RED/WHT
SHEET 5
1010/RED
FRC 1 FUSE 6
1310/RED 30 A 1360/RED/WHT
SHEET 7
1050/RED FRC1 FUSE 5
30 A
1350/RED/WHT
SHEET 6
FRC1 FUSE 11
25 A
SHEET 12
FRC1 FUSE 10
1340/RED 20 A 1330/RED/WHT
SHEET 11
1620/RNG/WHT
FRC1 FUSE 9 SHEET 8
1940/RNG/WHT
15 A SHEET 8
1320/RED/WHT 1930/RNG/WHT
SHEET 11 SHEET 8
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785/RNG/WHT
SHEET 9
1950/RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
5A SHEET 8
1570/RNG/WHT
SHEET 10
FRC1 FUSE 2
1760/RNG/WHT 25 A 1850/RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A 1550/RNG/WHT
SHEET 13
FRC1 FUSE1
25 A 1780/RNG/WHT
1750/RNG/WHT
C489 A
SWITCHED 1720/RNG/WHT
C404 B
POWER
1050/RED 30 WIRING SCHEMATIC
87 SHEET 12
2055/BLK 85 86 FRC1 FUSE 7 (ACS & SJC MACHINE)
SHEET 6 25 A
2030/BLK 1795/RNG/WHT 1730/RNG/WHT
SHEET 12
FRC1 FUSE 8
SHEET 5 T650 (S/N A3P011001 - A3P012213)
1740/RNG/WHT
8000/TAN
C492 6
25 A
1580/RNG/WHT
SHEET 9 (S/N A3P111001 - A3P111241)
J1A 4
1830/RNG/WHT
SHEET 5 Sheet 3 of 15
C408 6 SHEET 5
GROUND
SJC CONTROL PAGE 15
2080/BLK 2235/BLK
SHEET 5 C493 3
2070/BLK 2240/BLK
SHEET 5 C408 32 C493 4
2940/BLK 2950/BLK 2950/BLK
SHEET 8
2960/BLK 2510/BLK
SHEET 8 J1B 16
2920/BLK 2500/BLK 2110/BLK T6
SHEET 8 J1B 15 BATT GND
2250/BLK 2540/BLK
SHEET 8 J2B 16
2550/BLK 2090/BLK
J2B 15
2765/BLK
SHEET 11
2745/BLK
SHEET 12
2790/BLK T8
SHEET 9 BATT GND
2780/BLK
SHEET 13
2730/BLK
SHEET 9
2620/BLK
SHEET 11
2630/BLK 2720/BLK
SHEET 11 C103 B C489 B
2650/BLK 2600/BLK 2600/BLK
SHEET 10
2640/BLK 2810/BLK 2390/BLK
SHEET 11 SHEET 6
2610/BLK
SHEET 11
2200/BLK
SHEET 7
SHEET 13
2450/BLK
SHEET 7
2741/BLK
SHEET 13
2785/BLK 2710/BLK 2300/BLK T1
SHEET 13 SHEET 5 BATT GND
2930/BLK 2480/BLK
SHEET 9 C408 42 SHEET 7
2830/BLK 2900/BLK 2900/BLK
SHEET 13
2700/BLK 2105/BLK
SHEET 8 SHEET 11
2530/BLK 2000/BLK
SHEET 10
2520/BLK
SHEET 10
3530/LBL
SHEET 7
3800/LBL
SHEET 6
2370/BRN OR 3910/LBL
SHEET 9
3310/LBL 3010/LBL
SHEET 7 J1B 17
3410/LBL
SHEET 7
3110/LBL OR 2189/BRN
SHEET 6
3510/LBL
SHEET 6
3710/LBL Printable Version Click Here
SHEET 6
WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 4 of 15
CAN BUS
SJC CONTROL PAGE 15
9160/PUR/WHT
C503 2
9260/PUR RH DLX PANEL
C503 4
9200/PUR 9270/PUR 9210/PUR 9280/PUR 9230/PUR C408 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR
J1B 8 C479 4
GWY CTRLR 9100/PUR/WHT 9170/PUR/WHT 9110/PUR/WHT 9180/PUR/WHT 9130/PUR/WHT 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
SHEET 3
1830/RNG/WHT 1 #
2070/BLK 2
SHEET 4 RIGHT
9560/PUR/WHT 3 JOYSTICK
9660/PUR 4
9240/PUR
C492 1
9140/PUR/WHT ACS CTRLR C449
C492 4
9290/PUR 1840/RNG/WHT 1 #
C492 7 SHEET 3
9190/PUR/WHT DRIVE CTRLR 2080/BLK 2
C492 8 SHEET 4 LEFT
9540/PUR/WHT 3
JOYSTICK
9640/PUR 4
9220/PUR
J2B 8 AUX CTRLR
9120/PUR/WHT
J2B 9
C426
9500/PUR/WHT A
J1B 14
9600/PUR B
J1B 20
9400/PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730/RNG/WHT E
SHEET 3
1165/RED/WHT F
SHEET 3
2710/BLK G
SHEET 4
# CONNECTOR DOES NOT EXIST IN 7165991

WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 5 of 15
Printed In U.S.A.
ENGINE
SJC CONTROL PAGE 15
STARTER C109 STARTER
30 J1A 22
8250/TAN B 8250/TAN R M
B SHEET 3
1030/RED A
SHEET 3 87 8200/TAN 8200/TAN S 1015/RED
C110
2005/BLK 85 86 8210/TAN B
SHEET 12 J1A 7 S 1020/RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800/RNG/WHT 1815/RNG/WHT
SHEET 12
EXCITATION
2015/BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120/TAN D5 8100/TAN B 8100 TAN PULL
1350/RED/WHT 30 24.5 OHM
SHEET 3 87 8150/TAN J1B 4 8800/TAN A 8800 TAN HOLD 0.33 OHM
J1A 30
2810/BLK 2800/BLK C 2800 BLK
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 J1A 3
C106 GLOW
3600/LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550/TAN
3610/LBL B GND 1060/RED J1A 14
SHEET 3 87 8500/TAN
3800/LBL T14 PRE HEATER
SHEET 4
3210/LBL B SIG 85 86
ENGINE COOLANT 2016/BLK 8510/TAN
3200/LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055/BLK
SHEET 3
C104
C107
3500/LBL B +5V PWR
SHEET 9
3520/LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510/LBL A GND SENDER (0.5-4.5V)
SHEET 4
C406
C355 C
3100/LBL OR 3180/LBL 3100/LBL OR 3180/LBL A SIG
J1B 12 FUEL
3110/LBL OR 2189/BRN 3110/LBL OR 2180/BRN B GND SENDER Printable Version Click Here
SHEET 4
C355 D
C405 WIRING SCHEMATIC
3710/LBL B GND
SHEET 4
J1A 16
3700/LBL A SIG
AIR FILTER
SWITCH (ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 6 of 15
HYDRAULIC
SJC CONTROL PAGE 15
TRACTION
LOCK C425 TRACK MACHINES
30 4150/LGN
1360/RED/WHT J1A 13
SHEET 3 87 4100/LGN B C308
BRAKE
2025/BLK 4200/LGN A 4200/RED A SOLENOID
SHEET 6 85 86 J1B 6
2035/BLK 4110/LGN 2200/BLK C 2200/BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C SOLENOID
C362 C414
OPTIONAL REAR AUX
4440/LGN A 4440/LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440/BLK B 2440/BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410/BLK B HYD LOCK
4430/LGN C 4430/LGN 1 SIG OPTIONAL REAR AUX J1A 1 SOLENOID
J2B 7 4410/LGN A
2430/BLK D 2430/BLK 2 GND
DIRECIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER
7.5 OHM 12V C105
C416 HYDRAULIC
3410/LBL B CHARGE
4450/LGN E 4450/LGN 1 SIG OPTIONAL REAR AUX 3420/LBL C
J2B 4 J1B 1 PRESSURE
2450/BLK F 2450/BLK 2 GND BLEED / LOCK VALVE 3400/LBL A 0.5-7.5V
SHEET 4 SOLENOID MALE COUPLER J1B 23
C417
7.5 OHM 12 V +8V
C108 HYDRAULIC
4480/LGN G 4480/LGN 1 SIG OPTIONAL REAR AUX 3310/LBL B TEMPERATURE
J2B 6 BLEED / LOCK VALVE SHEET 4
2480/BLK H 2480/BLK 2 GND 3300/LBL A SENDER
SHEET 4 SOLENOID FEMALE COUPLER J1A 32 500 - 3000 OHM
9.8 OHM 12 V
C112
C415 3430/LBL A HYDRAULIC OIL
2460/BLK B GND J1A 34
J2A 26 OPTIONAL HIGH FLOW 3530/LBL B FILTER SWITCH
4460/LGN A SIG SOLENOID SHEET 4
J2B 26 7.5 OHM 12 V
C418
2330/BLK 2 GND
J2A 18 FRONT ROD SOLENOID (MALE)
J2B 19
C419
2340/BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
J2B 13
C437
2360/BLK 2 GND
J1A 27 OPTIONAL TWO SPEED
4360/LGN 1 SIG Printable Version Click Here
J1B 25 MAKEUP SOLENOID
C441
J1A 26
2350/BLK
4350/LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
WIRING SCHEMATIC
J1B 26
C446 (ACS & SJC MACHINE)
2910/BLK 2 GND HYDRAULIC
J1A 18
J1B 19
4010/LGN 1 SIG
FAN SOLENOID
7.2 OHM
T650 (S/N A3P011001 - A3P012213)
12 V
(S/N A3P111001 - A3P111241)
Sheet 7 of 15
SJC CONTROL PAGE 15
C500 RH KEY SWITCH

C408 4
9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 2
J1A 24
J1B 22
T13 C408 40
BUZZER (+) 1950/RNG/WHT 5
SHEET 3
1940/RNG/WHT 1420/RED/WHT 1
SHEET 3 SHEET 3
2960/BLK 3
SHEET 4
6
T2
BUZZER (-)
RH DLX PANEL
LEFT PANEL (BLACK) 1590/RNG/WHT C503 5
C479 10 SHEET 3
9320/PUR OR 7040/WHT C503 1
1240/RED/WHT
C479 2 SHEET 3
2920/BLK C503 3
SHEET 4 2250/BLK
SHEET 4
1440/RED/WHT C479 1
SHEET 3
1960/RNG/WHT 1620/RNG/WHT C479 5
SHEET 3 SHEET 3
SW9 6450/PNK C479 11
SHEET 13
TRAVEL CONTROL C479 8
SWITCH OPTIONAL 6550/PNK
SHEET 13
5 6 4500/LGN OR 3600/LBL C479 9
SHEET 9
4 C479 7
2700/BLK 2 3 4730/LGN
SHEET 4 1
C480 LEFT PANEL (GRAY)

4750/LGN 12
SHEET 9
9310/PUR OR 3610/LBL 2
SHEET 9
PTOL
C408 1 C499 (Press To Operate Loader)
J1A 20
9370/PUR OR 2380/BRN 9370/PUR OR 2380/BRN 4
J1A 19
C408 37
1930/RNG/WHT 1
SHEET 3
2940/BLK 3
SHEET 4
WIRING SCHEMATIC
(ACS & SJC MACHINE)
CAB DISPLAY T650 (S/N A3P011001 - A3P012213)

(S/N A3P111001 - A3P111241)
Sheet 8 of 15
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550/LGN C408 5 4550/LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS) C492 2
SWITCH
1785/RNG/WHT 2 1 4275/LGN C408 3 4275/LGN
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 C492 3
3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060/BLK 5 6 4235/LGN C408 2 4235/LGN 4230/LGN
4 SHEET 10
4220/LGN 4240/LGN
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14 C492 5 SHEET 10
SJC CONTROL PAGE 15
C212
2795/BLK 1
+
1375/RED/WHT 2 POWER SOCKET
-
C209
2790/BLK C408 24 2790/BLK 2010/BLK B
C408 23 SHEET 4
1370/RED/WHT 1370/RED/WHT 1390/RED/WHT A DOME LIGHT
SHEET 3
4760/LGN C
*
C676
1885/RNG/WHT 1
2885/BLK 2
C129 C279
1210/RED/WHT A
SHEET 3
1580/RNG/WHT
C408 16
1580/RNG/WHT * 1865/RNG/WHT B LEFT SPEAKER
1
2
+ 7820/WHT
7830/WHT
3
4 RADIO CONN
2820/BLK C -
ACCESSORY
CONN C278
2 - 7810/WHT 6
RIGHT SPEAKER 1 7800/WHT 5
+
2730/BLK C408 33 2730/BLK
SHEET 4
C277
1510/RNG/WHT 4
AIR RIDE
2210/BLK 5 SEAT SOLENOID
C482
SEATBAR
SENSOR C667 C250 SENSOR SHOWN
2370/BRN OR 3910/LBL C408 45 2370/BRN OR 3910/LBL A GND
SHEET 4 4750/LGN 4740/LGN 4 4740/LGN 1 WITH DOOR OPEN
SHEET 8
3920/LBL OR 3370/LBL 3920/LBL OR 3370/LBL 1400/RED/WHT 5 1400/RED/WHT 2 DOOR SENSOR C251
C408 46 B SIG SHEET 3
J1B 11 1860/RNG/WHT D SW PWR
3900/LBL OR 5370/YEL 3900/LBL OR 5370/YEL 6 7330/WHT C PARK
3930/LBL C PWR WIPER
J1B 24 1570/RNG/WHT 7300/WHT A LOW MOTOR
+5V 3500/LBL C408 44
SHEET 6 B GND
1850/RNG/WHT 1850/RNG/WHT 1 1850/RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310/WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN OR 3600/LBL 3 2 FRONT WIPER
SHEET 8 1 2840/BLK 2 2840/BLK SWITCH C252
9310/PUR OR 3610/LBL 4 5
SHEET 8 7310/WHT L
1775/RNG/WHT 6
SHEET 3 WASHER
2930/BLK
SHEET 4 2845/BLK X MOTOR
WIRING SCHEMATIC
(ACS & SJC MACHINE)
7165991 Standard Cab T650 (S/N A3P011001 - A3P012213)
7176098 Deluxe Cab (S/N A3P111001 - A3P111241)
Sheet 9 of 15
Printed In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7171253
MANUAL
CONTROLS
SJC CONTROL PAGE 15
C409
RIGHT HANDLE
2530/BLK K
SHEET 4
4230 LGN G
SHEET 9
1590/RNG/WHT A
4940/LGN H
J2A 30
4930/LGN J SKI CTRL
J2A 31
4920/LGN E DETENT FLOW
J2B 21
4910/LGN F
J2A 13 TWO SPD
4310/LGN C -
J2B 17
4320/LGN D
J2B 18 PWM
4300/LGN B +
J2B 23
C410
LEFT HANDLE
K
4640/LGN D
J2A 20
4840/LGN C
J2A 28
4830/LGN B SKI CTRL
J2A 22
4820/LGN G
J2A 12
4810/LGN F SIDE SHIFT
J2A 11
1570/RNG/WHT 1710/RNG/WHT A
SHEET 3
1560/RNG/WHT J
J2B 22
4240/LGN H
SHEET 9
2520/BLK E
SHEET 4
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A 7100/WHT C103 C 7100/WHT T19 1 B
+ BACKUP ALARM
2650/BLK 7001923 A HORN
SHEET 4 -
T20 1
C421
2370/BLK 3
J1A 10 TILT SPOOL LOCK SOLENOID
4370/LGN 1
J1B 7 (NOT USED WITH ACS)
2
WIRING SCHEMATIC
C422
J1A 2
2380/BLK 3
LIFT SPOOL LOCK SOLENOID
(ACS & SJC MACHINE)
4380/LGN 1 (NOT USED WITH ACS)
J1B 5
2 T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 10 of 15
LIGHTS
SJC CONTROL PAGE 15
C434-1
2735/BLK B LEFT FRONT
37.00 Watts
C434-2
2765/BLK C408 28 2765/BLK 2750/BLK B
SHEET 4 LEFT FRONT
50.00 Watts
C435-1
6000/PNK C408 25 6000/PNK 6120/PNK A RIGHT FRONT
37.00 Watts
C435-2
6130/PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610/BLK 2
1330/RED/WHT 30 C103 A 6310/PNK RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK 6320/PNK 1
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1
6320/PNK 2640/BLK 2 LEFT REAR
J1A 5 SHEET 4 TAIL LIGHT
6330/PNK
J1A 31
2620/BLK T16 1 RIGHT REAR

SHEET 4
6210/PNK WORK LIGHT
REAR
LIGHT T15 1
1320/RED/WHT 30 C103 H
SHEET 3 6200/PNK 6200/PNK T17 1
87 LEFT REAR
2630/BLK WORK LIGHT
85 86 SHEET 4
2045/BLK T18 1
2035/BLK
SHEET 7
6210/PNK
J1A 17
6230/PNK
J1A 28
WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 11 of 15
HVAC
SJC CONTROL PAGE 15
C630
7021/WHT 7020/WHT C408 34 7020/WHT B
J1A 11
7023/WHT 2570/BLK C
3320/LBL A
THERMOSTAT
C350
B C483
7024/WHT A EVAPORATOR 2560/BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980/RNG/WHT A DBL
C486 7220/WHT B WHT (TEMP CONTROL
C355 A 7024/WHT SWITCH)
7025/WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290/BLK 2280/BLK D SIG
SHEET 13
D4 2130/BLK C GND HEATER
1900/RNG/WHT 1910/RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT C408 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3 6 C611
2005/BLK
SHEET 6 3 1970/RNG/WHT A 14.00 Amps High
1790/RNG/WHT
SHEET 3 1520/RNG/WHT B 7.50 Amps Med BLOWER
1815/RNG/WHT
SHEET 6 7320/WHT C 5.00 Amps Low MOTOR
8020/TAN
J1A 21 2580/BLK D
2745/BLK 2745/BLK
SHEET 4
7040/WHT
C408 22
SW11
AC SWITCH
1 C
2100/BLK
3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 12 of 15
OPTIONS
SJC CONTROL PAGE 15
SW5
POWER
BOBTACH
SWITCH C408 9
C408 26 1 7000/WHT OR 4480/LGN 7000/WHT OR 4480/LGN
C411 1410/RED/WHT 1410/RED/WHT 1380/RED/WHT 2
C408 15 SHEET 3
B 6010/PNK 6010/PNK 1430/RED/WHT 3 C408 10
1200/RED/WHT 4 7010/WHT OR 4470/LGN 7010/WHT OR 4470/LGN
C 6550/PNK 5
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515/PNK 6500/PNK 6500/PNK 6530/PNK FLASHER CONN
5 PIN E 6540/PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415/PNK 6400/PNK 6400/PNK 6430/PNK 6570/PNK
C607
6450/PNK 2725/BLK 6 C355 E
SHEET 8 SW3 5 A 7010/WHT OR 4470/LGN/WHT
1 4
C103 E HAZARD SWITCH 2 C670 STROBE B 2770/BLK OR 2470/BLK/BLK 2751/BLK OR 2770/BLK
6410/PNK 3 1 2
(PINS 3 & 6 6700/PNK E BEACON 2751/BLK OR 2770/BLK
6510/PNK 4 3 2290/BLK SHEET 4
INTERNALLY SHEET 12 C355 B
5 2850/BLK 2420/BLK D
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK OR 2480/BLK
F
2780/BLK C408 30 2780/BLK A 7000/WHT C355 F
SHEET 4 B
6440/PNK
6540/PNK RIGHT PWR BOB OPEN
BLINKER
SW6
BUCKET
POSITION
C408 13 1550/RNG/WHT SWITCH
1550/RNG/WHT
SHEET 3
3 2
7022/WHT 1
C126
SHEET 4 SHEET 4 4
C412 2785/BLK B 2830/BLK 5
B 7210/WHT C408 38 7210/WHT A 6 C423
LEFT HANDLE C408 35 D3
2 PIN A 1460/RED/WHT 7022/WHT 7030/WHT A
SHEET 3
2741/BLK 2740/BLK B
SHEET 4
C497
7200/WHT C
J2A 5 SJC
6420/PNK A HORN/BLINKER
J2A 4
6520/PNK B
J2A 3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
T650 (S/N A3P011001 - A3P012213)
(S/N A3P111001 - A3P111241)
Sheet 13 of 15
ACS
CONTROLS
SJC CONTROL PAGE 15
J1-ACS
H 2280/BLK
2670/BLK See manual controls for harness
2240/BLK
connection
HANDLE TILT
MAINFRAME HARNESS 1170/RED/WHT HALL SENSOR C409
C492 K A
G 2250/BLK 8 J3-ACS HANDLE
G B
7 B 1190/RED/WHT LOCK
A
C 4450/LGN 2 C 1180/RED/WHT H
4220/LGN 5 J SKI CTRL
4275/LGN 3 C429 LIFT ACTUATOR E DETENT
9240/PUR 1 D 4690/LGN 8 F FLOW
9140/PUR/WHT 4 7 C TWO SPD
1740/RNG/WHT 6 6 D
F 4680/LGN 5 PWM
B
C493 J 2260/BLK 4
A 4 H 2270/BLK 1 GND C410
E 3 4670/LGN 2 SIG
2 K
D 1530/RNG/WHT 3 PWR
1 D
B FLOAT
C
C428 TILT ACTUATOR
C472 B SKI CTRL
K 4790/LGN 8
J2-ACS G
2650/BLK B B GND 7 SIDE
F
F 4650/LGN C C SIG HANDLE LIFT 6 SHIFT
A
1510/RNG/WHT A A PWR HALL SENSOR A 4780/LGN 5
J
4
H A
1630/RNG/WHT 3 PWR HANDLE
E B
4770/LGN 2 SIG LOCK
H 2770/BLK OR 2470/BLK 1 GND
C411
E
C467 E
A 2 C
B 4280/LGN 1 A
C 2510/BLK 3 LIFT D TURN SIGNAL
D SOLENOID B
C468
2 C412
C469 G 4260/LGN 4270/LGN 1 B
2750/BLK B B GND E 4220/LGN 2500/BLK 3 TILT A HORN
SOLENOID
G 4750/LGN C C SIG HANDLE TILT
1610/RNG/WHT A A PWR HALL SENSOR
C471
1520/RNG/WHT 1 PWR
J 4660/LGN 3 SIG LIFT PEDAL Printable Version Click Here
2660/BLK 2 GND HALL SENSOR
C470
1620/RNG/WHT 1 PWR
WIRING SCHEMATIC
K 4760/LGN 3 SIG TILT PEDAL
2760/BLK 2 GND HALL SENSOR (ACS & SJC MACHINE)
1610/RNG/WHT
1510/RNG/WHT
1500/RNG/WHT
1530/RNG/WHT
1630/RNG/WHT
T650 (S/N A3P011001 - A3P012213)
4275/LGN
4220/LGN
(S/N A3P111001 - A3P111241)
4670/LGN
4770/LGN Sheet 14 of 15
J5 - DRIVE CONTROLLER C454 LIFT
C429 ACTUATOR
29 2510/BLK 2580/BLK 3 GND 4680/LGN 5
1540/RNG/WHT 1 PWR 6
LEFT SPEED
33 3020/LBL 2 SIG SENSOR 4690/LGN 8
34 3080/LBL 4 SIG 2630/BLK 1 GND
40 1640/RNG/WHT C453
4
1530/RNG/WHT 1 PWR 4670/LGN 2 SIG
2570/BLK 3 GND 7
23 3000/LBL 2 SIG
RIGHT SPEED 1610/RNG/WHT 3 PWR
SENSOR
24 3070/LBL 4 SIG
1500/RNG/WHT
C428 TILT ACTUATOR
2250/BLK
C536 1630/RNG/WHT 3 PWR SCHEMATIC INDEX
1810/RNG/WHT 2 C543 HARNESS, A22 PUMP 7169309 OVERVIEW PAGE 1,2
4
2810/BLK 4 2810/BLK 1 GND POWER PAGE 3
4770/LGN 2 SIG
8 4720/LGN 3 4720/LGN 3 SIG RIGHT GROUND PAGE 4
6
1710/RNG/WHT 1 1770/RNG/WHT 2 PWR
SWASHPLATE CAN BUS PAGE 5
1 GND
ENGINE PAGE 6
C537
4780/LGN 5
HYDRAULICS PAGE 7
1820/RNG/WHT 2 C542 7
CAB DISPLAY PAGE 8
2860/BLK 4 2860/BLK 1 GND 4790/LGN 8
CABIN PAGE 9
7 4950/LGN 3 4950/LGN 3 LEFT
SIG MANUAL CONTROLS PAGE 10
SWASHPLATE
1770/RNG/WHT 1 1770/RNG/WHT 2 PWR K LIGHTS PAGE 11
HVAC PAGE 12
J2-ACS
C501 C546 J
E OPTIONS PAGE 13
43 4260/LGN 1 4260/LGN 1
RIGHT FORWARD DRIVE H ACS CONTROL PAGE 14
42 2660/BLK 2 2660/BLK 2
F SJC CONTROL PAGE 15
C547 G
C WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
44 4250/LGN 3 4250/LGN 1
RIGHT REVERSE DRIVE D GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
45 2650/BLK 4 2650/BLK 2 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
B
C545 A
ACS CONTROLLER
31 4280/LGN 5 4280/LGN 1 GROUNDING 2000 THROUGH 2999 BLACK BLK
41 2680/BLK 6 2680/BLK 2 LEFT REVERSE DRIVE
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
C544 G ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
J1-ACS
21 4270/LGN 7 4270/LGN 1 A LIGHTS 6000 THROUGH 6999 PINK PNK
11 2670/BLK 8 2670/BLK 2 LEFT FORWARD DRIVE ACCESSORIES 7000 THROUGH 7999 WHITE WHT
F
E ENGINE 8000 THROUGH 8999 TAN TAN
D COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
C474 HARNESS, OBW STOP LTS 7151696 C707 B COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
26 4210/LGN A 1730/RNG/WHT A H
6600/PNK B C C460
87 2730/BLK C
30 1 1830/RNG/WHT 1
C492
4210/LGN 85 86 2 2070/BLK 2
12 9190/PUR/WHT 8 BRAKE RIGHT
LIGHT 4 9660/PUR 4
22 9290/PUR 7 BRAKE LIGHT RELAY JOYSTICK
4 4550/LGN 2
K 3 9560/PUR/WHT 3
6 4220/LGN 5
16 4275/LGN 3 A
D C459
J3-ACS
9140/PUR/WHT 4
9240/PUR 1 F 1 1840/RNG/WHT +12V PWR 1
1740/RNG/WHT 6
MAINFRAME H
2 2080/BLK GND 2
50 1750/RNG/WHT HARNESS J LEFT
47 1250/RED/WHT C 4 9640/PUR CAN LOW 4
C493 JOYSTICK
48 1260/RED/WHT 1235/RED/WHT 2 B
3 9540/PUR/WHT CAN HIGH 3
27 2470/BLK 2235/BLK 3 E
28 2490/BLK 1170/RED/WHT 1 G
2240/BLK 4
1760/RNG/WHT WIRING SCHEMATIC

2280/BLK
2270/BLK
2260/BLK
(ACS & SJC MACHINE)
1180/RED/WHT
1190/RED/WHT
T650 (S/N A3P011001 - A3P012213)
C404
C103 C
(S/N A3P111001 - A3P111241)
36 7100/WHT A 7100/WHT
B
SHEET4
+
-
Sheet 15 of 15
BACKUP
(CONNECTS TO BACKUP ALARM
ALARM C404 ON MFR (PRINTED MARCH 2011)
HARNESS)
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C446 HYDRAULIC FAN 2 7 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C449 LEFT JOYSTICK (CAB HARN) 4 5 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C450 RIGHT JOYSTICK (CAB HARN) 4 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C453 RIGHT QUAD A DRIVE 4 15
C106 ENGINE SPEED SENSOR 2 6 C454 LEFT QUAD DRIVE 4 15 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C467 LIFT PEDAL LOCK 3 14 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C468 TILT PEDAL LOCK 3 14 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C469 TILT HANDLE 3 14 J2B AUX CONTROLLER 26 3-5,7,10,13
C110 ALTERNATOR 2 6 C470 TILT PEDAL 3 14
C112 HYD OIL FILTER SWITCH 2 7 C471 LIFT PEDAL 3 14 J1-ACS ACS CONTROLLER 8 14, 15
C126 HORN 2 13 C472 LIFT HANDLE 3 14 J2-ACS ACS CONTROLLER 10 14, 15
C129 CAB ACCESSORY 3 9 C474 BRAKE LIGHT 1 15 J3-ACS ACS CONTROLLER 10 14, 15
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 J5 DRIVE CONTROLLER 50 15
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW1 BRAKE SWITCH 6 8
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW2 BEACON SWITCH 6 13
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW3 HAZARD SWITCH 6 13
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C308 BRAKE SOLENOID 2 7 C492 ACS/SJC/AWS-MFR HARN 8 3,5,9 SW5 POWER BOBTACH SWITCH 6 13
C350 AC EVAPORATOR SWITCH 2 12 C493 ACS/SJC/AWS-MFR HARN 4, 15 3,4 SW6 BUCKET POSITION SWITCH 6 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C497 SJC HORN/BLINKER 3 13 SW9 TRAVEL CONTROL SWITCH 6 8
C404 BU ALARM-MFR HARN 2 3,10 C499 PTOL 4 8 SW10 BLOWER SWITCH 5 12
C405 AIR FILTER SWITCH 2 6 C500 RH KEY SWITCH 6 8 SW11 AC SWITCH 3 12
C406 FUEL SENDER 2 6 C501 A22 PUMP HARNESS 8 15
C408 CAB - MFR HARN CONNECTOR 48 3-5,8-9,11-13 C503 RH DLX PANEL 6 5,8 T1 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C542 LEFT SWASHPLATE 3 15 T2 BUZZER GROUND 1 8
C410 LEFT HANDLE 10 10 C543 RIGHT SWASHPLATE 3 15 T3 FLASHER 2 13
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C544 LEFT FORWARD DRIVE 2 15 T6 BATT GROUND 1 4
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C545 LEFT REVERSE DRIVE 2 15 T8 BATT GROUND 1 4
C415 HIGH FLOW SOLENOID 2 13 C546 RIGHT FORWARD DRIVE 2 15 T13 BUZZER POWER 1 8
C418 FRONT ROD (MALE) 2 7 C547 RIGHT REVERSE DRIVE 2 15 T14 PRE HEATER 1 6
C419 FRONT BASE (FEMALE) 2 7 T15 RIGHT REAR WORK LIGHT(+) 1 11
C420 HYD LOCK 2 7 T16 RIGHT REAR WORK LIGHT(-) 1 11
C440 RF BASE 2 14 C602 LEFT REAR TAIL LIGHT 2 11 T17 LEFT REAR WORK LIGHT (+) 1 11
C422 TILT SPOOL LCOK 3 10 C603 RIGHT REAR TAIL LIGHT 2 11 T18 LEFT REAR WORK LIGHT (-) 1 11
C423 BUCKET POSITION 2 13 C606 POWER BOBTACH OPEN 2 13 T19 BACKUP ALARM 1 10
C425 BRAKE SOLENOID 3 7 C607 POWER BOBTACH CLOSE 2 13 T20 BACKUP ALARM (GND) 1 10
C426 CAN (Remote Start Tool, ACD) 7 5 C610 HVAC DUCT FAN 2 12
C428 TILT ACTUATOR 8 14, 15 C611 BLOWER MOTOR 4 12
C429 LIFT ACTUATOR 8 14,15 C630 THERMOSTAT 3 12
C434-1 LEFT WORKLIGHT 1 2 11 C635 HEATER VALVE 6 12
C434-2 LEFT WORKLIGHT 2 2 11 C667 DOOR 6 9
C435-1 RIGHT WORKLIGHT 1 2 11 C670 EXTERIOR BEACON 6 13
C435-2 RIGHT WORKLIGHT 2 2 11 C676 RADIO 6 13
C437 TWO SPEED MAKEUP 2 13
C441 TWO SPEED 2 13 C707 OBW STOP BRAKE LIGHT 3 15

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 Printable Version Click Here
WIRING SCHEMATIC
move 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7 (ACS / SJC MACHINE)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9 T650 (S/N A3P012214 AND ABOVE)
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13
Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT SJC PAGE 15

A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-12 B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25
A-27 SPARE A-27
A-29 A-29
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

EXMF 7199263
MAINFRAME
LF 7196823
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TRK BRAKE ADP 7165061
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 2 of 15
1240/RED/WHT WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SHEET 8 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1400/RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB-MFR HARN SHEET 9
C667 DOOR HARNESS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1450/RED/WHT 17 1450/RED/WHT 1420/RED/WHT BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
SHEET 8
C500 RH KEY SWITCH CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
FC1 FUSE CENTER 1440/RED/WHT MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
2 SHEET 8
FUSE 1 25 A 1110/RED/WHT J1B HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C479 LH PANEL
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
+12V 1025/RED
FUSE 2 25 A
1160/RED/WHT 1150/RED/WHT 3
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
100.0 Amps
BATT_CABLE FUSE 3 25 A 1
1270/RED 1170/RED/WHT LEGEND
SCHEMATIC INDEX
C493 PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
SJC/ACS/AWS-MFR HARN
FUSE 4 25 A POWER PAGE 3
1280/RED 1235/RED/WHT 2 (4 PIN)
GROUND PAGE 4
1010/RED
SHEET 6 CAN BUS PAGE 5
STARTER FC2 FUSE CENTER ENGINE PAGE 6
CONNECTOR
FUSE 1 25 A HYDRAULICS PAGE 7
1190/RED 1165/RED/WHT CAB DISPLAY PAGE 8
SHEET 5
C426 REMOTE RUN, ACD CAB PAGE 9
FUSE 2 25 A MANUAL CONTROLS PAGE 10
1040/RED 1490/RED/WHT 1410/RED/WHT WIRE BREAK
SHEET 13
(TWO WIRE BREAKS LIGHTS PAGE 11
C408 CAB-MFR CONN (OPTIONS)
FUSE 3 OPEN JOIN ONE WIRE) HVAC PAGE 12
1460/RED/WHT
SHEET 13 SHEET # OPTIONS PAGE 13
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
SHEET 9 SJC PAGE 15
C408 CAB-MFR CONN (ACCESSORIES)
FRC1 FUSE RELAY CENTER
1050/RED
FUSE 5 30 A
1350/RED/WHT
SHEET 6
SHEET 6 1060/RED FRC1 FUEL SHUTOFF RELAY
FUSE 6 30 A
FRC1 PRE HEATER RELAY 1310/RED 1360/RED/WHT
SHEET 7
1030/RED FRC1 TRACTION LOCK RELAY
SHEET 6
FRC1 STARTER RELAY
SHEET 11
FRC1 REAR LIGH RELAY
1340/RED SHEET 11
C404
FUSE 11 25 A BU ALARM-MFR HARN 1620/RNG/WHT
1300/RED 1140/RED/WHT 1720/RNG/WHT B SHEET 8
SHEET 12 (SEE ADDITIONAL C479 LH PANEL
FUSE1 25 A FRC1 HVAC RELAY OPTIONS SHEET)
SHEET 8
A T13 LH PANEL BUZZER
1760/RNG/WHT FUSE 2 25 A 1850/RNG/WHT 1780/RNG/WHT C489
SHEET 9 MFR ACCESSORY 1930/RNG/WHT
C408 CAB-MFR CONN (FR WIPER) SHEET 8
FUSE 3 15 A C499 RH PANEL PTOL
1550/RNG/WHT C408
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
FUSE4 5 A 1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
43
SHEET 8
1530/RNG/WHT SHEET 10 C503 RH DELUXE PANEL
C410 LEFT HANDLE
SHEET 10 SHEET 8
C409 RIGHT HANDLE J2B C500 RH PANEL KEY SWITCH
FUSE 7 25 A 1560/RNG/WHT 22
1795/RNG/WHT 1730/RNG/WHT AUX CTRLR
SHEET 9
C426 REMOTE RUN, ACD SW4 H/ISO SWITCH
FUSE 8 25 A
FRC1 1580/RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050/RED 30
87
J1A
GWY CTRLR 1790/RNG/WHT
C110 ALT EXCITATION
SHEET 12
WIRING SCHEMATIC
85 86 C408 FRC1 HVAC RELAY
SHEET 6
2055/BLK
2030/BLK
3380/LBL 4
CAB-MFR HARN (ACS / SJC MACHINE)
SHEET 12
1920/RNG/WHT 6 1920/RNG/WHT 1840/RNG/WHT
SHEET 5
C449 LH JOYSTICK
C492 1830/RNG/WHT
1740/RNG/WHT 6
(8 PIN)
SHEET 5
C450 RH JOYSTICK (S/N A3P111242 AND ABOVE)
Sheet 3 of 15
GROUND
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
C493
2080/BLK
SHEET 5 SJC/ACS/AWS-MFR HARN
C449 LH JOYSTICK (4 PIN)
2070/BLK
SHEET 5
C450 RH JOYSTICK 3 2235/BLK
2920/BLK C408 4 2240/BLK
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940/BLK 2950/BLK 32 2950/BLK
SHEET 8
C499 PTOL
2960/BLK 16 2510/BLK 2110/BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500/BLK
2250/BLK
SHEET 8 2765/BLK
C503 RH DELUXE PANEL SHEET 11
16 2540/BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745/BLK BATT GND
2550/BLK 2090/BLK SHEET 12
2930/BLK AUX CTRLR
SHEET 8 C408 CAB-MFR CONN (HVAC)
SW1 BRAKE SWITCH 2790/BLK
2830/BLK 2900/BLK 42 2900/BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SW6 BKT POSITION SWITCH SHEET 11 2105/BLK
2780/BLK
SHEET 8 2700/BLK FRC1 FRONT LIGHT RELAY SHEET 13
SW9 TRAVEL CONTROL SWITCH 2530/BLK 2000 C408 CAB-MFR CONN (OPTIONS)
SHEET 10
2785/BLK C409 RIGHT HANDLE 2730/BLK
SHEET 13 SHEET 9
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
SHEET 10 2520/BLK
2620/BLK C410 LEFT HANDLE

SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630/BLK C489
SHEET 11 TAILGATE HARN B 2720/BLK
T18 LH REAR LIGHT MFR ACCESSORY
2650/BLK 2600/BLK B 2600/BLK
SHEET 10
T20 BU ALARM 2400/BLK 2390/BLK
SHEET 6
2640/BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200/BLK
C602 LH REAR LIGHT SHEET 7
2610/BLK C425 BRAKE
SHEET 11 2770/BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455/BLK
2170/BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710/BLK 2300/BLK
SHEET 5
SHEET 6 2160/BRN C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320/BRN
SHEET 7
C112 HYD OIL FILTER SWITCH
2370/BRN J1B
SHEET 9
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR
SHEET 7
2220/BRN 2230/BRN 17 WIRING SCHEMATIC
C108 HYD TEMP SENDER
SHEET 7 2190/BRN (ACS / SJC MACHINE)

C105 HYD CHG PRESSURE SENDER
SHEET 6
2180/BRN T650 (S/N A3P012214 AND ABOVE)
C355 FUEL HARN (FUEL SENDER)
2140/BRN
SHEET 6
C107 ENG OIL PRESS SENDER Sheet 4 of 15
2150/BRN
SHEET 6
C405 AIR FILTER SWITCH (PRINTED MARCH 2011)
CAN BUS
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK * DLX CAB HARN 7196753 ONLY
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200/PUR 9270/PUR 9210/PUR 9280/PUR 9230/PUR 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR 4
CAN LO C479
9 9100/PUR/WHT 9170/PUR/WHT 9110/PUR/WHT 9180/PUR/WHT 9130/PUR/WHT 7 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR C492 RESISTOR
(8 PIN)
C426 1 9260/PUR 4
9240/PUR C503
Remote Run Tool, ACD 9160/PUR/WHT 2
9140/PUR/WHT 4 ACS CTRLR RIGHT DELUXE PANEL
14 9500/PUR/WHT A
CAN HI
20 9600/PUR B
CAN LO
21 3090/LBL D REMOTE RUN KEY 9290/PUR 7
1830/RNG/WHT 1
C 9190/PUR/WHT 8 SHEET 3
SHEET 3
1730/RNG/WHT E SWITCHED POWER
DRIVE CTRLR
SHEET 4
2070/BLK
9560/PUR/WHT
2
3
* C450
RIGHT JOYSTICK
1165/RED/WHT F (SJC/AWS ONLY)
SHEET 3 UNSWITCHED POWER 9660/PUR 4
2710/BLK G GROUND 9220/PUR 8
SHEET 4 J2B
9120/PUR/WHT 9 AUX CTRLR
1840/RNG/WHT 1
SHEET 3
SHEET 4
2080/BLK
9540/PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640/PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 5 of 15

PARTIAL CONNECTOR
ENGINE
CONNECTOR
CAB DISPLAY PAGE 8
OPTIONS PAGE 13
ACS PAGE 14 SHEET #
SJC PAGE 15
FRC1
STARTER RELAY C109
30 S/R ADAPTER STARTER
1030/RED A
SHEET 3 87 8200/TAN TAN S M
B SHEET 3
3560/LBL B TAN R
85 86 8210/TAN 1015/RED
SHEET 12 2005/BLK C110
B S 1020/RED
ALTERNATOR G
L 1800/RNG/WHT SHEET 3
EXCITATION
2015/BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100/TAN B
1350/RED/WHT 30 8120/TAN PULL 0.33 OHM
SHEET 3 87 3410/LBL
2400/BLK 2800/BLK C GND
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 8800/TAN A HOLD
24.5 OHM
FRC1 T14
GLOW PLUG PRE HEATER
RELAY 8500/TAN
1060/RED 30
SHEET 3 87
2016/BLK 85 86
2055/BLK
SHEET 3
6 8510/TAN
14 3420/LBL
3 8110/TAN
30 3410/LBL
7 8210/TAN
22 3560/LBL
C107
5140/YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140/LBL C SIG ENGINE OIL PRESSURE
2140/BRN A GND SENDER (0.5-4.5V)
SHEET 4
C405
2150/BRN B GND
SHEET 4 AIR FILTER
16 3150/LBL A SIG
SWITCH (NC)
C106
15
SHEET 4
3160/LBL
2160/BRN
A
B
SIG
GND
ENGINE SPEED SENSOR WIRING SCHEMATIC
(163 OHM)
C104 (ACS / SJC MACHINE)

2170/BRN B GND ENGINE COOLANT
18
SHEET 4
3170/LBL A SIG
SENSOR (500-3000 OHM)
(8 VOLT)
4 8800/TAN
J1B
C355
GWY CTRLR FUEL HARN
C406 Sheet 6 of 15
12 3180/LBL C 3180/LBL OR 3100 LBL A SIG
FUEL SENDER
SHEET 4
2180/BRN D 2180/BRN OR 3110 LBL B GND (30 - 270 OHM) (PRINTED MARCH 2011)
HYDRAULICS
GROUND PAGE 4
CAB DISPLAY PAGE 8
CAB PAGE 9
OPTIONS PAGE 13 JOIN ONE WIRE)
ACS PAGE 14 SHEET # C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100/LGN 4200/LGN A 4200/LGN A SOLENOID
RELAY TRACK 2 SPEED
2200/BLK C 2200/BLK B 9.8 OHM ADAPTER (SEE
1360/RED/WHT 30 SHEET 4
SHEET 3 3430/LBL 12 V ADDITIONAL
87
2025/BLK WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035/BLK 4110/LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
C WHEEL SINGLE SPEED
8
TRACTION LOCK
13
C108
2220/BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 4
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND HYDRAULIC
SHEET 4
3190/LBL C SIG CHARGE
5190/YEL A +8V PWR PRESSURE
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330/BRN 2 GND FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330/LGN 1 SIG
3.3 OHM PWM
C419
(ACS / SJC MACHINE)
1 2 GND
2340/BRN
4340/LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) T650 (S/N A3P012214 AND ABOVE)
3.3 OHM PWM
19 13 Sheet 7 of 15
J2B
AUX CTRLR (PRINTED MARCH 2011)
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE LEGEND
OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
CAB DISPLAY
POWER PAGE 3 PARTIAL CONNECTOR
GROUND PAGE 4
CAN BUS PAGE 5
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
WIRE BREAK
(TWO WIRE BREAKS
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
SJC PAGE 15
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3 C499
LEFT PANEL
Press To Operate Loader
7040/WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930/RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940/BLK 3
7040/WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920/BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960/RNG/WHT 1440/RED/WHT 1 20 3030/LBL 1 3030/LBL OR 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
* SW9
TRAVEL CONTROL
SHEET 3
1620/RNG/WHT 5 SWITCHED POWER
J1A
19 2380/BRN 37 2380/BRN OR 9370, PUR 4
PTOL LED
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT
SHEET 13 GWY CTRLR
C500
5 6 3500/LBL 8
4 SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
2700/BLK 2 3 3650/LBL 7 24 8130/TAN 4 8130/TAN OR 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
3600/LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040/LBL 40 4
3040/LBL OR 9350, PUR RUN/ENTER SWITCH
3610/LBL OR 9310, PUR 4 5 GWY CTRLR
SHEET 3 1775/RNG/WHT 6
1950/RNG/WHT 5
SHEET 4 2930/BLK C480 SHEET 3 SWITCHED POWER
LEFT PANEL (GRAY) 1420/RED/WHT 1
3620/LBL 12 2960/BLK 3
SHEET 9 DOOR SIGNAL SHEET 4 GROUND
11
10
9 C503
3610/LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590/RNG/WHT 5
7 SHEET 3 SWITCHED POWER
6 1240/RED/WHT 1
5 2250/BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 8 of 15
PARTIAL CONNECTOR
CAB
CONNECTOR
CAB DISPLAY PAGE 8
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK
HVAC
OPTIONS
PAGE 12
PAGE 13
(TWO WIRE BREAKS
JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
ACS PAGE 14 SHEET #
SJC PAGE 15
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 3 3
2060/BLK 5 6
SHEET 9
4
C492
SHEET 10 4230/LGN C408
(8 PIN) CAB-MFR HARN
SHEET 10 4240/LGN
5
3
4220/LGN
4275/LGN
4235/LGN 2
3
4235/LGN
4275/LGN
*POWER
C212
SOCKET
2 4550/LGN 5 4550/LGN 2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
2790/BLK 24 2790/BLK 2790/BLK 2010/BLK

* C209B GND
SHEET 4
1370/RED/WHT 23 1370/RED/WHT 1390/RED/WHT A +12V PWR DOME
SHEET 3
3640/LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210/RED/WHT A +12V BATT PWR
1580/RNG/WHT 16 1580/RNG/WHT 1865/RNG/WHT B +12V SW PWR
SHEET 3
2820/BLK C GND
1510/RNG/WHT
SHEET 13
1885/RNG/WHT SHEET 13
2210/BLK SHEET 13
2885/BLK SHEET 13
2060/BLK
SHEET 4
2730/BLK 33 2730/BLK
SHEET 9
*
C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620/LBL 3630/LBL 4
SHEET 8 DOOR SIGNAL
1400/RED/WHT 5 DOOR UNSW PWR
SHEET 3
6
1850/RNG/WHT 27 1850/RNG/WHT 1850/RNG/WHT 1

SHEET 3 WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
2370/BRN 45 2370/BRN OR 3910, LBL A GND SENSOR 7310/WHT 3
WASHER SIGNAL
11 3370/LBL 46 3370/LBL OR 3920, LBL B SIG * C252

L SIG
WASHER
24 5100/YEL 5370/YEL 44 5370/YEL OR 3900, LBL C +5V PWR X MOTOR
+5V 2845/BLK GND
SHEET 6 5140/YEL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 9 of 15

LEGEND
PARTIAL CONNECTOR
MANUAL
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 7
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 WIRE BREAK
CONTROLS
LIGHTS PAGE 11 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 12
OPTIONS PAGE 13 SHEET #
ACS PAGE 14
SJC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530/BLK K
SHEET 4
AUX CTRLR 4230/LGN G
SHEET 9
1520/RNG/WHT A
SHEET 3
30 4940/LGN H
C404 31 4930/LGN J SKI CTRL
C103
BU ALARM-MFR HARN 4920/LGN E
TAILGATE HARN DETENT FLOW
T19 TERMINAL (+) 13 4910/LGN F
(SEE ADDITIONAL A 7100/WHT C 7100/WHT TWO SPD
OPTIONS SHEET)
4310/LGN C
BACK UP
4320/LGN D
2650/BLK ALARM PWM
SHEET 4 4300/LGN B (8 VOLT)
T20 TERMINAL (-)
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421 AUX CTRLR K
J1A 10 2670/BRN 3 GND 20 4640/LGN D
GWY CTRLR 4670/LGN 1 SIG TILT SPOOL LOCK 28 4840/LGN C
2 7.8 OHM 12V 22 4830/LGN B SKI CTRL
12 4820/LGN G
C422 11 4810/LGN F SIDE SHIFT
2 2680/BRN 3 GND 1530/RNG/WHT A
LIFT SPOOL LOCK SHEET 3
4680/LGN 1 SIG J
7.8 OHM 12V
2 4240/LGN H
SHEET 9
2520/BLK E
SHEET 4
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 10 of 15
LEGEND
RED RED POWER PAGE 3 PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499
LIGHTS
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 CONNECTOR
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT PAGE 15
SJC C434-1
2735/BLK B GND LEFT FRONT
C408
37.00 Watts
CAB-MFR HARN
C434-2
2765/BLK 28 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000/PNK 25 6000/PNK 6120/PNK A SIG RIGHT FRONT
37.00 Watts
C435-2
6130/PNK A SIG RIGHT FRONT
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
2610/BLK 2 GND
1330/RED/WHT 30 SHEET 4 RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 SIG
2640/BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 4 RIGHT REAR
6210/PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
RELAY
1320/RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200/PNK H 6200/PNK SIG LEFT REAR
2630/BLK GND WORK LIGHT
2045/BLK 85 86 SHEET 4
2035/BLK T18 TERMINAL (-)
SHEET 7
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Sheet 11 of 15
HVAC
CAB DISPLAY PAGE 8
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS
ACS
PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
PAGE 14 SHEET #
SJC PAGE 15
2440/BLK *
C610
2
#
GND HVAC DUCT
7440/WHT 1 SIG FAN (NOT IN STD FUEL HARN 7149219)
C483
2560/BLK * C BLK
7420/WHT A DBL POTENTIOMETER
7425/WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130/BLK C GND HEATER
7430/WHT A +12V PWR VALVE
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3
SHEET 6
2005/BLK
1790/RNG/WHT
6
3 7530/WHT
* C611
1 14.00 Amps High
SHEET 3 7410/WHT 7520/WHT 2 7.50 Amps Med BLOWER
SW11 7510/WHT 3 5.00 Amps Low MOTOR
21 3450/LBL
SHEET 4
2745/BLK 22 2745/BLK *
AC SWITCH 2580/BLK 4
J1A 7015/WHT 1 C 7400/WHT

GWY CTRLR 2100/BLK 3
11 7021/WHT 7020/WHT 34
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570/BLK 2

SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C355
FUEL HARN # C486
A 7024/WHT 7025/WHT 1 SIG
2290/BLK 2280/BLK
2 GND
MAGNET CLUTCH
(COMPRESSOR) WIRING SCHEMATIC
SHEET 13
D4
(ACS / SJC MACHINE)
Sheet 12 of 15
(PRINTEDMARCH 2011)
POWER PAGE 3
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
C355
POWER
# C607
1 4470/LGN OR 7010, WHT
FUEL HARN
E
C408
10 CAB-MFR HARN 4470/LGN
#
SIG 4470/LGN
BOB-TACH
CLOSE GND 2 2470/OR 2770, BLK 2770/OR 2751, BLK B 2770/BLK
SHEET 4 4480/LGN (NOT IN STD FUEL HARN 7149219)
SHEET 12 2290/BLK
#
*POWER
SW5 2 1
3
C606 BOBTACH
POWER 5 4
SIG 2 2480/OR 2775, BLK SWITCH 6
BOB-TACH 1 4480/LGN OR 7000, WHT 4480/LGN
GND F 9
OPEN
1380/RED/WHT
1410/RED/WHT 26 1410/RED/WHT 1200/RED/WHT
SHEET 3
X T3
C411
B 6010/PNK 15
1430/RED/WHT
6010/PNK L
* FLASHER CONN
C 3500/LBL
SHEET 8 D1
LEFT HANDLE A 6515/PNK 6500/PNK 36 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
(BLINKER / FLASHER) E 6540/PNK
5 PIN D2 SWITCH
D 6415/PNK 6400/PNK 29 6400/PNK 6430/PNK
3400/LBL 2725/BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700/PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
INSULATED)
2850/BLK
E 6410/PNK 6
EURO TAIL LIGHTS C670
(SEE ADDITIONAL D 6510/PNK * E
OPTIONS SHEET) 2780/BLK D
30 2780/BLK 2420/BLK BEACON/FLASHER
SHEET 4
6440/PNK F EXTERIOR HARNESS
6540/PNK B (SEE ADDITIONAL
1550/RNG/WHT 13 1550/RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820/WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450/LGN D3 4455/LGN 35 4455/LGN 1
4
2 *BUCKET
SW6 SPEAKER
-
2 7830/WHT 4
2830/BLK 5 POSITION C278 RADIO CONN
SOLENOID GND B 2450/BLK 2455/BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6 2 7810/WHT 6
RIGHT -
C126 SPEAKER 1 7800/WHT 5
SHEET 4 2785/BLK + 1885/RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885/BLK 2
LEFT HANDLE B 7210/WHT 38 7210/WHT A SIG SHEET 9 GND
HORN
(HORN) A 1460/RED/WHT
2 PIN
SHEET 3 C277
* 1
2
C497 3
5 7200/WHT C SJC 4 PWR
HORN/BLINKER AIR RIDE
4 6420/PNK A 2210/BLK 5 GND
(SEE ADDITIONAL SHEET 9 SEAT
J2A 3 6520/PNK B OPTIONS SHEET) 6
AUX CTRLR
C415
26 2460/BRN B GND HIGH FLOW
A SIG SOLENOID
4460/LGN
7.5 OHM 12 V
J2B
26
AUX CTRLR
WIRING SCHEMATIC
27 2360/BRN
C437
2 GND TWO SPEED (ACS / SJC MACHINE)
4360/LGN 1 SIG
MAKEUP SOLENOID
J1A
GWY CTRLR
8.8 OHM 12V TRACK 2 SPEED
ADAPTER (SEE
C441
26 2350/BRN
4350/LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
ADDITIONAL
OPTIONS SHEET) (S/N A3P111242 AND ABOVE)
5.1 OHM 12 V
Sheet 13 of 15
25 26
J1B (PRINTED MARCH 2011)
GWY CTRLR

ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
K TILT PEDAL K TILT MOTOR 2
ACS HARNESS 7164144
J1-ACS
CONTROLLER
H 2280/BLK
2280/BLK
SEE MANUAL CONTROL
2240/BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170/RED/WHT C409 C466
C492 C493 J3-ACS K A
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4280/LGN 1 LIFT C TWO SPD
4260/LGN
B 1740/RNG/WHT 6 2 SOLENOID D
A 2250/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GRD LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 3 SIG K 4645/LGN 8
4660/LGN LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4645/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 HALL SENSOR 2990/BRN 1 GND
+5V PWR
5750/YEL 3990/LBL 2 SIG
5650/YEL 5980/YEL
2250/YEL 5990/YEL
WIRING SCHEMATIC
H
E
3980/LBL
3990/LBL
(ACS / SJC MACHINE)
Sheet 14 of 15
Printed In U.S.A. 7197682 Printable Version Click Here
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
SJC PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN

A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
6 ISO LITE
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
13 LF ANGLE
HARNESS PART NUMBER LIFT 14 RF ANGLE
C429 ACTUATOR
SJC WHEEL 7159325 S630, S650 S730, S750, S770 15 LR ANGLE
4600/LGN 5
SJC TRACK 7159458 T630, T650, T730, T750, T770 16 H PAT LITE
J5 - DRIVE SUSP JSTK 7163706 S630, S650, S730, S750, S770, 4610/LGN
6
8 17 RR ANGLE
T630, T650, T730, T750, T770 18
CONTROLLER 2980/BRN 1
4
GND
19
L JOYSTICK X
L JOYSTICK Y
C454 3980/LBL 2 SIG 20 R JOYSTICK X
29 2890/BRN 2880/BRN 3 7
GND 21 L FWD DRIVE
5880/YEL 1 +5V PWR 5980/YEL 3 +5V PWR
LEFT SPEED 22 CAN LOW
33 3880/LBL 2 SIG SENSOR
C428 23 R QUAD A DRIVE
34 3885/LBL 4 SIG TILT ACTUATOR
5990/YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890/YEL C453 4 25 TWO SPEED 1
+5V
5970/YEL
5870/YEL 1 +5V PWR 3990/LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870/BRN 3 GND 6
23 3870/LBL 2 RIGHT SPEED 27 GROUND
SIG 2990/BRN 1 GND
SENSOR 28 GROUND
24 3875/LBL 4 SIG 4640/LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970/BRN
5810/YEL 2 C543 4650/LGN 8
2810/BRN OR BLK 4 2810/BRN or BLK 1 GND
31 L REV DRIVE
8 3810/LBL OR 4720/LGN 3 3810/LBL OR 4720/LGN 3 SIG 32 CAN SHIELD
1710/RNG/WHT 1 1710/RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860/YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860/BRN OR BLK/BRN 4 2860/BRN or BLK 1 GND 36 BACKUP ALARM
F
7 3860/LBL OR 4950/LGN 3 3860/LBL or 4950/LGN 3 SIG 37 R JOYSTICK Y
G
1770/RNG/WHT 1 1770/RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260/LGN 1 4260/LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660/BRN OR BLK 2 2660/BRN or BLK 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250/LGN 3 4250/LGN 1 A 43 R FWD DRIVE
RIGHT REVERSE DRIVE +5V 44 R REV DRIVE
45 2650/BRN OR BLK 4 2650/BRN or BLK 2 G
J1-ACS
F 45 R REV RETURN
C545 9240/PUR E 46 TWO SPEED 2
31 4280/LGN 5 4280/LGN 1
9140/PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN OR BLK 6 2680/BRN or BLK 2 LEFT REVERSE DRIVE
1760/RNG/WHT B 48 UNSWITCHED BATTERY
2280/BLK H
49 SPARE PWN COIL 6
C544 C
21 4270/LGN 7 4270/LGN 1 50 SWITCHED BATTERY
11 2670/BRN OR BLK 8 2670/BRN or BLK 2 LEFT FORWARD DRIVE
K
C460
TO SJC BRAKE A 1 1
C474 1830/RNG/WHT +12V PWR
HARNESS D 2 2
26 4210/LGN A C450 2070/BLK GND
J3-ACS
(SEE ADDITIONAL OPTIONS F RIGHT
RIGHT JOYSTICK 4 9660/PUR 4 CAN LO
SHEET)
2270/BLK H (CONNECTS TO JOYSTICK
2260/BLK J DLX CAB HARNESS)
3 3
C492 9560/PUR/WHT CAN HI
1180/RED/WHT C
12 9190/PUR/WHT 8
1190/RED/WHT B
22 9290/PUR 7 C459
E
4 4550/LGN 2 1 1840/RNG/WHT 1 +12V PWR
G
6 4220/LGN 5
C449 2 2080/BLK 2 GND
16 4275/LGN 3 LEFT JOYSTICK
9140/PUR/WHT 4
LEFT
(CONNECTS TO 4 9640/PUR 4 CAN LO
9240/PUR 1 DLX CAB HARNESS) JOYSTICK
50 1750/RNG/WHT 1740/RNG/WHT 6
MAINFRAME 3 9540/PUR/WHT 3 CAN HI
HARNESS
27 2470/BLK C493
28 2490/BLK 2235/BLK 3
47 1250/RED/WHT 1235/RED/WHT 2
48 1260/RED/WHT 1170/RED/WHT 1
2240/BLK 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
1760/RNG/WHT
2280/BLK T650 (S/N A3P012214 AND ABOVE)
2270/BLK
2260/BLK (S/N A3P111242 AND ABOVE)
1180/RED/WHT
C404
1190/RED/WHT Sheet 15 of 15
36 7100/WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR
HARNESS)
7197682 Printable Version Click Here
Printed In U.S.A.
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
WIRE BREAK
(TWO WIRE BREAKS
JOIN ONE WIRE)
SHEET #
SW7
C667 REAR
C129 WIPER
DOOR HARN C250 SENSOR SHOWN
A SWITCH C667
4 3630/LBL 1 SIG WITH DOOR OPEN
TO CAB B DOOR HARN C250 SENSOR SHOWN
1865/RNG/WHT 1 2
5 1400/RED/WHT 2 PWR DOOR SENSOR HARNESS 4 3630/LBL 1 SIG WITH DOOR OPEN
C 2820/BLK 3
TO DLX CAB 6 4 7230/WHT T6 1 5 1400/RED/WHT 2 PWR DOOR SENSOR
5 REAR
HARNESS 1 6 C251
3 WIPER
MOTOR 6 7330/WHT C PARK
2 1570/RNG/WHT
CAB E
7170531 SPECIAL APPS DOOR HARNESS HARNESS
7180207 REAR WIPER HARNESS
1 1850/RNG/WHT 3 7300/WHT A LOW
1 2 WIPER
3 7310/WHT 6 1860/RNG/WHT D SW PWR MOTOR
4 5
R2 SW8
C667 750 OHM RESISTOR FRONT WIPER
DOOR HARN C250
1W 5% 2 2840/BLK SWITCH B GND
5 1400/RED/WHT 1 1400/RED/WHT
1410/RED/WHT
7155024 DOOR HARNESS

R1
300 OHM RESISTOR
0.5W 5% C251
SENSOR SHOWN
4 3630/LBL 2 3630/LBL 3635/LBL 2 SIG WITH DOOR OPEN
2860/BLK 3 2860/BLK 1 GND DOOR SENSOR
6
7195485 DOOR SENSOR HARNESS
TO DLX
CAB HARNESS Printable Version Click Here
C251
SW8
7330/WHT
1570/RNG/WHT
C PARK
WIRING SCHEMATIC
E
FRONT WIPER
1 1850/RNG/WHT SWITCH
3 7300/WHT A LOW
(KIT AND OPTION HARNESS)
1 2 WIPER
3 7310/WHT 6
4 5
1860/RNG/WHT D SW PWR MOTOR ALL MODELS
2 2840/BLK 2850/BLK B GND
Sheet 1 of 4
7171105 FORESTRY DOOR HARNESS
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR C425
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED TO B C427
BRAKE
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT MAINFRAME A 4200/LGN 1 SOLENOID
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT HARNESS C 2200/BLK 2 9.8 OHM
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 12 V
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR C437 C428
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL TO
2 2360/BRN 2 GND TWO SPEED
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN MAINFRAME MAKEUP SOLENOID
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL HARNESS 1 4360/LGN 1 SIG
8.8 OHM 12V
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS C441 C429
TO
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE) MAINFRAME 2 2350/BRN 2 GND TWO SPEED
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET # HARNESS 1 4350/LGN 1 SIG SOLENOID
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 5.1 OHM 12 V
EXMF, LF: 7177692 2 SPD TRACK ADAPTER

EXLF: 7190709 2 SPD TRACK ADAPTER
7110/WHT
BACK-UP ALARM
SWITCHES
C404
TO A 7100/WHT
MAINFRAME B 1720/RNG/WHT
HARNESS
7175017 BACK-UP ALARM HARNESS
C362 C414
A 4440/LGN 1 SIG
REAR BASE (M) C411 TO
B 2440/BLK 2 GND 7.5 OHM 12V MAINFRAME
WHITE TIE STRAP A C E B D HARNESS
C413 (5 WAY LH)
6000/PNK
C 4430/LGN 1 SIG
REAR ROD (F)
D 2430/BLK 2 GND 7.5 OHM 12V
BROWN TIE STRAP C497 6510/PNK
TO
MAINFRAME C416 B 6415/PNK 2780/BLK
HARNESS E 4450/LGN 1 SIG REAR ROD LOCK 86 85
6410/PNK
F 2450/BLK 2 GND 7.5 OHM 30
87
12 V TO A 6515/PNK 2790/BLK
YELLOW TIE STRAP MAINFRAME
C417 86 85
HARNESS
G 4480/LGN 1 SIG 30 6010/PNK 6020/PNK
REAR BASE LOCK 87
H 2480/BLK 2 GND
9.8 OHM
GREEN TIE STRAP 12 V C 7200/WHT 2770/BLK
86 85
7173271 REAR AUX HARNESS C412 30
TO 87
B 2785/BLK
MAINFRAME
HARNESS A 1420/RED/WHT
(2 WAY LH)
TO C489-1 C489-2
ADDITIONAL
MAINFRAME B B
2720/BLK 2740/BLK ACCESSORY
HARNESS
C414 A 1720/RNG A POWER
(ACCESSORY
4440/LGN 1 SIG CONNECTOR
REAR BASE POWER)
AUX CTRLR J2B PIN 5
2440/BRN 2 GND 7.5 OHM 12V 7151940 SJC/AWS/SCPA HRN/BLKR HARNESS
AUX CTRLR J2A PIN 2
WHITE TIE STRAP
C413
AUX CTRLR J2B PIN 7 4430/LGN 1 SIG
REAR ROD
2430/BRN 2 GND 7.5 OHM 12V Printable Version Click Here
AUX CTRLR J2A PIN 10
BROWN TIE STRAP
C416
TO
MAINFRAME
C489-1
J2B PIN 4
4450/LGN 1 SIG
REAR ROD LOCK
WIRING SCHEMATIC
B 2720/BLK 2450/BLK 2 GND
HARNESS 7.5 OHM
(ACCESSORY
POWER)
A 1780/RNG/WHT 2725/BLK YELLOW TIE STRAP
C417
12 V (KIT AND OPTION HARNESS)
C489-2 4480/LGN 1
ADDITIONAL
ACCESSORY A 2480/BLK 2
SIG
GND REAR BASE LOCK ALL MODELS
POWER B J2B PIN 6 9.8 OHM
CONNECTOR
GREEN TIE STRAP 12 V
Sheet 2 of 4
7191339 or 7201414 REAR AUX HARNESS (PRINTED MARCH 2011)

LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C129
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB ACCESSORY
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK POWER CONN
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS A 1410/RED/WHT 1200/RED/WHT
JOIN ONE WIRE)
SHEET # 1430/RED/WHT X T3
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B FLASHER CONN
TO STANDARD SW2
CAB HARNESS
L
BEACON
SWITCH
C 2780/BLK
2725/BLK 6
SW3 5
4
4 WAY FLASHER 1 2
SWITCH
3
6570/PNK 1
C670 C609 2 2780/BLK
3 C670
E 6700/PNK 1 C669 (PINS 3 & 6 4
STD CAB: STROBE 5 2850/BLK 6700/PNK E
D 2780/BLK 2775/BLK 2 INTERNALLY
TO ACC HARNESS BEACON 1 6440/PNK RIGHT 6 D
C INSULATED) 2420/BLK
FLASHER TO EXTERIOR
A 2785/BLK 2 2785/BLK 2795/BLK C
DLX CAB: LIGHT CAB HARNESS
F 2790/BLK A
TO DLX CAB HARNESS 6440/PNK
B 3 LEFT 6440/PNK F
6540/PNK 6540/PNK
FLASHER 6540/PNK B
7169130 ACC HARNESS
LIGHT
(STD CAB HARNESS ONLY)
6718872 EXTERIOR CAB HARNESS
7169753 4 WAY FLASHER HARNESS
C800
6340/PNK A 6340/PNK REGISTRATION
2670/BLK B 2670/BLK (LICENSE PLATE)
LAMP
7153090 HARNESS LICENSE LIGHT
TO EURO
TAILGATE C603
HARNESS E Taillight Right
C103 F 7104670
D 6510/PNK 6510/PNK A BLU
C407-A C407-B 6610/PNK C RED
H 6200/PNK 6320/PNK A A 6430/PNK B YEL
B 2600/BLK 2610/BLK D BLK
BREAK CONNECTION
FOR ROADLIGHT KIT 2620/BLK -
6210/PNK +
Backup Alarm
6660294
WITH ROADLIGHT KIT: C 2650/BLK
7100/WHT -
TO ROADLIGHT KIT +
C602
HARNESS G 6600/PNK Taillight Left
E Printable Version Click Here
F 7104671
WITHOUT ROADLIGHT E 6410/PNK 6410/PNK A BLU
KIT: TO MAINFRAME
HARNESS
6620/PNK C RED WIRING SCHEMATIC
6330/PNK B YEL
F
2640/BLK D BLK
(KIT AND OPTION HARNESS)
2630/BLK
6210/PNK
-
+
ALL MODELS
A 6310/PNK 6310/PNK
Sheet 3 of 4
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT F 1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK E 3
7210/WHT A 6330/WHT 2
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN 2310/BLK B 2120/BLK 6
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C 6120/LGN 5 Front Turn Light
7230/WHT
7270/WHT D 6340/RED 4
Position Light
C407-B
TO EURO
6430/PNK
TAILGATE F F
HARNESS Relay1
Right Side Lights 6420/PNK A 7210/WHT E
87 6410/PNK 6440/PNK D 7250/WHT 7260/WHT B

6510/PNK E 7200/WHT C Brake Light
10.0 Amps 30 7200/WHT
6400/PNK 6220/PNK C 7220/WHT 7240/WHT A
85 86 2020/BLK
2110/BLK B 2300/BLK 2320/BLK D Rear Turn Light
T01
Relay2
Left Side Lights
87 6310/PNK
10.0 Amps 30
T02
6300/PNK 85 86 2030/BLK
2120/BLK B 2300/BLK E
ADDITIONAL
1510/RNG A
ACCESSORY 6330/PNK A 7210/WHT F
2210/BLK B POWER
6120/PNK C 7220/WHT 7240/WHT A
CONNECTOR
6340/PNK D 7250/WHT 7260/WHT B Rear Position Light
1730/RNG A 1520/RNG 1500/RNG A 6520/PNK E 7200/WHT C
C 2200/BLK B HARNESS F 2320/BLK D Brake Light
2730/BLK 2230/BLK
87
6600/PNK B 6500/PNK
30
87A
85 86
TO
SJC/AWS/SCPA A 6330/WHT 2
4210/LGN 1 7210/WHT
CONTROLS HARNESS
(1 PIN CONN) 7270/WHT D 6340/RED 4 Position Light
7175581 - SJC BRAKE HARNESS E 3
(ONLY FOR SJC OPTION) 7230/WHT C 6120/LGN 5
2310/BLK B 2120/BLK 6
F 1
H 6010/PNK 6320/PNK H
6530/PNK G
B 2000/BLK 2010/BLK B
D 6210/PNK 6230/PNK D
E 6110/PNK 6130/PNK E HARNESS WIRING SCHEMATIC
HARNESS F F
G (KIT AND OPTION HARNESS)
A 6000/PNK 6000/PNK A
C 7100/WHT 7100/WHT C ALL MODELS
Sheet 4 of 4

ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ 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.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
O FF
activated manually by a switch.
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
positions.
4 5 RESISTOR - Limits current flow.
6
DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
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.)

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 TEMPERATURE SENDER - Provides

B 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 TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
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

Standard Cab Harness Connectors
C129 C479
C480 C434-1
C434-2
C482
T13
T2
C499
C503
SW1
C435-1
C435-2
C500
C408
C126
MS2824

Deluxe Cab Harness Connectors
C209
C670 C479 C434-1

C480 C434-2
C499
T13
C482 T2
SW1
SW3
C500
C503 SW2
SW6
C435-1
C435-2
SW4
C667
C426
SW5
SW9
C611 C252
C630
C635
C126
C129 C253
C277 C279
C449 C483
C450 S3
T3
C278
C676
C212
MS2827

Mainframe Harness Connectors
C426
C405
C103 C 350
408
T11 T6
T1
T8 C355
T10 T4
C101 C105
C110 C104
C362
T12 C107
FRC1
C486 C446
FC1
C108 FC2
C423 C362
C441 C489
C415 C497
J2A
C409 J2B
C419 J1A
C420 C410 J1B
C418 C404 C411
C421 C437 C412
C422
C425
C492
C493
MS2825

Description
Figure 60-10-1
P-13849
P-85472
The loader has a 12 volt, negative ground, alternator

charging system.
The electrical system is protected by fuses located in the

operator cab (located under the operator cab in earlier
models) and a 100 ampere master fuse [Figure 60-10-1]
located under the air cleaner in the engine compartment.
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

Fuse And Relay Location / Identification
Earlier Models
Figure 60-10-2
P-85411
The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-2].
Figure 60-10-3
P-85412
Remove the covers to check or replace the fuses [Figure

60-10-3].
A decal is located inside the large cover to show location

and amperage ratings.
A table is provided with details on amperage ratings and

circuits affected by each fuse and relay. [Figure 60-10-7
on Page 11]

ELECTRICAL SYSTEM (CONT’D) Figure 60-10-6
Fuse And Relay Location / Identification (Cont’d)
Later Models
Figure 60-10-4
P100416
Remove the covers to check or replace the fuses [Figure

1
60-10-6].
P100414 A decal is located inside the access panel to show

location and amperage ratings.
The fuse / relay panels are located behind an access Line up the clips on the back of the access panel with the
panel near the left foot pedal / footrest. Pull the panel at slots provided and push the panel into place when
each end (Item 1) [Figure 60-10-4] to remove. finished [Figure 60-10-4]. A locating pin prevents the
panel from being installed upside down.
Figure 60-10-5
A table is provided with details on amperage ratings and
circuits affected by each fuse and relay. [Figure 60-10-7
on Page 11]
P100415
The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-5].

ELECTRICAL SYSTEM (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
Figure 60-10-7
1 13 17 21 25
5 7 9 11
2 18 22 26
14
3 15 19 27
23
6 8 10 12
4 16 20 24 28
The location and amperage ratings are shown in the table below and on the decal [Figure 60-10-7]. Relays are identified
by the letter “R” in the AMP column.
REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 Alternator 15 11 Glow Plugs R 21 Bobcat Controller 25
2 Heater / HVAC 25 12 Fuel Shutoff R 22 ACS Controller 25
3 Front Lights 20 13 Cab Switched 5 23 Attachments 25

Power
4 Rear Lights 15 14 Bucket Position 15 24 Not Used --
5 Starter R 15 Wiper / Washer 25 25 Auxiliary 25

Controller
6 Front Lights R 16 Switched Power & 25 26 Drive Controller & 25

Back-up Alarm Back-up Alarm
(Standard/ACS) (SJC)
7 Heater / HVAC R 17 Switched Power 25 27 Accessories & 25

Front Horn
8 Rear Lights R 18 Switched Power 25 28 Power Port 15
9 Switched Power R 19 Traction 30
10 Traction R 20 Fuel Shutoff 30

Solenoid Testing
Figure 60-10-8
P9175
Use a test meter to measure coil resistance [Figure 60-

10-8]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807
metal parts with the battery terminals.
Open the rear door. Connect the negative (-) cable last to prevent sparks.
Figure 60-20-1 Connect and tighten the battery cables.
Install and tighten the battery hold down.

3
2 WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
1 SERIOUS INJURY OR DEATH
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

P-85473
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
Disconnect the negative (-) cable (Item 1) [Figure 60-20- connecting or disconnecting cables to battery. Never
1]. lean over battery while boosting, testing or charging.
W-2066-0910
Remove the battery hold down clamp (Item 2) [Figure
60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.

BATTERY (CONT’D)
Servicing
Figure 60-20-3
P-09589 P-09590
The battery cables must be clean and tight [Figure 60-

20-3]. Check electrolyte level in the battery. Add distilled
water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
WARNING
Batteries contain acid which burns eyes and skin on

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONT’D) Keep cables away from moving parts. Start the engine.
Using A Booster Battery (Jump Starting) After the engine has started, remove the ground (-) cable
(Item 4) first. Remove the cable from the positive terminal
If it is necessary to use a booster battery to start the (Item 2) [Figure 60-20-4].
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.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
WARNING disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
BATTERY GAS CAN EXPLODE AND CAUSE both cables from the battery.)
SERIOUS INJURY OR DEATH • Extra battery cables (booster cables) are
Keep arcs, sparks, flames and lighted tobacco away connected wrong.
from batteries. When jumping from booster battery I-2023-1285

connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
Figure 60-20-4
2
4
3
P-85474
Connect the end of the first cable (Item 1) to the positive

(+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-4] to the
positive terminal on the loader starter.
Connect the end of the second cable (Item 3) 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.

ALTERNATOR Figure 60-30-3
Belt Adjustment
1
The alternator belt is a special maintenance free type that
is pretensioned over the pulleys. This belt eliminates the
need for a tensioning device and does not require
periodic adjustment. Contact your Bobcat dealer for
replacement parts.
Belt Replacement

2
Remove the air conditioning belt. (See REGULAR
MAINTENANCE on Page 80-20-1.) P-90474
Figure 60-30-1
Remove the top alternator mounting bolt (Item 1) and
loosen the bottom alternator mounting bolt (Item 2)
[Figure 60-30-3].
Move the alternator toward the engine as far as it will go

and remove the belt from the pulleys. Inspect the pulleys
for wear.
2
1 Install new belt.
Figure 60-30-4
P-90472
Remove the belt shield mounting nuts and bolts (Item 1)

and remove the belt shield (Item 2) [Figure 60-30-1].
Figure 60-30-2
1
1
P-90475
Use a prybar (Item 1) [Figure 60-30-4] to move the

alternator until the top alternator mounting bolt (Item 1)
[Figure 60-30-3] can be installed.
2 Tighten the top and bottom alternator mounting bolts

(Items 1 and 2) [Figure 60-30-3].
P-90521A
Install the air conditioning belt. (See REGULAR

Remove the cable bracket mounting nut and bolts (Item MAINTENANCE on Page 80-20-1.)
1) and move the cable bracket (Item 2) [Figure 60-30-2]
up slightly. Install the cable bracket and belt shield.

ALTERNATOR (CONT’D) Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) Replace belt if
Charging System Inspection worn or deteriorated.
Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
WARNING tight.
Check the fuse for the alternator in the fuse panel. If fuse
AVOID INJURY OR DEATH is burned, find the cause and repair / replace. If fuse is in
Batteries contain acid which burns eyes and skin on doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)
In case of eye contact get prompt medical attention Verify the charge of the battery. Make sure battery is fully
and wash eye with clean, cool water for at least 15 charged.
minutes.
Disconnect the battery cables (negative first, then
If electrolyte is taken internally drink large quantities positive). Inspect the cable clamps and battery posts for
of water or milk! DO NOT induce vomiting. Get corrosion. Remove acid or corrosion from the battery and
prompt medical attention. cables with a sodium bicarbonate and water solution. Put
W-2065-0807 grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery

connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
IMPORTANT
disconnected.
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
If the charging system malfunctions check the following:

ALTERNATOR (CONT'D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-6
Figure 60-30-5
P-85914
P-85916
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.) Figure 60-30-7
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test. 2
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test. 1
P-85915
Check the voltage across the “L” terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

ALTERNATOR (CONT'D)
High Voltage Testing
Figure 60-30-8
P-85917
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-6] off the alternator.
Check the continuity between the “S” terminal (Item 1)

[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair.

ALTERNATOR (CONT'D) Figure 60-30-10
Remove the air conditioning belt. (See Compressor Drive

Belt Replacement on Page 80-20-2.)
1
IMPORTANT 2

disconnected.
P-85718
both cables from the battery.)
• Extra battery cables (booster cables) are Remove the alternator rain shield mounting nut and bolts
connected wrong. (Item 1) and remove the alternator rain shield (Item 2)
I-2023-1285 [Figure 60-30-10].
Figure 60-30-9 Remove the belt shield mounting nuts and bolts (Item 1)
and remove the belt shield (Item 2) [Figure 60-30-11].
Figure 60-30-11
2
1
P-85914
Disconnect the negative (-) cable from the battery. P-85609
Disconnect the red wire (Item 1) [Figure 60-30-9] from

the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2)

[Figure 60-30-9] from the alternator.

ALTERNATOR (CONT'D) Parts Identification
Figure 60-30-12 1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
1 7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1
6
2 4 7 13 14
3 12
2
P-85611
10 11
5
Remove the top alternator mounting bolt (Item 1) and the 9
bottom alternator mounting bolt (Item 2) [Figure 60-30- 8
12].
Remove the belt and alternator from the loader. 19
18
17
16
15 C-3529B

STARTER Removal And Installation
Testing Figure 60-40-3
Figure 60-40-1 2
3
Bat
S
M
1
Cranking 3
Motor
P-85857
A-1992
Open the rear door.
The key switch must be in the OFF position.
Disconnect the negative (-) cable from the battery.
The battery must be at full charge.
Disconnect the wires and positive (+) cable (Item 1)
The cable connections on the battery must be clean and [Figure 60-40-3] from the starter solenoid.
tight.
Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -
Connect a jumper wire between S terminal and BAT 12.3 ft-lb) torque.
terminal [Figure 60-40-1].
Disconnect the wire connector (Item 2) [Figure 60-40-3]
If the starter turns but does not turn the engine, the from the two solenoid wires.
starter drive has a defect.
Remove the three mounting bolts (Item 3) [Figure 60-40-
Figure 60-40-2 3].
Remove the starter from the engine.

Bat
S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT'D)
1. Starter 30 13. Lever

2. Shaft 14. Gear
3. Gear 15. Bracket
4. Washer 16. Spring
5. Shaft 17. Gear
6. Stop Ring 34 18. Stop
33
7. Lever 19. Stop Ring
8. Holder 13 20. Ball
9. Spring 21. Armature
10. Spring 36 22. Washer
11. Plate 8 23. Seal
11
12. Seal 9
10
31
32 7
21
15
12 37
16
14
17 20
19 18
14
6
29
1 4
3
28
2
27
24. Yoke
35 25. Holder
26. Bracket
27. Ring
22 26
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
35. Boot
24
36. Bracket
37. Bearing
B-19824

INSTRUMENT PANELS
Left Panel
Figure 60-50-1
2 3 12
7
1
16
4 13
6 8 9 11
10 15
5 14
17 20
18 19
21 22
23
P-90726B
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left flasher 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 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right flasher signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED will
light.) Press a second time to add REAR work lights. (Left and right green
LEDs will light.) Press a third time to turn all lights off. (Left and right green
LEDs will be off.)
Press and hold five seconds to display software version in display screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED will
light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On startup)
• 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. (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™ when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold three seconds to access Drive Response and Steering
Drift Compensation adjustment menus. (See DRIVE RESPONSE and
STEERING DRIFT COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all loaders) Press the top to engage the Parking Brake. Press the bottom to disengage.
(See PARKING BRAKE in this manual.)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)

INSTRUMENT PANELS (CONT’D)
Display Screen
The display screen can display the following information:
• Operating hours.
• Engine revolutions per minute (rpm).
• Speed management setting.
• Maintenance clock countdown.
• Battery voltage.
• Service codes.
• Engine preheat countdown.
• Steering drift compensation setting.
• Drive response setting.
Figure 60-50-2
3 4 5 6 7
P-76461A
The display screen is shown in [Figure 60-50-2]. The

data display will show operating hours upon startup.
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine Revolutions Per Minute
6. Battery / Charging Voltage
7. Service

INSTRUMENT PANELS (CONT’D) The switch location (Item 2) [Figure 60-50-3] can have
different functions depending on machine configuration.
Right Panel (Standard Key Panel) See the following table for more information.
Figure 60-50-3
FUNCTION /
REF. DESCRIPTION
OPERATION
ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
Controls.
SELECTABLE Press the top to select

JOYSTICK ‘ISO’ Control Pattern;
CONTROLS (SJC) bottom to select ‘H’
(Option) Control Pattern.
FOUR-WAY Press the top to turn

FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING Press the top to turn

BEACON (Option) light ON; bottom to
P-85285 or turn OFF.
STROBE LIGHT
(Option)
This machine may be equipped with a Standard Key
Panel [Figure 60-50-3].
The Standard Key Panel has a key switch (Item 1)

[Figure 60-50-3] used to turn the loader’s electrical
system on and off, and to start and stop the engine.

INSTRUMENT PANELS (CONT’D) The switch location (Item 7) [Figure 60-50-4] can have
Right Panel (Keyless Start Panel) See the following table for more information.
Figure 60-50-4
FUNCTION /
REF. DESCRIPTION
OPERATION
1 Controls.

2 3 JOYSTICK ‘ISO’ Control Pattern;
5
6 FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING Press the top to turn

BEACON (Option) light ON; bottom to
P-90819B or turn OFF.
STROBE LIGHT
(Option)
1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
2. LOCK Key: Used to lock keypad. The lock key will

display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
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 loaders electrical system.
6. RUN Button: Used to turn on the loaders electrical

system.

INSTRUMENT PANELS (CONT’D) 5. START Button: Used to start the engine.
Right Panel (Deluxe Instrumentation Panel) 6. STOP Button: Used to stop the engine and shut
down the loader’s electrical system.
Figure 60-50-5
7. RUN Button: Used to turn on the loader’s electrical
system.
1
The switch location (Item 8) [Figure 60-50-5] can have
2 See the following table for more information.
3 FUNCTION /
REF. DESCRIPTION
OPERATION
Controls.
4
5
6
7 JOYSTICK ‘ISO’ Control Pattern;

FLASHER LIGHTS lights ON; bottom to
P-90212A
(Option) turn OFF.
This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].
1. Keypad (1 through 0): The keypad has two ROTATING Press the top to turn
functions: BEACON (Option) light ON; bottom to
or turn OFF.
- To enter a number code (password) to allow starting STROBE LIGHT
the engine. (Option)
- To enter a number as directed for further use of the

display screen.
2. Display Screen: The Display Screen is where all

system setup, monitoring and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen

choices.
4. ENTER Button: Used to make selections on the

display screen.

INSTRUMENT PANELS (CONT’D) Enter The Password:
Right Panel (Deluxe Instrumentation Panel) (Cont’d) Use the numbers on the keypad to enter the password.
Then Press the [ENTER] button a symbol will appear on
Figure 60-50-6 the display screen for each number entered [Figure 60-
50-6]. The left scroll button can be used to backspace if
an incorrect number is entered.
If the correct password is not entered, [INVALID

PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
See CONTROL PANEL SETUP for further description of

screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
NA3017
The first screen you will see on your new loader will be as
shown in [Figure 60-50-6].
When this screen is on the display you can enter the

password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. Keep your password in a safe
place for future needs.
Change Language:
Press the left or right scroll button to cycle through the

languages. The language that is stopped on will be the
default language used for the deluxe instrumentation
panel [Figure 60-50-6].
The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-180-1.)

INSTRUMENT PANELS (CONT’D) Right Switch Panel
Left Switch Panel Figure 60-50-8
Figure 60-50-7
P-85320
P-85319
This machine may be equipped with a Right Switch Panel
[Figure 60-50-8].
This machine may be equipped with a Left Switch Panel
[Figure 60-50-7].
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER Press and hold the up arrow to
NO.
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
(Option)
3 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
POSITIONING bottom to disengage.
(Option)

INSTRUMENT PANELS (CONT’D) Right Panel (Standard Key Panel) Removal And
Installation
Left Panel Removal And Installation
Figure 60-50-11
Figure 60-50-9
1 1
1 1 2
2
P-85929
P-85928
Remove the two mounting bolts (Item 1) and the fastener

Remove the two mounting bolts (Item 1) and the fastener (Item 2) [Figure 60-50-11].
(Item 2) [Figure 60-50-9].
Installation: Be careful to not overtighten the instrument
Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded
panel mounting bolts to prevent stripping of the threaded holes in the panels. Tighten the panel screws to 3 - 4
holes in the panels. Tighten the panel screws to 3 - 4 N•m (25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
NOTE: Inspect and replace the seal as needed (Item 3) [Figure 60-50-11].
3) [Figure 60-50-9].
Figure 60-50-12
Figure 60-50-10
1 P-85931
P-85930
Pull the right instrument panel down and disconnect the

Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-12].
wire harness connectors (Item 1) [Figure 60-50-10] from
the panel. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Right Panel (Deluxe Instrumentation Panel) Removal
And Installation
Right Panel (Keyless Start Panel) Removal And
Installation Figure 60-50-15
Figure 60-50-13
3
3
1
1 1
1
2
2 P-90527
P-90819A
(Item 2) [Figure 60-50-15].
(Item 2) [Figure 60-50-13]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 3 - 4
panel mounting bolts to prevent stripping of the threaded N•m (25 - 35 in-lb) torque.
holes in the panels. Tighten the panel screws to 3 - 4
N•m (25 - 35 in-lb) torque. NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-15].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-13]. Figure 60-50-16
Figure 60-50-14
P-90530
P-90818A
wire harness connector (Item 1) [Figure 60-50-16].
wire harness connector (Item 1) [Figure 60-50-14]. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Alarm Disassembly And Assembly
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-18
Disconnect the key switch wiring harness.
Figure 60-50-17
2
P-85947
Remove the left side instrument panel.

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-18] from
the loader alarm.
Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure Remove the alarm from the loader instrument panel.
60-50-17] from the switch.
Remove the ignition switch from the control panel.

INSTRUMENT PANELS (CONT'D) Right Switch Panel Removal And Installation
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) Removal And Installation on Page 60-50-9.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-9.) Figure 60-50-21
Figure 60-50-19
1 2
1
P-85943
1
P-85945
Remove the two fasteners (Item 1) and the knob (item 2)
[Figure 60-50-21].
Remove the two fasteners (Item 1) [Figure 60-50-19].
Figure 60-50-22
Figure 60-50-20
1 1
P-85944
P-85946
Remove the fastener (Item 1) and the left side panel

Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-22].
(Item 2) [Figure 60-50-20].

LIGHTS Figure 60-60-3
Front Removal And Installation 1
Disconnect the negative(-) cable from the battery. (See

Figure 60-60-1
1
P-85436
1
Figure 60-60-4
P-85433
Installation: Tighten the two bolts to 22 - 27 N•m (40 - 45

in-lb) torque.
Figure 60-60-2
P-85435
1 Remove the two bulbs (Item 1) [Figure 60-60-3] and

[Figure 60-60-4] from the housing by turning bulb a 1/4
1 turn.
NOTE: Two different light bulbs are used, take note

when removing to assure correct installation.
Reverse the above procedure to install the bulb.
P-85434
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness connectors.

LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-7
Figure 60-60-5
1 2
P-85274
P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light to far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.
P-85437 P-85783
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Reverse this procedure for installation.

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)
Description
The Gateway controller is the main controller, it provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
On Early Model Machines
The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.
On Later Model Machines
The Gateway and Auxiliary controller are located under

the cab on the left inner frame.

AUXILIARY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL
12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL

Auxiliary Controller
1 1
34 26
J2A J2B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLERS (GATEWAY AND Figure 60-70-2

1 1
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
1 1
1.)
Raise the operator cab. (See OPERATOR CAB on Page

10-30-1.)
Remove the left inside access panel. (See ACCESS

P-85901
PANEL (INSIDE) on Page 50-120-1.)
Figure 60-70-1 Remove the controller mounting bolts (Item 1) [Figure

60-70-2] from the left fender.
3 4
Installation: Tighten the controller mounting bolts to 16 -
2
Remove the Gateway and Auxiliary controllers from the
loader.
Figure 60-70-3
1
5
5
2
P-85900
On earlier machines the Gateway controller (Item 3) and

Auxiliary controller (Item 4) [Figure 60-70-1] are located 1
behind the left foot panel.
3 5
Unplug the two harness connectors (Item 1) [Figure 60- 4
70-1] from the Gateway controller. P103379
Unplug the two harness connectors (Item 2) [Figure 60- On later machines the Gateway controller (Item 3) and
70-1] from the Auxiliary controller. Auxiliary controller (Item 4) [Figure 60-70-3] are located
under the cab on the left inner frame.
NOTE: The connectors are keyed and will only plug
in one way. Unplug the two harness connectors (Item 1) [Figure 60-
70-3] from the Gateway controller. Unplug the two
harness connectors (Item 2) [Figure 60-70-3] from the
Auxiliary controller.
Remove the controller mounting bolts (Item 5) [Figure
60-70-3] from the left fender.
Remove the Gateway (Item 3) and Auxiliary (Item 4)
[Figure 60-70-3] controller from the loader.
Tighten the controller mounting bolts to 16 - 19 N•m (12 -
14 ft lb) torque.

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.

BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONT’D) NOTE: The calibration procedure must be followed
when replacing a controller. (See Lift And Tilt
Removal And Installation Calibration (ACS) on Page 60-160-11.)

1.)
Figure 60-71-1
P-85903
Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.
NOTE: The connectors are keyed and will only plug

in one way.
Figure 60-71-2
P-85902

from the controller.
Remove the controller from the loader.

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 as those used on
drive functions. the ACS 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 operator’s 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 main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
RIGHT
HAND DRIVE HYDRAULIC
PANEL CONTROL MOTOR
ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS
GEAR ENGINE
INTERNAL CAN BUS
PUMP
SERIAL TT BUS
RIGHT
JOYSTICK
FWD / REV
ISO SWASH PLATE
SWITCH LEFT
JOYSTICK SENSORS
AUXILIARY DRIVE
CONTROL PUMP
LEFT SPEED
HAND SENSOR
PANEL
ACD HYDRAULIC
EXTERNAL CONTROL MOTOR
CAN BUS
GATEWAY
CONTROL
NA1208

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
P-64295

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4
Remove the three bolts (Item 1) [Figure 60-72-1] that

secure the controller.

Figure 60-72-2
J S
P-64325
Remove the drive controller [Figure 60-72-4].

1
P-64324
Remove the screw and wire harness (Item 1) [Figure 60-

72-2].
Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

SPEED SENSORS (SJC) Figure 60-80-2
Description
The speed sensors are used to monitor travel speed. The

speed sensor communicates to the system by sending a
pulse of electricity to the SJC controller.
Testing
Figure 60-80-1 1
2
P-85924
Locate the electrical connector (Item 1) [Figure 60-80-2]

for the left rpm speed sensor.
Disconnect the rpm speed sensor wire connector (Item

1), from the loader harness wire connector (Item 2)
[Figure 60-80-2].
P-28302 Connect the rpm speed sensor test harness (Item 1)

[Figure 60-80-1] in line, between the loader wiring
harness and the speed sensor harness.
procedure: Turn the remote start key to ON position without starting
the loader.
MEL1609 - RPM Speed Sensor Test Harness [Figure 60-
80-1] Take a voltage reading, with the multimeter, at the speed
MEL1563 - Remote Start Tool Kit sensor test harness, between pin 1 and pin 3 [Figure 60-
80-1].
Multimeter
The voltage should be 5 volts.
device. (See Installing on Page 10-20-1.) Repeat the procedure for the opposite side speed sensor.
(If needed.)

REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.)
or (See REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-5

1
Remove the loader track. (See Track Removal And

Installation on Page 40-20-4.) 1
Figure 60-80-3
2 P-48741
Remove the access cover mount bolts (Item 1) [Figure

60-80-5].
1
Remove the speed sensor access cover from the loader.
Figure 60-80-6
P-85927
Remove the four access cover mount bolts (Item 1)

[Figure 60-80-3]. 1
Remove the access cover (Item 2) [Figure 60-80-3] from 2

the loader.
Figure 60-80-4
1
P-48742
Clean the area around the speed sensor, to prevent

1 contamination from getting into the hydrostatic motor
after the speed sensor is removed.
Remove the two speed sensor mount bolts (Item 1)

[Figure 60-80-6].
Installation: Lubricate the speed sensor O-ring with oil

before installing. Seat the sensor into the motor port prior
to installing the bolts. Tighten down the bolts, alternate
P-48740 tightening from left to right to evenly load the o-ring.
Tighten the speed sensor mount bolts to 9,94 N•m (88 in-
lb) torque.
At the back side of the hydrostatic motor mount (Item 1)
[Figure 60-80-4], locate the speed sensor access cover. Remove the speed sensor (Item 2) [Figure 60-80-6] from
the motor.

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-9
Figure 60-80-7 1
2 P-26294
With a thin screwdriver lift the tabs and remove the wires
P-85924 from the connector (Item 1) [Figure 60-80-9].
Wire Code
Remove the zip tie (Item 1) [Figure 60-80-7] from the
wiring harness. 1 Red
2 White
Disconnect the speed sensor harness (Item 2) [Figure 3 Black
60-80-7] from the loader harness. 4 Blue
Remove the speed sensor from the loader.
Figure 60-80-8
P-26293
The electrical connector can be replaced.
Remove the connector wedge (Item 1) [Figure 60-80-8].

DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions which can damage your machine.
The last 40 codes stored in history can also be viewed
Figure 60-90-1 using the Deluxe Instrumentation Panel.
Figure 60-90-2
Press a scroll button
2 (Item 1) repeatedly until
the Active Warnings
screen icon (Inset) is
highlighted.
1 1
The ACTIVE WARNINGS
screen displays active
1 service codes. Press [9]
P-76455G
to view the next service
code if more than one is
present. Press [4] to
Press the INFORMATION button (Item 1) to cycle the display a history of
DATA DISPLAY (Item 2) [Figure 60-90-1] until the service codes.
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the The WARNINGS
DATA DISPLAY. HISTORY screen will list
the Service Code
NOTE: Corroded or loose grounds can cause Number (CODE),
Hourmeter reading when
multiple service codes and / or abnormal the error occurred
symptoms. All instrument panel lights (HOUR), and the User
flashing, alarm sounding, headlights and (USER) who was logged
taillights flashing, could indicate a bad in to operate the machine
ground. The same symptoms could apply if when the error occurred.
the voltage is low, such as loose or corroded Press [9] to view the next eight Service Codes.
battery cables. If you observe these
symptoms, check grounds and positive leads A total of 40 Codes can be stored. When more than 40
first. codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.
Press the list number

next to the service code
for more detail.
Press left scroll button to

back up one screen.
P-90378 / NA3025 / NA3000 / NA3038 / NA3035

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-3 The following word errors may be displayed:
2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.
Service Codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-90-3]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed A8503 ACD output ‘F’ error OFF
A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003 ACD output ‘A’ error OFF A8506 ACD output ‘F’ short to ground
A8005 ACD output ‘A’ short to battery A8507 ACD output ‘F’ open circuit
A8006 ACD output ‘A’ short to ground A8532 ACD output ‘F’ overcurrent
A8007 ACD output ‘A’ open circuit A8602 ACD output ‘G’ error ON
A8032 ACD output ‘A’ overcurrent A8603 ACD output ‘G’ error OFF
A8102 ACD output ‘B’ error ON A8605 ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high

Service Codes List (Cont’d)

D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF
D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541 Right swash plate sensor out of range high D7592 Right swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7593 Right speed sensor unresponsive
D7543 Left forward drive solenoid error ON D7594 Left speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545 Right forward drive solenoid error ON D7596 Right speed sensor reversed
D7546 Right reverse drive solenoid error ON D7597 Controller programmed
D7547 Right front steer extend short to battery D7598 In drive calibration mode
D7548 Left front steer extend short to battery D7599 In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent


H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic / Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic / Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low
H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure


M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807 Lift spool lock open circuit M4803 Front light relay error OFF
M1832 Lift spool lock overcurrent M4807 Front light relay open circuit
M2005 Two-speed primary short to battery M4902 Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit M4907 Rear light relay open circuit
M2032 Two-speed primary overcurrent M5002 Front light output error ON
M2102 Glow plug output error ON M5003 Front light output error OFF
M2103 Glow plug output error OFF M5007 Front light output open circuit
M2107 Glow plug output open circuit M5028 Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202 Starter output error ON M5103 Rear light output error OFF
M2203 Starter output error OFF M5107 Rear light output open circuit
M2207 Starter output open circuit M5128 Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF


M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224 ACS calibration failed W3264 Pedal lock short to battery
W3231 Tilt actuator fault W3265 Sensor supply voltage out of range
W3232 Tilt actuator wiring fault W3266 Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle / pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error
W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236 Lift actuator fault W3271 Right hand drive short to battery
W3237 Lift actuator wiring fault W3274 Left joystick X-axis out of range
W3238 Lift handle wiring fault W3275 Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240 Lift handle / pedal not in neutral W3277 Remote control information error
W3241 No communication W3905 Left joystick X-axis not in neutral
W3249 Lift actuator short to ground W4005 Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Figure 60-100-1
1 2 3
4
3
P-85413C
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system
consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-100-1] of the loader cab.
The Press To Operate button (Items 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS™ (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
Figure 60-100-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 PRESS TO OPERATE LOADER button.
2 3
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
4 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5
brake is disengaged.
6 Inspecting The Lift Arm Bypass Control

P-85413C
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob clockwise 1/
1. Sit in operator’s seat. Turn key to RUN or press RUN
4 turn. Pull up and hold lift arm bypass control knob
button. Lower seat bar and disengage parking brake.
until lift arms slowly lower.
Press the PRESS TO OPERATE LOADER button
(Item 6). Two BICS™ lights (Items 1 and 2) [Figure
Inspecting Deactivation Of Lift And Tilt Functions
60-100-2] [SEAT BAR AND LIFT & TILT VALVE] on
(ACS And SJC)
left instrument panel must be OFF. The PRESS TO
OPERATE LOADER button will light.
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
2. Raise seat bar fully. All three BICS™ lights (Items 1,
LOADER button.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE and PARKING BRAKE] on left instrument
10. Raise lift arms about 2 m (6 ft) off the ground.
panel must be ON. The PRESS TO OPERATE
LOADER button light will turn OFF.
11. Turn key OFF or press STOP button and wait for the
engine to come to a complete stop.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
3. Sit in operator’s seat, lower seat bar and press the
(foot pedal, hand control or joystick) to lower the lift
PRESS TO OPERATE LOADER button (Item 6).
arms. Lift arms must not lower.
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
13. Move the control (foot pedal, hand control or joystick)
60-100-2]. Raise the seat bar. The light must be OFF.
to tilt the bucket (or attachment) forward. The bucket
(or attachment) must not tilt forward.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt. WARNING
5. Start engine and operate at low idle. Press the
PRESS TO OPERATE LOADER button. While raising AVOID INJURY OR DEATH
the lift arms, raise the seat bar fully. The lift arms must The Bobcat Interlock Control System (BICS™) must
stop. Repeat using the tilt function. deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:
Connect the seat bar sensor adapter leads (MEL1567) to

the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operators seat.
Figure 60-110-5
1 2
P100745
Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-110-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-110-7].
2
P100742
Remove the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5]. Disconnect the sensor wiring
Figure 60-110-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-110-6].
NOTE: Approximately 4 turns of the clevis bolt

should be adequate to release the spring
tension. When tension is released, the clevis
pin can easily be rotated using the retaining
pin.


3
Figure 60-110-8
2
1
4
P100748
Install the new keyed bushing (Item 1), magnet bushing

P100746
(Item 2) and seat bar sensor (Item 3) [Figure 60-110-10].
Reinstall the metal pivot bushing (Item 4) [Figure 60-
110-10].
Pull the front of the seat bar down slightly from the top of
the cab, while raising the sensor end of the seat bar up, NOTE: The sensor must be centered on the metal
away from the mount [Figure 60-110-8]. pivot bushing. When centered, the assembly
will slide freely into the mount.
NOTE: The sensor end of the seat bar will raise easily
ONLY if the front of the seat bar is pulled Figure 60-110-11
slightly down from the top of the cab.
Figure 60-110-9
5
3
4 1
6 1 2
P100749
2 Position the clevis (Item 1) over the mount (Item 2) and

P100747
lower the end of the seat bar until the mounting bolt (Item
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9] 3) [Figure 60-110-11] is resting on the top of the mount.
on the cab side screen to hold the seat bar above the
mount. Remove the nut from the mounting bolt. Remove the
mounting bolt and lower the seat bar until the seat bar
Remove the clevis pin bushing (Item 2) [Figure 60-110- and mount holes align and the clevis is over the clevis pin
9]. Apply grease to the shoulder of the bushing to help bushing. Reinstall the seat bar mounting bolt. Apply
retain it during assembly. Reinstall the clevis pin bushing. Loctite® 243 to the nut threads. Install the nut and tighten
Remove and dispose of the keyed bushing (Item 3), to 46 N•m (34 ft-lb) torque.
magnet bushing (Item 4), and seat bar sensor (Item 5)
[Figure 60-110-9].
Remove and save the metal pivot bushing (Item 6)
[Figure 60-110-9].

SEAT BAR SENSOR (CONT'D)
Figure 60-110-12
1
2
P100751 3
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-110-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5] and tighten to 6,8 N•m (60 in-lb)
torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.

Bobcat Interlock Control System (BICS™) Circuit

Test
Figure 60-110-13
3
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-14] on the sensor tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-110-13].
NOTE: The sensor test light (Item 3) [Figure 60-110-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)
Figure 60-110-15
P-85413
The BICS™ seat bar indicator light (Item 1) [Figure 60-

110-15] should turn OFF.
Figure 60-110-16
P-4699
Move the toggle switch (Item 1) [Figure 60-110-16] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-15] should

illuminate.
If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.

TRACTION LOCK
Description
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS™).

TRACTION LOCK (CONT'D)
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, 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 ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Check the brake solenoid mounting nut for correct torque.
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 the flywheel rpm sensor and wiring.

TRACTION LOCK (CONT'D) Figure 60-120-2
Inspecting
Figure 60-120-1
P-85923
1
Check the wire connections at the engine speed sensor
P-85413 (Item 1) [Figure 60-120-2].
Check the adjustment of the flywheel speed sensor and

Fasten the seat belt, disengage the parking brake button, replace the speed sensor if needed. (See Adjustment on
press the PRESS TO OPERATE LOADER Button (Item Page 60-170-2.)
1) and raise the Seat Bar fully. Move the steering levers
slowly forward and backward. The TRACTION lock (Item NOTE: When the Traction Lock Override Button is
4) should be engaged. Lower the Seat Bar. Press the activated, the Traction Lock Override Control
PRESS TO OPERATE LOADER Button (Item 1) [Figure System will NOT engage the Traction Lock if
60-120-1]. the engine stops.
Engage the parking brake pedal and move the steering

levers slowly forward and backward. The TRACTION lock
should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

CONTROL SYSTEM (ACS)
Description
The ACS option allows the operator to quickly switch

between foot and hand control modes. It uses the electric
actuators to control the lift and tilt spools, foot sensors,
handle sensors and a specially designed control handle.

CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
1
3
2
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be
removed from the handle sensor wires, use the following 1-Terminal - Red
procedure. 2-Terminal - Black
3-Terminal - Green
Figure 60-130-2
1 1
1 1
P13725
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

Switch Handle Removal
Figure 60-130-4
3 1
2
P13735
2 1
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.

130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
P13725 P13732

harness connector (Black) that connects to the handle
1 lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

Switch Handle Removal (Cont'd)
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 152,4 mm (6 in) piece of
heat shrink tube side on the end of the wires. Remove
Cut the wires (Item 2) [Figure 60-130-12] below the the heat shrink tube from the end of the wires before
switch handle and remove switch handle. routing through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the 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 up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Pull harness (Item 1) [Figure 60-130-13] out the bottom

of the control lever tube.

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
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
1 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
P-21700 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 B-Terminal - Dk. Blue
casting, along side the handle sensor and into the control C-Terminal - White
lever tube. D-Terminal - Purple
E-Terminal - Yellow/Red
NOTE: Do not pull the wire harness tight, allow a F-Terminal - Tan
small amount of slack or slight bend at the G-Terminal - Pink
handle pivot area. Verify the control handle 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
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
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

152,4 mm (6 in) of heat shrink tube (Item 1) [Figure 60-
130-16] approximately 76,2 mm (3 in) into the control
lever. Apply heat to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
1 P13735
Install the wires into the connectors as listed below:

P-90995
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
Figure 60-130-20
1
1
1
3
P-90994 2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
P13735
connectors.
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

Switch Handle Installation (Cont'd)
Figure 60-130-21
N-17741
Installation: Install the wires into the connector as listed

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)
3. Terminal-Red/Green-Larger diameter wire (16
NOTE: Actuator shown removed for clarity. Not gauge)
necessary for procedure. 4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
Figure 60-130-22 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.

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
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
130-24] from the handle lock solenoid connector. Figure 60-130-27
Figure 60-130-25
P-21789
1
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for
damage. Replace as necessary.
Remove the two screws (Item 1) [Figure 60-130-25]
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38

in-lb) torque.
Remove handle lock solenoid assembly from handle.

Foot Sensor Removal And Installation
Figure 60-130-28
2‘
1
1
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].

Remove the hairpin clip and the pin (Item 1) [Figure 60-
130-28] from the foot sensor.
Figure 60-130-29
P-90982
Disconnect the wire harness (Item 1) [Figure 60-130-29]

from the foot sensor.

CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Lock Solenoid Removal And Installation
Foot Sensor Disassembly And Assembly Figure 60-130-33
Figure 60-130-31
1 1
P-90992
1
P-24269
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Tighten the bolts to 10,2 N•m (90 in-lb) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite® #242 to the threads. and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-32
Figure 60-130-34
5
4
3 1
2
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130- Check the O-ring (Item 1) [Figure 60-130-34] for
32]. damage. Replace as necessary.
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-32]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA1014A / B-15781E
REF. NO. DESCRIPTION

1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 ENGINE SPEED CONTROL
6 STEERING LEVERS
7 LIFT ARM PEDAL
8 TILT PEDAL
9 LIFT ARM BYPASS CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3

for more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
12, 13,
B-16447 14 B-16448
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
12, 13,
B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA1164A / B-15781E

4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9 TILT PEDAL
13 NOT USED

ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front
11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA1165A / B-19874A

1 SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 ENGINE SPEED CONTROL (HAND)
9 JOYSTICKS
10 FOOTRESTS
11 ENGINE SPEED CONTROL (FOOT)
14 NOT USED
16 NOT USED
18 FLOAT CONTROL

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-150-1
1 2
2
3
1
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start
Tool (Service Tool) Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
NOTE: Make all connections with the key in the OFF 7003030 - Remote Start Tool (Service Tool)
position. 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item 6689745 - BOSS® Service Tool Harness
2) [Figure 60-150-1]. When connected to the loader, the NOTE: Make all connections with the key in the OFF
Service PC is used to monitor, conduct diagnostics, and position.
upgrade software.
The Service PC (Item 1) with the Remote Start Tool
Connect the Service Tool Harness Communicator (Service Tool) (Item 2) [Figure 60-150-2]. When
(MEL1566) (Item 3) [Figure 60-150-1] to the designated connected to the loader, the Service PC is used to
serial port on the Service PC. monitor, conduct diagnostics, and upgrade software.
NOTE: The recommended serial cable length should Connect the Remote Start Tool (Service Tool) Computer
not exceed 4,6 m (15 ft). A serial cable longer Service Tool Harness (Item 3) [Figure 60-150-2] to the
than 4,6 m (15 ft) will create a degraded signal designated serial port on the Service PC.
causing communication errors.
NOTE: The recommended serial cable length should
Connect the other end to the connector on the Remote not exceed 4,6 m (15 ft). A serial cable longer
Start Tool. than 4,6 m (15 ft) will create a degraded signal
causing communication errors.
REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.) Connect the other end to the connector on the Remote
Start Tool (Service Tool).
NOTE: Refer to BobcatNET for PC requirements and
the latest Service Analyzer software. Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and

the latest Service Analyzer software.

CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting
controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
If a Service PC is not available, (See Lift And Tilt
The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-11.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path cannot be attained or replacing the 22°C (72°F), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a

Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
If the Actuator Test failed due to a slow return to neutral
• Actuator did not fully extend / retract. During the test, after checking the probable causes in Column 1 [Figure
the spool was not able to fully stroke in both 60-160-2], check the following probable causes in
directions. Column 2 [Figure 60-160-2].
• Actuator out of neutral. The spool did not return to the • Contamination in the spool.
neutral window during the test.
• The spool end cap may be defective or the centering
NOTE: A time out will occur if the test cannot be spring may be broken. Inspect the end cap and the
completed within 8 seconds. If this happens, centering spring, replace if necessary.
retry the test.
• The wire harness or connectors may have an
Figure 60-160-2 intermittent short. Check the connections and wire
Run Actuator Test harnesses.
• The controller may be defective, replace the

Pass Fail controller.
Retest With Warm Hydraulic Oil
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.
• The actuator may be defective, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.

CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
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-85958 P-85958
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s). Move the right joystick to the forward-right corner position
[Figure 60-160-4] and hold in position.
Figure 60-160-3
SJC
P-85307
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
P-85413C
P-85493A
At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the ignition key ON [Figure (Item 1) [Figure 60-160-7] while holding the right joystick
60-160-5]. in position.
NOTE: Do not start the engine. Release the joystick.
Figure 60-160-6 NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
SJC complete, code W3224 (Calibration
Performed) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-85307
The loader Control Pattern Switch (Item 1) [Figure 60-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.

CALIBRATION (CONT'D) Figure 60-160-9
Hydrostatic Pump Calibration (SJC)
WARNING
W-2017-0286 P-85493A

With the seat bar down, turn the ignition key ON [Figure
10-10-1.)
60-160-9].
Operator must be in the seat and the seat bar down.
NOTE: Do not start the engine.
Figure 60-160-8
Figure 60-160-10
SJC
SJC
1
1
P-85307
P-85307
Close the cab door. (If loader is so equipped.)

The Control Pattern ISO Switch (Item 1) [Figure 60-160-
10] will start flashing.
Place the loader Control Pattern Switch (Item 1) [Figure
60-160-8] in the ISO position.
Verify the parking brake.

Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-11
B-19873
P-85960
B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-160-13] and hold in position.
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
P-85413C
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-12] while holding the left joystick in
position.
Three audible beeps will sound.

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC
Figure 60-160-15
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-85961 17] 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 60-160-18
60-160-15].
Figure 60-160-16
P-85760A
1
P-85413C Move the throttle (Item 1) [Figure 60-160-18] 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 60-160-16]. the seat bar, or return the joystick to the
neutral position.
Three audible beeps will sound.
The calibration procedure will stop.
Start the engine from the RUN, RUN / ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel To return to calibration mode, the operator
the calibration mode and the procedure would have to be must start the complete procedure from the
repeated. beginning.

Hydrostatic Pump Calibration (SJC) (Cont'd)
1 2
WARNING
W-2017-0286
Figure 60-160-19 P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-20] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-20] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the forward position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
B-19873 Forward calibration is complete.

P-85962
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 60-160-19] until the forward calibration is operator must shut the loader OFF, and start
completed. the calibration procedure from the beginning.

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-21 the calibration procedure from the beginning.
There will be an audible beep, the 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 D7598 error code will clear. There should
be no other codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.
B-19873 Press the PRESS TO OPERATE LOADER button. Move

P-85963 the left joystick to forward position [Figure 60-160-19]
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 60-160-21] until the reverse calibration is 160-21] and check for normal reverse wheel or track
completed. rotation.
Figure 60-160-22 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
1 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot 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 30-10-2.)
or (See Troubleshooting on Page 60-10-8.)
P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-22] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-22] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
P-85493A
NOTE: This calibration procedure must be followed

when replacing a hydraulic control valve, Close the cab door. (If loader is equipped.)
actuator or ACS controller. Failure to calibrate
after component replacement may result in With the seat bar down, turn the ignition key ON (Deluxe
poor performance or reduced life of Instrumentation Panel press RUN / ENTER) (Item 1)
actuator(s). [Figure 60-160-24].
Figure 60-160-23 NOTE: Do not start the engine.
ACS
Figure 60-160-25
P-85307B 1
Update the loader service software to the latest version. P-85413C
Place the rocker switch (Item 1) [Figure 60-160-23] in

Push the PRESS TO OPERATE button (Item 1) [Figure
the hand control mode.
60-160-25] to unlock the hand controls.

Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-26
Stroke Both Handles Fully In and Hold Them
P-85413C
Push the PRESS TO OPERATE button (Item 1) [Figure

B-16628 60-160-27] 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 60-160-26]. 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 60-160-27] to go OFF.
NOTE: During the calibration cycle, the system will
Lower the seat bar. beep three times. Once the calibration is
complete, code W3224 (Calibration
Performed) will be generated.
Release the control handles.
Calibration is complete.

STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to activate the BICS™.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
• Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
6. Current drive response setting will be displayed briefly
• Driving on uneven terrain such as crowned road in the data display.
surfaces.
NOTE: Raising the seat bar or changing control
Figure 60-161-1 mode (ISO / H) will cause the machine to
disengage from steering drift compensation.
STEERING DRIFT COMPENSATION The last displayed setting will remain in effect
until the machine is turned OFF.
B-23580D
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-161-2 to appear in the data display (Item 2) [Figure 60-161-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-161-3
2
1
NA1011
3 4 5
P-76461L 2
P-76461N
P-76461M
1
NA1011
Left Joystick Right Joystick
3 4
P-76461K
P-76461O
6 7
P-24820C P-24802C Saving The Steering Drift Compensation Setting:
The current steering drift compensation setting can be

Press and hold the PRESS TO OPERATE LOADER
saved by pressing and holding the PRESS TO
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 machine is turned OFF. The machine
will revert back to the last saved setting the
next time it is started.

FLYWHEEL RPM SENSOR
Description
The flywheel rpm sensor has a magnet located on the

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
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.

FLYWHEEL RPM SENSOR (CONT’D) NOTE: New rpm sensors have a plastic tip which is
used as a gauge during installation. The
Adjustment plastic tip is designed to come off after the
engine is started.
Figure 60-170-1
1
2
P-85922
When reinstalling 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.
Figure 60-170-2
P-85921
Turn the rpm sensor and the jam nut out from the
flywheel. Set a clearance of 1,27 mm (0.050 in) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Remove the feeler gauge.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 16 - 23


CONTROL PANEL SETUP Example
Right Panel Setup (Deluxe Instrumentation Panel) Languages
Icon Identification Figure 60-180-2
Figure 60-180-1 Press a scroll button

(Item 1) repeatedly until
the Display screen icon
(Inset) is highlighted.
1 1
Select [2. LANGUAGES].
NA3025 Select the desired

language.
ICON DESCRIPTION
DATE / TIME
USER / HOURMETER
P-90385 / NA3025 / NA3012 / NA3023
CURRENT JOB HOURS
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
LEFT SCROLL button
RIGHT SCROLL button
ENTER button

CONTROL PANEL SETUP (CONT’D) The Deluxe Instrumentation Panel is easy to use.
Continue to set your own preferences for running /
Right Panel Setup (Deluxe Instrumentation Panel) monitoring your Bobcat loader.
(Cont’d)
More Examples
Clocks
Select …
DISPLAY screen icon
[1. CLOCKS]
SET TIME AND DATE

Select [1. TIME]
Use the keypad to enter date.
Press ENTER to continue.
Use the keypad to enter time.
Select AM / PM / 24hr.
RESET JOB CLOCK

(Owner password required if Job Clock is locked.)
Select [2. JOB CLOCK]
Press [4] to cycle between lock and unlock.
Press [9] to reset.
SET ALARM
Select [3. ALARM CLOCK]
Select alarm 1, 2 or 3.
Press [1] to cycle between ON and OFF.
Press [2] and use the keypad to enter alarm time.
Select AM / PM / 24hr.
Press [3] to cycle between ONCE, DAILY and
WEEKLY.
Selecting WEEKLY will prompt for a day selection
using number [4].
Vitals (Monitor the engine, hydraulic / hydrostatic,

electrical functions when engine is running.)
Select …
VITALS screen icon
Press [6] to cycle between METRIC or ENGLISH (M /
E) readouts.
You can monitor real-time readouts of:

Engine Speed
Engine Oil Pressure
Engine Coolant Temperature
System Voltage
Hydraulic Charge Pressure
Hydraulic Oil Temperature

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-190-1
Password Setup is available on machines with a Deluxe
Press a scroll button (Item
Instrumentation Panel. 1) repeatedly until the
Security screen icon
Password Description (Inset) is highlighted.
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
1 1
mode. This means that a password must be used to start
the engine. Enter owner password and
press [ENTER].
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:
Select [1. USER
A permanent, randomly selected password set at the SETTINGS].
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
password.
Owner Password:
Select [1. OWNER].
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
password as soon as possible for security of the
loader.
Select [2. CHANGE
User Password: PASSWORD].
Allows starting and operating the loader; cannot

change password or any of the other setup features.
For the procedures to change passwords (See Changing

The Owner Password on Page 60-190-1.) and (See
Enter new owner password
Changing The User Passwords on Page 60-190-2.) and press [ENTER].
You will be prompted to

reenter the new owner
password.
Press [ENTER].
P-90399/NA3025/NA3016/NA3031/NA3033/NA3028/NA3015/NA3027

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
Figure 60-190-2 every time the engine is started.
Press a scroll button (Item
1) repeatedly until the Figure 60-190-3
Security screen icon
(Inset) is highlighted. Press a scroll button
(Item 1) repeatedly until
the Security screen icon
(Inset) is highlighted.
1 1
Enter owner password and
press [ENTER].
1 1
Enter owner password
and press [ENTER].
Select [1. USER

SETTINGS].
Select [2. MACHINE

LOCK].
Select user.
P-90399 / NA3025 / NA3016 / NA3031
NOTE: The procedure above can be followed to reset

Select [2. CHANGE the machine lock so that the machine requires
PASSWORD]. a password to start the engine.
Enter new user password

and press [ENTER].
Press [ENTER].
P-90399/NA3025/NA3016/NA3031/NA3033/NA3026/NA3010/NA3027

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 loaders electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-191-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
Press the RUN button to turn on the loaders electrical

system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.
1 2
Figure 60-191-1
P-90805
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-90805 NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds. Press the RUN button to turn on the loaders electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.

MAINTENANCE CLOCK This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
Description maintenance clock is reset.
The Maintenance Clock alerts the operator when the next Figure 60-200-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-200-1
1
1
3 NA3040
P-76461R
The Deluxe Instrumentation Panel, if equipped, will
display a bar (Item 1) [Figure 60-200-3] showing time
During machine operation, a two beep alarm will sound remaining until next service. This bar will turn red when
when there are less than 10 hours until the next planned service is past due. NEXT MAINTENANCE DUE will
maintenance. change to MAINTENANCE PAST DUE and display the
number of hours past due.
The remaining hours before maintenance is required will
appear in the data display (Item 1) for five seconds while Keys [4] and [9] can be used to adjust the service
the service icon (Item 3) and hourmeter icon (Item 2) interval when the owner is logged in [Figure 60-200-3].
[Figure 60-200-1] flash.
NOTE: Loaders equipped with a Standard Key Panel
NOTE: The display will show negative numbers after or Keyless Start Panel will not display the
counting down to zero. BobCARE PMSM message or NEXT
MAINTENANCE TYPE on the right panel.
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
NA3034
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.
Figure 60-200-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.

Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
200-11] to reset and set the maintenance clock.

Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
P-76455H
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.
Press and hold the information button (Item 2) for seven

seconds until [RESET] (Inset) appears in the display
screen (Item 1) [Figure 60-200-16].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.

BACK-UP ALARM SYSTEM Figure 60-210-2
Description
The back-up alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound. 1
Inspecting
Figure 60-210-1
2
P100042A
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 1)
[Figure 60-210-3] for tightness and damage. Repair or
1 replace any damaged components.
If the back-up alarm switches require adjustment, (See

P-85994 Adjusting Switch Position on Page 60-210-2.)
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.

BACK-UP ALARM SYSTEM (CONT’D) Figure 60-210-4
Adjusting Switch Position

1
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. 2
Standard Controls And ACS (If Equipped) 3
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Place the steering levers in the neutral position.

P-85723A
Figure 60-210-3
Loosen the screws (Item 3) [Figure 60-210-4] securing

1
the back-up alarm switch. (Left side shown)
Position the back-up alarm switch so that the roller (Item

1) just makes contact with the bellcrank (Item 2) [Figure
60-210-4] without compressing the switch spring.
Torque the screws (Item 3) [Figure 60-210-4] securing

the switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Repeat adjustment procedure for the other switch.

P-85722 3.)
Inspect back-up alarm system for proper function. (See

The back-up alarm switches (Item 1) [Figure 60-210-3] Inspecting on Page 60-210-1.)
are located alongside the steering bellcranks. Both
switches must be adjusted properly for the back-up alarm
to operate correctly.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The back-up alarm or switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches.
Standard Controls and ACS (If Equipped)
Figure 60-210-5
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
2 Figure 60-210-6
P-85280
1
Disconnect the alarm connector (Item 1) [Figure 60-210-

5] from the alarm.
P-85723A
Remove the two nuts (Item 2) [Figure 60-210-5].
Remove the alarm and bracket from the loader. Place the steering levers in the neutral position.
Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch (Item 2) [Figure 60-210-6] off
the mounting bracket.
Mark the wires for ease of assembly and disconnect

them from the switch.
Installation: Slide the alarm switches onto the mounting

bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjust the switches (See
Adjusting Switch Position on Page 60-210-2.) and inspect
back-up alarm operation (See Inspecting on Page 60-
210-1.) are required.

FRONT HORN Figure 60-220-3
NOTE: Two different style horns are used.
Remove the left side lower panel. (See Removal And

Figure 60-220-1
1
1
1
P-90886
1
Remove the two bolts and nuts (Item 1) [Figure 60-220-

2 3].
2
3
Remove the front horn from the bracket.
P-90885 P-90901
Figure 60-220-2
2
3
1 3
P-90903 P-90902
Disconnect wire harness (Item 1) [Figure 60-220-1] and

[Figure 60-220-2] from the front horn.
Remove the two bolts and nuts (Item 2) [Figure 60-220-

1] and [Figure 60-220-2].
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
ENGINE SPEED CONTROL (SJC) S/N A3P011522 & BELOW AND S/N A3P111118 &
BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
ENGINE SPEED CONTROL (SJC) S/N A3P011523 & ABOVE AND S/N A3P111119 & ABOVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-22-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-2
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-50-6
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-6
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-9
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-10

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Relief Valve - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-70-3
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-19
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-19
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm And Bridge Arm Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm Shaft - Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2

ENGINE INFORMATION
Description
The T650 has a Kubota direct injected V3307-DI-T turbo

diesel engine with a displacement of 3,3 L (203 in3). The
engine is rated at an SAE Gross 55,4 kW (74.3 hp) and
has a closed breather system) [Figure 70-10-1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
To meet emission regulations it is also equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic /
hydrostatic fluid temperature sensor.
Figure 70-10-1
P-85028

ENGINE INFORMATION (CONT'D)
Specifications
Valve Springs
Free Length (Intake and Exhaust) 35,1 - 35,6 mm (1.39 - 1.40 in)
Allowable Limit 34,6 mm (1.36 in)
Fitted Length (Intake and Exhaust) 31,5 mm (1.24 in)
Setting Load / Setting Length (Intake and Exhaust) 63,5 N / 31,5 mm (14.3 lb / 1.24 in)
Allowable Limit 45,9 N / 31,5 mm (10.3 lb / 1.24 in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 mm (0.039 in)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 40 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 14 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 14,973 - 14,984 mm (0.58949 - 0.58992 in)
I.D. of Rocker Arm Bushings 15,000 - 15,018 mm (0.59056 - 0.59125 in)
Oil Clearance Between Rocker Arm And Bushing 0,016 - 0,045 mm (0.00063 - 0.0017 in)
Camshaft
Journal O.D. 1 34.934 - 34,950 mm (1.3754 - 1.3759 in)
Bearing I.D. 1 35,0 - 35,025 mm (1.3780 - 1.3789 in)
Journal O.D. 2 43,934 - 43,950 mm (1.7297 - 1.7303 in)
Bearing I.D. 2 44,000 - 44,025 mm (1.7323 - 1.7332 in)
Oil Clearance 0,050 - 0,091 mm (0.002 - 0.0035 in)
Alignment Allowable Limit 0,01 mm (0.0004 in)
Cam Lobe Height (Intake) 37,50 mm (1.476 in)
Allowable Limit (Intake) 37,00 mm (1.457 in)
Cam Lobe Height (Exhaust) 37,90 mm (1.492 in)
Allowable Limit (Exhaust) 37,40 mm (1.472 in)
Side Clearance Allowable Limit 0,10 mm (0.0039 in)
Tappet
Oil Clearance Between Tappet And Guide 0,020 - 0,050 mm (0.0079 - 0.0019 in)
Tappet O.D. 9,965 - 9,980 mm (0.3924 - 0.3929 in)
Tappet Guide I.D. 10,000 - 10,015 mm (0.39370 - 0.39429 in)

ENGINE INFORMATION (CONT’D)
Specifications (Cont’d)
Cylinder Liner
Cylinder Bore I.D. 94,000 - 94,022 mm (3.7008 - 3.7016 in)
Oversized Cylinder Liner (Bore) I.D. 94,500 - 94,522 mm (3.7205 - 3.7213 in)
Piston Rings
Ring Gap (Top Ring) 0,25 - 0,40 mm (0.0099 - 0.015 in)
Ring Gap (2nd Ring) 0,30 - 0,45 mm (0.012 - 0.017 in)
Ring Gap (Oil Ring) 0,25 - 0,45 mm (0.0099 - 0.017 in)
Side Clearance of Ring Groove:
Top Ring 0,050 - 0,090 mm (0.0020 - 0.0035 in)
Second Ring 0,090 - 0,12 mm (0.0035 - 0.0047 in)
Oil Ring 0,020 - 0,060 mm (0.00079 - 0.0023 in)
Pistons
Piston Pin Bore 28,000 - 28,013 mm (1.1024 - 1.1028 in)
Connecting Rod
Piston Pin O.D. 28,006 - 28,011 mm (1.1026 - 1.1027 in)
Small End Bushing I.D. 28,031 - 28,046 mm (1.1036 - 1.1041 in)
Oil Clearance Between Piston Pin And Small End Bushing 0,020 - 0,040 mm (0.00079 - 0.0015 in)
Connecting Rod Alignment Allowable Limit 0,05 mm (0.002 in)
Oil Pump
Oil Pressure Rated RPM 193,1 - 186,2 kPa (1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (0,48 bar) (7 psi)
Clearance Between Inner Rotor And Outer Rotor 0,030 - 0,090 mm (0.002 - 0.003 in)
Clearance Between Outer Rotor And Pump Body 0,100 - 0,184 mm (0.00394 - 0.00724 in)
End Clearance Between Inner Rotor And Cover 0,025 - 0,075 mm (0.00099 - 0.0029 in)

Specifications (Cont’d)
Crankshaft
Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)
Oil Clearance Between Journal And Bearing 0,030 - 0,073 mm (0.0012 - 0.0028 in)
Limit Permitted 0,020 mm (0.0079 in)
Journal O.D. 79,977 - 79,990 mm (3.1487 - 3.1492 in)
Oil Clearance Between Crank Pin And Bearing 0,017 - 0,048 mm (0.00067 - 0.0018 in)
Crank Pin O.D. 49,980 - 49,991 mm (1.9678 - 1.9681 in)
Crank Pin I.D. (Blue) 53,010 - 53,020 mm (2.0870 - 2.0874 in)
Crank Pin I.D. (No Color) 53,000 - 53,010 mm (2.0867 - 2.0870 in)
Crankshaft Side Clearance 0,15 - 0,35 mm (0.0059 - 0.013 in)
Timing Gear
Timing Gear Backlash:
Crank Gear-Cam Gear 0,0410 - 0,139 mm (0.00162 - 0.00547 in)
Idle Gear-Cam Gear 0,0410 - 0,134 mm (0.00162 - 0.00527 in)
Idle Gear-Injection Pump Gear 0,0410 - 0,134 mm (0.00162 - 0.00527 in)
Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing: 0,050 - 0,091 mm (0.0020 - 0.0035) in
Idle Gear Bushing I.D. 35,025 - 35,050 mm (1.3790 - 1.3799 in)
Idle Gear Shaft O.D. 34,959 - 34,975 mm (1.3764 - 1.3769 in)
Idle Gear Side Clearance 0,15 - 0,25 mm (0.0059 - 0.0098 in)
Thermostat
Valve Opening Temperature 74,5 - 78,5°C (166.1 - 173°F)
Valve Fully Open 90°C (194°F)

Torque Values
Thread Size Material

(Dia. x Pitch)
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

ENGINE INFORMATION (CONT’D) Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Engine Removal And Installation
Figure 70-10-2
DANGER
1
2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-90575

can cause lift arms to drop. Loosen the engine speed control cable adjustment nuts
• Keep out of this area when lift arms are raised (Item 1) and remove the engine speed control cable from
unless supported by an approved lift arm the ball pivot (Item 2). [Figure 70-10-2].
D-1009-0409
Figure 70-10-3
1
WARNING
support device can allow the lift arms or attachment 2
W-2059-0598
Put jackstands under the rear corners of the loader.

P-85852
Disconnect engine ground cable (Item 1) and chassis
Raise the operator cab. (See Raising on Page 10-30-2.) ground cable (Item 2) [Figure 70-10-3].

Disconnect the steering linkage.
Remove the battery from the loader. (See Removal And

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-4.)
Remove the air cleaner. (See Housing Removal And


ENGINE INFORMATION (CONT’D) Figure 70-10-6
Engine Removal And Installation (Cont'd) 2

1
Figure 70-10-4
2 3
3
4
1
4
P-85857
5
Disconnect flywheel rpm sensor (Item 1) [Figure 70-10-
P-85849 6].
Cut cable ties (Item 2) [Figure 70-10-6].

Disconnect engine oil pressure sender connector (Item 1)
[Figure 70-10-4]. Disconnect the engine starter positive cable (Item 3)
[Figure 70-10-6].
Disconnect the alternator wiring (Item 2) [Figure 70-10-
4]. Disconnect the starter wiring harness connector (Item 4)
[Figure 70-10-6].
Disconnect the engine ground cable (Item 3) [Figure 70-
10-4]. Figure 70-10-7
Disconnect fuel shut-off solenoid connector (Item 4)

[Figure 70-10-4].
Cut cable tie (Item 5) [Figure 70-10-4].

1
Figure 70-10-5
P-85854
Disconnect fuel line (Item 1) [Figure 70-10-7] for lift

pump and plug.
P-85853
Disconnect glow plug wiring (Item 1) [Figure 70-10-5].

Engine Removal And Installation (Cont'd)
Figure 70-10-8
P-85894
Disconnect radiator hose (Item 1) [Figure 70-10-10].

P-85855
Figure 70-10-11
Disconnect and plug fuel return line (Item 1) [Figure 70-

10-8].
Figure 70-10-9
1
P-85892
Disconnect radiator hose (Item 1) [Figure 70-10-11] from

the thermostat housing.
P-85895
Disconnect coolant return line (Item 1) [Figure 70-10-9].


3
Figure 70-10-12
2 3
1
1
1
P-85909
Mark and disconnect the drive motor hoses (Item 1)

P-85893 [Figure 70-10-14].
Disconnect the tandem pump case drain hose (Item 2)

Disconnect coolant temperature connector (Item 1) [Figure 70-10-14].
[Figure 70-10-12] from thermostat housing.
Installation: Tighten the four fittings (Item 3) [Figure 70-
Figure 70-10-13 10-14] to 190 - 216 N•m (140 - 160 ft-lb) torque.
NOTE: Loaders with S/N A3P111001, A3P111002, and

A3P011001 - A3P011102. Tighten the drive
1 motor hoses (Item 1) [Figure 70-10-14] to 190 -
216 N•m (140 - 160 ft-lb) torque.
2
Loaders with S/N A3P111003 & Above and
A3P011103 & Above. Tighten the drive motor
hoses (Item 1) [Figure 70-10-14] to 127 - 138
Figure 70-10-15
P-85897 1
1
Remove and cap fan inlet hose (Item 1) [Figure 70-10-

13].
Remove and cap fan outlet hose (Item 2) [Figure 70-10-

2
13].
P-85907
Disconnect tandem pump suction hoses (Item 1) [Figure

70-10-15].
Disconnect the charge pump inlet hose (Item 2) [Figure

70-10-15].

Figure 70-10-16 1
1 P-85911
Remove the mounting bolt (Item 1) [Figure 70-10-18]

P-85908 from the left engine mount.
Installation: Tighten the mounting bolt (Item 1) [Figure

Disconnect hydraulic control valve inlet hose (Item 1) 70-10-18] to 135 N•m (100 ft-lb) torque.
[Figure 70-10-16].
Figure 70-10-19
Cap or plug all hoses and fittings.
Figure 70-10-17
P-85910
P-85876 Remove the mounting bolt (Item 1) [Figure 70-10-19]

from the right engine mount.
Remove rear engine mounting bolt (Item 1) [Figure 70- Installation: Tighten the mounting bolt to 135 N•m (100
10-17]. ft-lb) torque.
Installation: Tighten the mounting bolt to 135 N•m (100

ft-lb) torque.

Figure 70-10-20
P-85912
Install the engine removal attachment (MEL1653-5)

[Figure 70-10-21] on the engine.
Figure 70-10-22
P-76872
Use the engine removal tool (MEL 1653-1) [Figure 70-

P-85920
10-20] and the attachment (MEL 1653-5) [Figure 70-10-
21] to aid in the removal and installation of the engine.
Install the engine removal attachment (Item 1) on the left
hand muffler support bracket (Item 2) [Figure 70-10-22].
Installation: Use 9,525 x 38,1 mm (0.375 x 1.5 in) bolts

and nuts grade 5 minimum.
Tighten the all bolts and nuts that hold the engine
removal attachment onto the engine.

Figure 70-10-23
P-85918
Install the engine removal attachment (Item 1) on the

right hand muffler support bracket (Item 2) [Figure 70-
10-22].
Figure 70-10-24
P-85919
Install the engine removal tool (Item 1) into the

attachment (Item 2) and insert the pin (Item 3) [Figure
70-10-24].
Install the chain hoist on the eyelet [Figure 70-10-24] of

the removal tool.
Remove the engine / hydrostatic pump assembly from

the loader.

Engine Mount Replacement Washer

Engine
Figure 70-10-25 Mounting
Bracket
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-27].
Tighten the mounting bolts to 135 N•m (100 ft-lb) torque.

Use the following procedure to install new rear engine
mount: Figure 70-10-27
Remove the existing mount from the engine. Refer to 1

engine removal and installation for engine mount 4
locations.
Replace all three engine mounts one rear and two sides. 5 2
Use the parts shown to install the new engine mounts 6 3

[Figure 70-10-25]:
7
Hex Nut - (Item 1)
Washer - (Item 2)
Cup Washer - (Item 3) P-85990A
Engine Mount - (Item 4)

Use the parts shown to install the new side engine
Tube Spacer - (Item 5) mounts [Figure 70-10-25].
Engine Mount - (Item 6) Mounting Bolt - (Item 1)
Cup Washer - (Item 7) Cup Washer - (Item 2)
Mounting Bolt - (Item 8) Engine Mount - (Item 3)
Tube Spacer - (Item 4)
Engine Mount - (Item 5)
Cup Washer - (Item 6)
Retaining Nut - (Item 7)

ENGINE INFORMATION (CONT’D) Compression - Checking
Engine Mount Replacement (Cont’d) Figure 70-10-29
Figure 70-10-28
Washer
Engine
Mounting 1
Bracket
Engine
Mount
Snubbing
Washer
Spacer P-85940
Loader
Frame P-85987
procedure:
Install the new engine mount as shown in the cut away
side view [Figure 70-10-27]. MEL10630 - Engine Compression Kit
MEL1655 - Compression Adapter
Tighten the mounting bolts to 135 N•m (100 ft-lb) torque. MEL1712 - Push Button Starter Switch
The engine must be at operating temperature.
Remove the glow plugs. (See CYLINDER HEAD on Page

70-80-1.)
Install the correct compression adapter (Item 1) [Figure

70-10-29] into the cylinder head.

Compression - Checking (Cont’d)

1
Figure 70-10-30
P100685
Figure 70-10-32
P-85941
Connect the compression gauge to the adapter [Figure

70-10-30].
1
Make sure the engine speed control is fully backward
(engine idle). 2
Disconnect the fuel stop solenoid.
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 70-10-31] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 70-10-32].
Engage the starter 7 - 10 seconds until a maximum
compression reading is obtained.
Repeat this procedure multiple times per cylinder until an

average compression reading is recorded.
If the measurement is below the allowable limit, check the

cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 3,9 MPa (39,2 bar)

(569 psi)
Allowable Limit (minimum) is 2,9 MPa (29,0 bar) (421 psi)
No more than 10% variance among cylinders.

Compression - Checking (Cont’d)
Figure 70-10-33
P-85939
Push the button on the compression gauge to release

pressure [Figure 70-10-33].
Connect the fuel stop solenoid.

ENGINE SPEED CONTROL Disassembly And Assembly
Figure 70-20-1
1 2
P-85791
P-85789
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the handle (Item 3) [Figure 70-20-3].
Figure 70-20-2
Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].
Installation: Tighten the nut (Item 1) [Figure 70-20-3]

until the speed control lever moves backward and forward
2 1 at a comfortable tension.
3
Figure 70-20-4
P-85790
The speed control cable (Item 1) is connected to the

speed control handle (Item 2) by a ball and socket end
[Figure 70-20-2].
Disconnect the speed control cable (Item 1) from the

speed control handle (Item 2) [Figure 70-20-2].
P-85792
Loosen the jam nut (Item 3) [Figure 70-20-2] from the
speed control cable.
Inspect and replaced any damaged parts [Figure 70-20-
Remove the cable from the speed control handle. 4].

ENGINE SPEED CONTROL (CONT’D) Figure 70-20-7
Cable Removal And Installation

1
Remove the speed control lever. (See Removal And

P-85805
Figure 70-20-5
P-85801
Remove the bolt (Item 1) [Figure 70-20-7] from the

clamp that secures the cable.
Figure 70-20-8
1
P-85806
Remove the bolt (Item 1) [Figure 70-20-5] from the

clamp that secures the cable.
2
Figure 70-20-6 3
P-85804
The speed control cable is connected to the linkage by a

1 ball and socket end [Figure 70-20-8].
Loosen the jam nut (Item 1) [Figure 70-20-8] from the

speed control cable.
Disconnect the speed control cable (Item 2) from the

linkage (Item 3) by rolling the cable away from the engine
[Figure 70-20-8].
P-85801
Remove the speed control cable.
Remove the three bolts (Item 1) [Figure 70-20-6] from

the clamps that secure the cable.

ENGINE SPEED CONTROL (SJC) S/N A3P011522 & Figure 70-21-3
BELOW AND S/N A3P111118 & BELOW
Figure 70-21-1 1
2
1
P-90735
Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-21-3].
Lay the assembly down.

P-90733
Figure 70-21-4
Remove the two mounting nuts (Item 1) [Figure 70-21-1]

1
from the right side foot rest.
1
Remove the foot rest from the loader.
Figure 70-21-2
2
2
P-90754
1
2 Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
P-90734 Remove panel assembly from the loader.
Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-21-2].
Installation: Install the engine speed foot pedal (Item 2)

but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-21-2].

BELOW AND S/N A3P111118 & BELOW (CONT'D)

4 3
Figure 70-21-5
2 1
3 P-90769
1 Remove the nut (Item 1) and pivot bolt (Item 2) from the
engine speed control hand bracket assembly (Item 3)
P-90756 [Figure 70-21-7].
Remove the engine speed control hand throttle cam lever

Remove the spring (Item 1) from the engine speed (Item 4) [Figure 70-21-7].
control foot pedal pivot assembly (Item 2) and the engine
speed control hand throttle bracket (Item 3) [Figure 70- Figure 70-21-8
21-5]
Figure 70-21-6
P-90767
P-90755 The pivot assembly shown disassembled [Figure 70-21-

8].
Remove the two bolts (Item 1) [Figure 70-21-6] from the NOTE: No lubrication is necessary or recommended
engine speed control hand assembly. on the engine speed control.

BELOW AND S/N A3P111118 & BELOW (CONT'D)
Figure 70-21-9
P-90773
The engine speed control foot pedal pivot assembly roller

bearing [Figure 70-21-11] shown disassembled.
P-90736

engine speed control foot pedal pivot.
Figure 70-21-10
P-90771
The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-21-10] replace worn
parts as needed.
NOTE: No lubrication is necessary or recommended

on the engine speed control.

ABOVE AND S/N A3P111119 & ABOVE
Figure 70-22-1 1
2
1
P-90735
Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-22-3].
Lay the assembly down.

P-90733
Figure 70-22-4
Remove the two mounting nuts (Item 1) [Figure 70-22-1]

from the right side foot rest. 1
Remove the foot rest from the loader.
Figure 70-22-2 2
P100359
1
2 Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-22-4].
P-90734 Remove panel assembly from the loader.
Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-22-2].
Installation: Install the engine speed foot pedal (Item 2)

but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-22-2].

ABOVE AND S/N A3P111119 & ABOVE (CONT'D)
Disassembly And Assembly 4
Figure 70-22-5
3
2 1
2 5
3 P100381
1 Remove the nuts (Item 1) and pivot bolts (Item 2) from

the engine speed control hand bracket assembly (Item 3)
P100382 [Figure 70-22-7].
Remove the engine speed control hand throttle cam lever

Remove the spring (Item 1) from the engine speed (Item 4) and engine throttle cable lever Item 5) [Figure
control foot pedal pivot assembly (Item 2) and the engine 70-22-7].
speed control hand throttle bracket (Item 3) [Figure 70-
22-5] Figure 70-22-8
Figure 70-22-6
P100380
P-90755
The pivot assemblies shown disassembled [Figure 70-
22-8].
Remove the two bolts (Item 1) [Figure 70-22-6] from the
engine speed control hand assembly. NOTE: No lubrication is necessary or recommended

ABOVE AND S/N A3P111119 & ABOVE (CONT'D)
Figure 70-22-9
P100375
The engine speed control foot pedal pivot assembly roller

bearing [Figure 70-22-11] shown disassembled.
P-90736

engine speed control foot pedal pivot.
Figure 70-22-10
P100376
The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-22-10] replace worn
parts as needed.
NOTE: No lubrication is necessary or recommended


MUFFLER
Figure 70-30-1
2
1
1 1
3 3
P-85843
Open the rear door and remove the rear grille and side
panels. (See Removal And Installation on Page 50-60-1.)
Remove the bolts (Item 1) from the engine cover (Item 2)

[Figure 70-30-1] and remove engine cover.
Remove the muffler mounting bolts (Item 3) [Figure 70-

30-1].
Remove exhaust manifold to muffler mounting bolts (Item

4) [Figure 70-30-1].
Remove the muffler from the loader.
Installation: Tighten the muffler mounting bolts to 43 - 47


AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Open the rear door. 3 4
Figure 70-40-1
1
1
2
P-85694
Disconnect the wire connector (Item 1) [Figure 70-40-3]

from the air cleaner sender.
P-85689 Loosen the hose clamp (Item 2) and disconnect the hose
(Items 3) [Figure 70-40-3] from the air cleaner.
Remove the top two mounting bolts (Item 1) [Figure 70- Installation: Tighten the hose clamp (Item 2) [Figure 70-
40-1] from the air cleaner mount bracket. 40-3] to 3,4 - 4,0 N•m (30 - 35 in-lb) torque.
Figure 70-40-2 NOTE: Disconnect the scavenger hose (Item 4)

[Figure 70-40-3] if equipped.
Remove the air cleaner from the loader.
P-85688
Remove the bottom mounting bolt (Item 1) [Figure 70-

40-2] from the air cleaner mount bracket.

AIR CLEANER (CONT’D)
Housing Bracket Removal And Installation
Figure 70-40-4
P-85691
Remove the three bolts (Item 1) and remove the air

cleaner bracket (Item 2) [Figure 70-40-4].

ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation
Remove the rear grille and side panels. (See Removal 1

Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)
WARNING
P-85606
AVOID BURNS
Do not remove radiator cap when the engine is hot. Remove hose (Item 1) [Figure 70-50-2] on the engine oil
You can be seriously burned. cooler and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1
2
3
4
2
P-85949
P-90574
Disconnect the pressurized expansion tank fill hose (Item

Loosen the radiator cap (Item 1) from the pressurized 1), disconnect the coolant air bleed hose (Item 2) and the
expansion tank. Disconnect and plug radiator air bleed radiator hose (Item 3) [Figure 70-50-3].
Remove the radiator hold down bolt (Item 4) [Figure 70-
50-3].

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4
2 2
1 P-85954
Remove radiator hold down bolt (Item 1) [Figure 70-50-

P-90555 6].
Remove the radiator (Item 2) [Figure 70-50-6].

Disconnect the radiator hose (Item 1) and remove the
radiator hold down bolt (Item 2) [Figure 70-50-4]. Lift the radiator up and remove it from the loader.
Figure 70-50-5 NOTE: Coolant recovery tank removed for photo

clarity
P-90590
Remove radiator hold down bolt (Item 1) [Figure 70-50-

5].

Hydraulic Fan Description
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.
The hydraulic fan is used to cool the engine and hydraulic

/ hydrostatic systems. The hydraulic fan consists of a fan
and hydraulic motor that is controlled by a proportioning
valve.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field due to
the adjustment being tamper proof.
The fan speed is determined by the engine coolant

temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpm)
can range from 0 - 4000 rpm.
The hydraulic fan speed at cold engine startup will range

from 0 - 500 rpm until the engine coolant and the
hydraulic fluid reach normal operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 - 3500 rpm.

ENGINE COOLING SYSTEM (CONT’D) Installation: Install coil mounting nut with the
counterbored space (Item 4) [Figure 70-50-8] facing
Hydraulic Fan Disassembly And Assembly towards the coil and tighten securely by hand.
Figure 70-50-7 Installation: Tighten coil valve stem (Item 3) [Figure 70-
50-8] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Figure 70-50-9
4
1
3
1
P-76714A 2
NOTE: The mounting gasket (Item 1), proportioning

P-76637
valve, and proportioning valve O-rings, back
up washer and coil mounting nut (Item 2) are
available from Bobcat Parts. The fan motor Inspect and replace O-rings (Item 1) and back up washer
(Item 3) [Figure 70-50-7] must be replaced as (Item 2) [Figure 70-50-9] if necessary.
an assembly if damaged.
Figure 70-50-10
Remove the filter cover (Item 4) [Figure 70-50-7].
Installation: Tighten filter cover (Item 4) [Figure 70-50-

7] to 47,5 - 54 N•m (35 - 40 ft-lb) torque.
Figure 70-50-8
1
4
3
P-76717
2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 10].
P-76716A Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-10] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.
Remove coil mounting nut (Item 1), the coil (Item 2), and
the coil valve stem (Item 3) [Figure 70-50-8].
NOTE: Coil mounting nut must be replaced each time

it is removed. Coil mounting nuts are
available from Bobcat Parts.

ENGINE COOLING SYSTEM (CONT'D) Blower Housing Removal And Installation
Hydraulic Fan Disassembly And Assembly (Cont’d)
Figure 70-50-11
IMPORTANT
damage the system.
I-2003-0888
Remove the air conditioning condenser if equipped. (See

1 Removal And Installation on Page 80-60-1.)
Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)
P-76726
Remove the radiator. (See Radiator Removal And
Inspect and replace the O-ring (Item 1) [Figure 70-50-
11] if necessary.
Figure 70-50-13
Lower Fan Duct Removal And Installation
Figure 70-50-12
1 1
2
P-90063
1
Remove the four bolts (Item 1)[Figure 70-50-13].
P-85470
Remove the blower housing (Item 2)[Figure 70-50-13]
from the loader.
Unhook the rubber straps (Item 1) [Figure 70-50-11] and
remove lower fan duct.
NOTE: Engine and hydraulic fan assembly removed
for photo clarity.
NOTE: Line up the bushings and bolts thru the fan

shroud

ENGINE COOLING SYSTEM (CONT’D) Fan Removal And Installation
Hydraulic Fan Motor Assembly Removal And Figure 70-50-16

Installation
Figure 70-50-14
1
1 2
2
5
4
5 1
P-90313
3
P-85897 Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-16].
Remove the fan motor inlet hose (Item 1) and outlet hose Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
(Item 2) [Figure 70-50-14]. torque.
Remove the fan case drain hose (Item 3) [Figure 70-50- Figure 70-50-17
14].
Remove the charge pressure hose (Item 4) [Figure 70-

50-14].
Cap and plug all hose’s.

1
Disconnect the electrical connectors (Item 5) [Figure 70-
50-14].
Figure 70-50-15
P-90065
Remove the nut (Item 1) [Figure 70-50-17] and washer

1 1 from the motor shaft.
Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)

torque.
P-90268
Remove the four bolts (Item 1) [Figure 70-50-15].
Remove fan assembly (Item 2) [Figure 70-50-15].

ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-20
Hydraulic Fan Motor Removal And Installation
Figure 70-50-18
2 2
P-90062
Use the following procedure to remove the fan hub from

P-90069 the fan motor shaft:
Install a bushing (Item 1) [Figure 70-50-20] in the hub to

Remove and discard the two nuts and cotter pins (Item 1) protect the fan motor shaft and threads during removal.
[Figure 70-50-18].
Use two bolts to position a puller (Item 2) on the bushing
Remove the two washers (Item 2) [Figure 70-50-18]. (Item 1) as shown [Figure 70-50-20].
Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb) NOTE: If a puller is not available one can be made if
torque. needed to remove the hub from the shaft.
Figure 70-50-19 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.
P-90076
Remove and discard the two bolts (Item 1) [Figure 70-

50-19] then remove motor.
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)

torque.
NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.

ENGINE COOLING SYSTEM (CONT'D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-22
Drain the cooling system.

3
Remove the alternator belt.
Remove the water pump bolts.

2
Figure 70-50-21
1
4
1 P-90019
Remove the flange (Item 1) [Figure 70-50-22].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-22] out the impeller side of the water pump.
2
P-90018 Remove the impeller (Item 3) [Figure 70-50-22] from the
shaft.
Remove the water pump (Item 1) [Figure 70-50-21]. Remove the seal (Item 4) [Figure 70-50-22].
Installation: Always use a new gasket (Item 2) [Figure Install a new seal (Item 4) [Figure 70-50-22] when
70-50-21] when installing the water pump. assembling the water pump.

ENGINE COOLING SYSTEM (CONT'D)
Thermostat Housing Removal And Installation
Figure 70-50-23
7 4
6
P-90166
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-23].
Remove bolts (Item 5), housing (Item 6), and gasket

(Item 7) from the cylinder head [Figure 70-50-23].

Thermostat - Checking
Figure 70-50-24
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-
24].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory spec. 74,5 - 78,5°C

opening tempera- (166.1 - 173°F)
ture
Temperature at Factory spec. 90°C
which thermostat (194°F)
completely opens

LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Figure 70-60-3
Remove the engine and hydrostatic pump assembly from

Page 70-10-7.)
The engine will have to be on an engine stand or

suspended in the air safely to remove the oil pan.
Figure 70-60-1
2 1
1
P-85061
Remove the bolts from the front cover / oil pump (Item 1)
[Figure 70-60-3].
Installation: Use a liquid gasket adhesive.Tighten the

front cover / oil pump mounting bolts to 24 - 27 N•m (18 -
20 ft-lb) torque.
P-85062
Remove oil pan bolts (Item 1) securing oil pan (Item 2)

[Figure 70-60-2]. Slightly tapping on the oil pan with a
soft mallet will break loose the oil pan from the engine
block.
Installation: Use a liquid gasket adhesive to the oil pan

side of the oil pan gasket. Tighten oil pan bolts to 18 - 20
Figure 70-60-2
2
1
P-85056
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.

LUBRICATION SYSTEM (CONT’D) Installation: Tighten cover screws to 7,9 - 9,3 N•m (5.8 -
6.8 ft-lb)
Relief Valve - Testing
Clearance 0,030 - 0,090 mm
Figure 70-60-4 Between Inner & (0.0012 - 0.0035 in)
Outer Rotor
Allowable limit 0,30 mm (0.012 in)
If the clearance exceeds the allowable limit, replace the

oil pump.
Figure 70-60-6
1
2
4
3 P-85057
Remove the relief valve retaining screw (Item 1) from the

front cover / oil pump (Item 2) and remove the relief valve
spring (Item 3) and relief valve (Item 4) [Figure 70-60-4].
Measure free length of relief valve spring (Item 3) [Figure
70-60-4] and check the entire surface of spring for any P-85059
scratches. Replace if out of spec or any scratches.

Measure the clearance between the outer rotor and
Free Length 60,0 - 60,5 mm pump body [Figure 70-60-6].
(2.37 - 2.38 in)
Allowable Limit 55,0 mm (2.17 in) Clearance 0,100 - 0,184 mm
Between Outer (0.00394 - 0.00724 in)
Rotor & Body
Installation: Tighten relief valve retaining screw (Item 1)
[Figure 70-60-4] 69 - 78 N•m (51 - 57 ft-lb) torque. Allowable limit 0,30 mm (0.012 in)
Oil Pump Inspection If the clearance exceeds the allowable limit, replace the
oil pump.
Figure 70-60-5
P-85058
Remove oil pump cover screws. Measure the clearance

between the lobes of the inner rotor and outer rotor
[Figure 70-60-5].

LUBRICATION SYSTEM (CONT’D) Oil Filter Cooler Removal And Installation
Oil Pump Inspection (Cont’d) Figure 70-60-8
Figure 70-60-7
1
3
2
P-85072
P-85060
Remove the cooling hose’s (Item 1) [Figure 70-60-8].
Put a piece of press gauge on the rotor face [Figure 70- Remove oil filter cartridge (Item 2) and the oil cooler joint
60-7]. screw (Item 3) [Figure 70-60-8].
Install the cover and tighten the bolts. Remove oil cooler (Item 4) [Figure 70-60-8].
Remove the cover carefully. Measure the width of the Installation: Tighten oil cooler joint screw (Item 3)
press gauge [Figure 70-60-7]. [Figure 70-60-8] 64 - 73 N•m (47 - 54 ft-lb) torque.
If the clearance exceeds the allowable limit replace the oil

pump.
End Clearance 0,25 - 0,75 mm

(0.00099 - 0.0029 in)

LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-9
PI-10010
Install a pressure gauge [Figure 70-60-9].
Start the engine and run until it is at operating

temperature.
If the oil pressure is less than the allowable limit, check

the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable 48,3 kPa (0,48 bar) (7 psi)

Limit
At Rated Speed 193,1 - 393,0 kPa
(1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)

FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Checking Figure 70-70-3
Figure 70-70-1
P-85956
P-85956
Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].
Disconnect the connector (Item 1) [Figure 70-70-1] from Figure 70-70-4

the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2
P-85957
Remove the mounting screws (Item 1) [Figure 70-70-4]

of the fuel shutoff solenoid.
P-85955
Reverse the above procedure to install the fuel shutoff
solenoid.
The reading between electrical connector terminal C and
terminal A must be between approximately 0.33 ohm
[Figure 70-70-2].
The reading between electrical connector terminal C and

terminal B must be between approximately 24.5 ohm.

FUEL 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 pressure
The injection pump contains parts which have a very can not reach the allowable limit, replace the injection
close tolerance and its operation has a direct effect on pump assembly.
the performance of the engine.
Fuel Tightness of Pump 18,6 MPa
Element Allowable Limit (186,3 bar) (2702 psi)
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 18,6
AVOID INJURY OR DEATH MPa (186,3 bar) (2702 psi).
penetrate skin or eyes, causing serious injury or Turn the flywheel back approximately one-half turn. Keep
death. Fluid leaks under pressure may not be visible. the flywheel at this position, and measure the time it
Use a piece of cardboard or wood to find leaks. Do takes the pressure to decrease from 17,7 MPa (176,5
not use your bare hand. Wear safety goggles. If fluid bar) (2560 psi).
from a physician familiar with this injury. Fuel Tightness of Delivery 5 Seconds
W-2072-0807 Valve Allowable Limit

procedure:
MEL 1237 - Adapter Fuel Line

MEL 1173-1 Pressure Gauge
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.
Installation: Tighten the injection pipe retaining nuts to

23 - 36 N•m (17 - 26 ft-lb) torque.
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].

FUEL SYSTEM (CONT'D) Figure 70-70-7
Fuel Injection Pump Assembly Removal And

Installation
Remove the alternator. (See Removal And Installation on

Page 60-30-5.)
Figure 70-70-6 2
1
P-85082
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-7] from the injection pump
vent.
Cap the inlets on the injection pump vent where the

P-85085 hoses were removed [Figure 70-70-7].
Figure 70-70-8
Clean the area around the injection pump thoroughly.
Disconnect the high pressure fuel lines (Item 1) [Figure

70-70-6] from the fuel injectors.
2
IMPORTANT 1
Do not bend the high pressure fuel injection tubes

when removing or installing them.
I-2029-0289
P-85082
Remove the high pressure fuel lines (Item 1) [Figure 70-

70-8] from the injection pump.
Installation: Tighten the injection pipe retaining nuts to

23 - 36 N•m (17 - 26 ft-lb) torque.
Remove the engine speed control linkage (Item 2)

[Figure 70-70-8].

Fuel Injection Pump Assembly Removal And

Installation (Cont'd)
Figure 70-70-9
P-85215
Make flywheel stop tool as shown above in [Figure 70-

70-11].
P-85095
A 144 mm (5.67 in)
Remove the window cover for the fuel injection pump B 104 mm (4.09 in)
assembly (Item 1) [Figure 70-70-9] from the flywheel C 20,0 mm (0.787 in)
housing. D 10,0 mm dia. (0.394 in dia.)
Figure 70-70-10 E 12,0 mm dia. (0.472 in dia.)

F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
1 H 32,0 mm (1.26 in)
I 16,0 mm (0.630 in)
Figure 70-70-12
M8 X 1.25
5,0 mm
5,0 mm (0.20 in) (0.20 in) dia
0,79 rad (45°)
P-85094
Place the number four piston at top dead center on the

compression stroke and lock the flywheel in place using
10 mm (0.39 in) 4,0 mm (0.16 in)
the flywheel stopper tool as described below.
Look for the alignment mark on the idler gear and 45 mm (1.8 in)
P-85091
injection pump gear (Item 1)[Figure 70-70-10] then using
a white marking pen or the like put a alignment mark to
help reassemble these gears in mesh later. Construct two fuel camshaft lock screws as shown above
[Figure 70-70-12]
NOTE: When the already existing marks align with
each other, there is no need to put another
alignment mark.

Fuel Injection Pump Assembly Removal And 2

Installation (Cont'd)
Figure 70-70-13
P-85093
Remove the lubricating oil pipe (Item 1) [Figure 70-70-

15].
P-85095
Remove the three injection pump mounting nuts (Item 2)
[Figure 70-70-15]
Remove the two plugs (Item 1) [Figure 70-70-13].
Installation: Tighten the lubricating oil pipe to 16 - 19
Installation: Tighten the plugs to 9,81 - 11,2 N•m (7.24 - N•m (12 - 14 ft-lb) torque.
8.31 ft-lb) torque.
Installation: Tighten the injection pump mounting nuts to
Figure 70-70-14 18 - 20 N•m (13 - 15 ft-lb) torque.
Figure 70-70-16
2
1
P-85090
P-85095
Install one lock tool in the upper plug opening (Item 1)
and tighten until it comes in contact with the fuel
camshaft. Make sure the fuel camshaft is not moving. Remove injection pump support (Item 1) [Figure 70-70-
Install second lock tool in lower opening (Item 1) [Figure 16].
70-70-14] and repeat the process.
Remove injection pump assembly (Item 2) [Figure 70-
NOTE: Do not over tighten the lock screws after they 70-16].
have contacted the fuel camshaft. Otherwise
the injection pump may become damaged.

FUEL SYSTEM (CONT'D) Q 2,955 - 2,965 mm dia.
(0.1164 - 0.1167 in dia.)
Governor Housing Disassembly And Assembly R 3,020 - 3,030 mm dia.
(0.1189 - 0.1192 in dia.)
The governor serves to keep the engine speed constant S Ra = 1.6a
by automatically adjusting the amount of fuel supplied to
AA Governor housing side
the engine according to changes in the engine load.
BB Press in side
a 0,60 mm radius (0.024 in radius)
Disassemble and assemble the governor and fuel
b 1,0 mm radius (0.039 in radius)
camshaft as shown in figure.
C0.2 Chamfer 0,20 mm (0.0079 in)
Check all the parts for wear or damage and replace as C0.4 Chamfer 0,40 mm (0.016 in)
needed. C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in)
Figure 70-70-17 C2 Chamfer 2,0 mm (0.079 in)
Make the tool as shown in figure [Figure 70-70-17] or

purchase part number below to connect the governor
connecting rod to the rack pin of the fuel injection pump.
MEL1667 - Jig for Governor Connecting Rod
(Item 1) [Figure 70-70-17] Material: S43C-D

(Item 2) [Figure 70-70-17] Permanent Magnet: 8 mm dia.
(0.31 in dia.) Thickness: 3 mm (0.12 in)
P-85182
Jig for Governor Connecting Rod
Application: Use this tool for connecting the governor

connecting rod to the rack pin of the fuel injection pump
assembly.
A 0,50 mm (0.020 in)

B 12,7 - 13,0 mm (0.500 - 0.511 in)
C 8,70 - 9,00 mm (0.343 - 0.354 in)
D 39 mm dia. (1.54 in dia.)
E 10,0 mm (0.394 in)
F 7,0 mm (0.28 in)
G 6,0 mm (0.24 in)
H 80,0 mm (3.15 in)
I 27,95 - 28,05 mm (1.101 - 1.104 in)
J 5,0 mm (0.20 in)
K 3,000 - 3,010 mm dia. 6,0 mm depth
(0.1182 - 0.1185 in dia, 0.24 in depth)
L 9,0 mm (0.35 in)
M 5,0 mm (0.020 in)
N 14,45 - 14,55 mm (0.5689 - 0.5728 in)
O 5,0 mm (0.020 in)
P 4,0 mm (0.16 in)

FUEL SYSTEM (CONT’D) NOTE: (See Fuel Injection Pump Removal And
Installation on Page 70-70-13.) for proper
Governor Housing Disassembly And Assembly alignment of the governor connection rod
(Cont’d) procedure. The procedure will require a
special tool as shown on page 70-70-6.
Figure 70-70-18
Figure 70-70-20
3 2 1
P-85095
P-85100
Remove the fuel injection pump assembly. (See Fuel
Injection Pump Assembly Removal And Installation on
Page 70-70-3.) Slide off the governor connecting rod (Item 1) [Figure 70-
Remove the governor lubricating pipe (Item 1) [Figure 70-19] from the rack pin of injection pump assembly.
70-70-18].
For convenient sake, temporarily hook the start spring on
Remove the stop solenoid (Item 2) [Figure 70-70-18]. the rack pin hole of the governor connecting rod.
Remove the sight cover (Item 3) [Figure 70-70-18] from Remove the governor housing mounting bolts.
the injection pump unit.
Figure 70-70-19 Installation: Tighten the governor housing bolts to 9,81 -

11,2 N•m (7.24 - 8.31 ft-lb) torque.
2
Figure 70-70-21
1
3 1
P-85099
Unhook the start spring (Item 1) from the rack pin (Item P-85097
2) [Figure 70-70-19] of injection pump assembly.
Remove the nut (Item 3) [Figure 70-70-19]. Remove the governor housing assembly (Item 1) [Figure
70-70-21] from the injection pump unit.
Installation: Reverse procedure to install. Tighten the
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque. NOTE: The injection pump unit is lubricated with
engine oil. Oil will leak when the governor
NOTE: Be careful not to drop the nut inside. housing is removed from the injection pump.

FUEL SYSTEM (CONT’D) Figure 70-70-24
Governor Disassembly And Assembly
Figure 70-70-22
1
1
2
P-85189
Remove the governor fork lever assembly (Item 1) from

P-85101 the housing [Figure 70-70-24].
Figure 70-70-25
Remove the governor fork shaft lever (Item 1) using a bolt
4 mm dia. (0.16 in dia.), pitch 0,7 mm (0.03 in) at least
25,4 mm (1 in) long (Item 2) [Figure 70-70-22].
NOTE: When assembling the inside parts, lightly put 3

oil on each inside part.
Figure 70-70-23 2
1 2
P-85190
Remove the spring pin (Item 1), then remove speed

control lever (Item 2) and the return spring (Item 3)
[Figure 70-70-25].
P-85188
Unhook the governor spring (Item 1) at the fork lever

(Item 2) [Figure 70-70-23].

FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly (Cont’d)
Figure 70-70-26
P-85192
Remove the start spring (Item 1) [Figure 70-70-26] from

the governor housing.
After reassembling the governor housing assembly,

check the movement of the governor fork lever (Item 2)
[Figure 70-70-23], the speed control lever (Item 2)
[Figure 70-70-25], stop lever (not shown), governor
spring (Item 1) [Figure 70-70-23] and governor fork lever
shaft (Item 1) [Figure 70-70-22].
NOTE: When assembling the inside parts, lightly put

oil on each inside part.
NOTE: Be careful not to deform the start spring.

FUEL SYSTEM (CONT’D) M 31,0 mm (1.22 in)
Fuel Camshaft Removal And Installation N 57,5 mm (2.26 in)
O 100 mm (3.94 in)
Remove the fuel injection pump assembly. (See Fuel
P 3,75 - 4,00 mm (0.148 - 0.157 in)
Injection Pump Assembly Removal And Installation on
Page 70-70-3.) Q 16,17 mm (0.6366 in)
Remove the fuel injection pump unit. (See Fuel Injection
Pump Removal And Installation on Page 70-70-13.)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.5 Chamfer 0,50 mm (0.020 in)
WARNING To remove and replace the fuel camshaft, make the tool
as shown in figure [Figure 70-70-27] or purchase part
number below.
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and
MEL1666 - Injection Pump Gear Puller
clothing. Failure to wear eye and body protection can
result in serious injury.
W-2009-1285
Figure 70-70-27
P-85123
A M35 x P1.5, 6,0 mm depth (0.24 in depth)

B 35,0 mm dia.,12,0 mm depth
(1.38 in dia., 0.472 in depth)
C 30,0 mm dia., 27,5 mm depth
(1.18 in dia., 1.08 in depth)
D 40,00 - 40,20 mm dia. (1.575 - 1.582 in dia.)
E 35,90 - 36,10 mm dia. (1.414 - 1.421 in dia.)
F 2.09 rad (120 degrees)
G M8 x P1.25
H 9,0 mm dia. (0.35 in dia.)
I 19,0 mm dia. (0.748 in dia.)
J 12,0 mm (0.472 in)
K 15,0 mm (0.591 in)
L 27,5 mm (1.08 in)

FUEL SYSTEM (CONT'D) F 16,0 mm dia. (0.630 in dia.)
Fuel Camshaft Removal And Installation (Cont’d) G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
Figure 70-70-28
I 16,0 mm (0.630 in)
Figure 70-70-30
2
1
2
P-85186A
1
P-85183
Remove the governor sleeve (Item 1) and remove the two
fuel camshaft lock allen screws (Item 2) [Figure 70-70-
Install injection pump housing to the engine and tighten.
28].
Fix the flywheel with the flywheel stop tool (Item 1)
[Figure 70-70-32].
NOTE: Do not use the fuel camshaft locks screws
when removing governor weight, otherwise
Loosen the injection pump gear mounting nut (Item 2)
damage may occur to the allen screws or the
[Figure 70-70-32].
governor housing.
Installation: Tighten injection pump gear mounting nut to
Figure 70-70-29
138 - 156 N•m (102 - 115 ft-lb).
NOTE: The injection pump gear mounting nut is a left
hand thread to loosen turn towards B and to
tighten turn towards A as seen from the
flywheel side
Figure 70-70-31
2
P-85215
Make flywheel stop tool as shown above in [Figure 70-

70-29].
A 144 mm (5.67 in)

P-85121
B 104 mm (4.09 in)
C 20,0 mm (0.787 in) Remove the fuel injection pump gear (Item 1) using the
D 10,0 mm dia. (0.394 in dia.) tool (Item 2) [Figure 70-70-31].
E 12,0 mm dia. (0.472 in dia.)

FUEL SYSTEM (CONT'D)
Fuel Camshaft Removal And Installation (Cont’d)
Figure 70-70-32
P-85122
Loosen fuel camshaft stopper mounting bolts (Item 1)

and remove camshaft stopper (Item 2) [Figure 70-70-
32].
Installation: Tighten fuel camshaft stopper mounting

bolts to 9,81 - 11,2 N•m (7.24 - 8.37 ft-lb).
NOTE: When reassembling fuel camshaft stopper

make sure the oil path hole (Item 3) [Figure 70-
70-32] is the proper alignment.
Figure 70-70-33
P-85120
Remove fuel camshaft (Item 1), then remove fuel

camshaft stopper bearing screws (Item 2) [Figure 70-70-
33].
If replacing the fuel camshaft bearings tighten the fuel

camshaft stopper bearing plate screws (Item 2) [Figure
70-70-33] to 3,9 - 4,2 N•m (2.9 - 3.1 ft-lb) torque.

FUEL SYSTEM (CONT'D) Installation: Reverse procedure to install. Tighten the
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
Fuel Injection Pump Removal And Installation
NOTE: Be careful not to drop the nut inside.
Figure 70-70-34
Figure 70-70-36
1
3 1
P-85199
P-85100
Remove all injection pipes (Item 1) [Figure 70-70-34].

Slide off the governor connecting rod (Item 1) [Figure 70-
Installation: Tighten the injection pipe retaining nuts to 70-36] from the rack pin of injection pump assembly.
23 - 36 N•m (17 - 26 ft-lb) torque.
For convenient sake, temporarily hook the start spring on
Remove overflow hose (Item 2) [Figure 70-70-34]. the rack pin hole of the governor connecting rod.
Remove fuel stop solenoid (Item 3) [Figure 70-70-34]. Figure 70-70-37
Remove sight cover from housing (Item 4) [Figure 70-70-

34].
NOTE: The injection pump can be removed and

installed with the crankshaft at any position.
Figure 70-70-35
1
3 1
P-85198
2
Remove all of the mounting bolts and nuts (Item 1)
[Figure 70-70-37] from the fuel injection pump.
P-85099
Unhook the start spring (Item 1) from the rack pin (Item
2) [Figure 70-70-35] of injection pump assembly.

FUEL SYSTEM (CONT'D) Hook starter spring (Item 5) to rack pin (Item 2) [Figure
70-70-36].
Fuel Injection Pump Removal And Installation
(Cont’d) Installation: Tighten the nut (Item 3) [Figure 70-70-36]
to 2,9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
Figure 70-70-38
NOTE: A = 27,95 - 28,05 mm (1.100 - 1.104 in)
1
2
P-85200
Remove the fuel injection pump (Item 1) [Figure 70-70-

36].
Installation: Reverse procedure to install. Tighten the

bolts to 24 - 27 N•m (18 - 20 ft-lb) torque.Tighten nuts to
18 - 20 N•m (13 - 15 ft-lb)
Remove top cover (Item 2) [Figure 70-70-36] for

adjusting the governor connecting rod.
Figure 70-70-39
1 2
3 5
P-85203
Hook the governor connecting rod (Item 1) to the rack pin

(Item 2) and hand tighten the nut (Item 3) [Figure 70-70-
36].
Place service jig (Item 4) (Refer to page 70-70-6) in place

of top cover and make sure the magnet is contacting the
governor connecting rod (Item 1) [Figure 70-70-36].
Holding down the service jig tighten the nut to specified
torque.

Fuel Injection Pump - Timing
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Remove fuel injection high pressure lines.
Remove the fuel shutoff solenoid. (See Fuel Shutoff P-85104

Solenoid Removal And Installation on Page 70-70-1.)
Figure 70-70-40 Rotate the flywheel counterclockwise (viewed from the

flywheel side) until fuel fills up the hole of the delivery
valve holder for the number one cylinder as shown in
[Figure 70-70-41] below.
1
Figure 70-70-42
2
1
P-85102
Align timing mark between the injection pump assembly

and the flywheel housing (Item 1) [Figure 70-70-40].
P-85098
NOTE: Timing the injection pump is done by rotating
the injection pump assembly up for advance,
down for retard. After fuel fills up the hole of the number one cylinder
delivery valve holder (Item 1) [Figure 70-70-42] turn
back the flywheel clockwise 1,6 rad (90 degrees) then
turn counterclockwise to 0,17 rad (10 degrees) before top
dead center.
Slowly turn the flywheel counterclockwise and stop

turning when the fuel begins to come up to get the
present injection timing (Item 2) [Figure 70-70-42].

FUEL SYSTEM (CONT'D)
Injection Pump - Timing (Cont’d)
Figure 70-70-43
P-85103
Check to see the degree marks on the flywheel (Item 1)

[Figure 70-70-43]. The flywheel has a 1TC mark for the
crank angle before the top dead center of cylinder
number one.
NOTE: If the injection pump timing is not within the

specification, then rotate the injection pump
assembly upwards for advancing, downwards
for retarding injection pump timing.
The injection timing is 0,00960 - 0,0357 rad. (0.550 - 2.05

degrees) before T.D.C.

FUEL SYSTEM (CONT'D) Installation: Tighten the injection pipe retaining nuts to
23 - 26 N•m (17 - 26 ft-lb) torque.
Fuel Injector Removal And Installation
Remove the high pressure fuel lines from the engine.
Remove the glow plugs. (See Glow Plugs Removal And

WARNING Installation on Page 70-80-1.)
Remove the cylinder head valve cover (See Cylinder

Head Removal And Installation on Page 70-80-4.)
Figure 70-70-45
not use your bare hand. Wear safety goggles. If fluid 1
W-2072-0807
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289 P-85117
Figure 70-70-44 Remove the overflow pipe (Item 1) [Figure 70-70-45].
Installation: Tighten the overflow pipe assembly

retaining screws to 9,81 - 11,2 N•m (7.24 - 8.31 ft-lb)
1 torque.
Figure 70-70-46
P-85085
The following are some problems caused by faulty

injectors:
-Engine is hard to start or will not start

P-85118
-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke Remove the nozzle holder clamps (Item 1) [Figure 70-
70-46].
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-44] from the fuel injectors and from the injection Installation: Tighten the nozzle holder clamp screws to
pump. 24 - 27 N•m (18 - 20 ft-lb) torque.

FUEL SYSTEM (CONT'D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 70-70-47
MEL4200 - Injector Nozzle Tester
MEL4201 - Injector Nozzle Tester Adapter Set
Figure 70-70-49
1
P-85119
Remove the injector nozzle (Item 1) [Figure 70-70-47]

from the cylinder head.
3EEABAC1P012A
Pull on the injector nozzle to remove the injector nozzle

from the cylinder head. Install the injector nozzle assembly onto the nozzle tester
(MEL 4200).
Figure 70-70-48
Slowly move the tester handle to measure the pressure
at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

specifications, replace or repair the injection nozzle
1 assembly.
2
NOTE: Injection nozzle gasket must be replaced
when the injection nozzle is removed for
checking.
Injection Factory 18,6 - 19,6 MPa

pressure spec. (186,4 -196,1 bar)
(2703 - 2844 psi)
P-37583
[Figure 70-70-48] shows the injector nozzle removed

from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) before installing new or
used injectors. [Figure 70-70-48].

FUEL SYSTEM (CONT'D) Valve Seat Tightness
Nozzle Spray Condition The tool listed will be needed to do the following
procedure:
procedure: MEL 4200 - Injector Nozzle Tester
MEL 4200 - Injector Nozzle Tester Figure 70-70-51
Figure 70-70-50
Correct Incorrect
3EEABAC1P014A
3EEABAC1P013A
Install the injector nozzle assembly onto the nozzle tester
(MEL 4200) and check the nozzle spraying condition.
Set the injection nozzle to a nozzle tester, and check the
nozzle spraying condition. Raise the fuel pressure, and keep at 16,7 MPa (166,7
bar) (2418 psi) for 10 seconds.
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 tightness Factory spec No fuel leak at

16,7 MPa
(166,7 bar)
(2418 psi)

CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-3
Figure 70-80-1 1 2
1 3
2
3
P-85178
P-85178
Disconnect the glow plug nuts (Item 1),remove glow plug
connecting strap (Item 2) and glow plugs (Item 3) [Figure
Disconnect the glow plug nuts (Item 1), remove glow plug 70-80-3].
connecting strap (Item 2) and glow plugs (Item 3) [Figure
70-80-1]. Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque. Figure 70-80-4
Figure 70-80-2
2 1
P-85179
P-85179
NOTE: Adjust the direction of the ditch (Item 1)
[Figure 70-80-4] to the terminal side when the
Touch one probe to the end of the glow plug (Item 1) and seal is installed on the glow plug.
the other probe to the body of glow plug (Item 2) [Figure
70-80-2].
Use an ohmmeter to check the glow plugs.The resistance

should be approximately one ohm.
Repeat the procedure for each glow plug.
NOTE: Adjust the direction of the ditch (Item 3)

[Figure 70-80-2] to the terminal side when the
seal is installed on the glow plug.

CYLINDER HEAD (CONT'D) Valve Clearance Adjustment
Glow Plugs Removal And Installation (Cont’d) Figure 70-80-6
Figure 70-80-5
2
1
3
P-85181
P-48708
Adjust the valve clearance as follows:
Photo [Figure 70-80-5] shows the glow plug removed Loosen the lock nut (Item 1) [Figure 70-80-6].
from the engine. Inspect the glow plugs and replace
when necessary. Turn the adjustment screw (Item 2) [Figure 70-80-6] until
the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and bridge head (Item 3) [Figure
70-80-6].

CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7 3 4
2
4 3 2 1
B 8 7 6 5 4 3 2 1 A
1 P-85974
B-05569
NOTE: (A) is the front cover side, (B) is the flywheel Remove the engine / hydrostatic pump package from the
housing side. loader. (See Engine Removal And Installation on Page
70-10-7.)
Figure 70-80-8
Remove the flywheel. (See Flywheel Removal And
Cylinder Number 1 2 3 4
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
Valve Number 1 2 3 4 5 6 7 8
Make sure timing marks are in correct alignment [Figure
70-80-9].
Valve Injection Pump Gear (Item 1) [Figure 70-80-9].

I=Intake I E I E I E I E
E=Exhaust Idle Gear (Item 2) [Figure 70-80-9].
Crank Gear (Item 3) [Figure 70-80-9].
Cam Gear (Item 4) [Figure 70-80-9].

Adjust the valve clearance cold as follows:
0,13 - 0,17 mm (0.0052 - 0.0068 in) Intake & Exhaust
Use the following sequence to set the valves [Figure 70-

80-7] and [Figure 70-80-8]:
1. With the No. 1 cylinder set at compression top dead

center set valves 1,2,3 and 6.
2. With the No. 1 cylinder at overlap position set valves

4,5,7 and 8.

CYLINDER HEAD (CONT'D) Installation: Tighten overflow pipe to 9,81 - 11,2 N•m (7 -
8 ft-lb) torque.
Cylinder Head Removal And Installation
Figure 70-80-12
Figure 70-80-10
4 2 1
1
3
P-85118
P-85174
Remove the nozzle holder clamps (Item 1) [Figure 70-

Remove the glow plug connecting strap (Item 1), glow 80-12].
plugs (Item 2), and injection pipes (Item 3) [Figure 70-
80-10]. Installation: Tighten the nozzle holder clamp bolts to 24
- 27 N•m (18 - 20 ft-lb) torque.
Remove the valve cover (Item 4) [Figure 70-80-10] and
gasket. Figure 70-80-13
Installation: Gradually tighten the valve cover bolts to

9,81 - 11,2 N•m (7 - 8 ft-lb) torque. Tighten center bolts
first, then work your way to the front and back of the valve
cover.
1
Installation: Tighten injection pipe retaining nuts to 23 -
Installation: Tighten glow plugs to 7,7 - 9,3 N•m (5.7 -

6.8 ft-lb) torque.
Figure 70-80-11
P-85119
1
Remove the nozzle holder assembles and nozzle

gaskets (Item 1) [Figure 70-80-12].
Installation: Tighten the nozzle holder clamp bolts to 24

- 27 N•m (18 - 20 ft-lb) torque.
P-85117
Remove the overflow pipe (Item 1) [Figure 70-80-11].

CYLINDER HEAD (CONT'D) Figure 70-80-16
Cylinder Head Removal And Installation (Cont'd) 1

2
Figure 70-80-14
1 2
P-85170
Remove the thermostat housing bolts and then remove

P-85115 the housing (Item 1), gasket (Item 2) and thermostat
(Item 3) [Figure 70-80-16].
Remove rocker arm assembly (Item 1)[Figure 70-80-14] Figure 70-80-17

as a unit.
Remove push rods (Item 2) and bridge arms (Item 3)

[Figure 70-80-14].
Figure 70-80-15
P-85168
Remove the cylinder head bolts in order of #10 to #1

[Figure 70-80-17].
P-47245 NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Installation: The push rod (Item 1) must be seated in the Installation: Put oil on the bolt threads. Tighten the bolts
tappet (Item 2) [Figure 70-80-15] correctly or the push in the correct sequence in order of #1 - #10 to 187 - 196
rods will be damaged. N•m (138 - 144 ft-lb).
After installing the rocker arm assembly and push rods, NOTE: It is not necessary to retighten the cylinder
the valve lash must be adjusted. (See Valve Clearance head bolts after the engine has been run for 30
Adjustment on Page 70-80-2.) minutes.

Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-18 1
P-47252
Find the average measurement of the highest piston

protrusion and the lowest piston protrusion (recorded
P-85171
earlier) for each piston (Item 1) [Figure 70-80-20].
Figure 70-80-21
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-18].
Figure 70-80-19 a b c
2 B
P-85967
When identifying which head gasket you need [Figure

70-80-21] shows the correct number of notches and how
1 they should look (a) 2 notches, (b) 1 notch and (c) no
notch.
A
P-85968
Figure 70-80-22
Gasket Size
When replacing just the head gasket (Item 1), use a new Piston Protrusion
(Number)
gasket that has the same mark (Item 2) [Figure 70-80-
19] as the original gasket. 2 notches 0,0775 - 0,150 mm
0.00306 - 0.00590 in
When replacing the gasket after an engine rebuild, the 0,150 - 0,250 mm
1 notch
piston protrusion must be measured. 0.00591 - 0.00984 in
no notches 0,2500 - 0,3425 mm
(See Cylinder Head Top Clearance on Page 70-80-8.) 0.009843 - 0.01348 in
NOTE: (A) is the front cover side, (B) is the flywheel Select the correct gasket size (thickness) from the chart
housing side. [Figure 70-80-22].
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.

CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-23 Figure 70-80-25
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-25] on the
spring [Figure 70-80-23]. cylinder head.
Figure 70-80-24 NOTE: Do not put the straight edge across

combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-25] between

the straight edge and the surface of the cylinder head.
Figure 70-80-26
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

Remove the valve spring retainer (Item 3) and the spring

PI-9988
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-23] and [Figure 70-80-24]. and two diagonal as shown in figure [Figure 70-80-26].
The maximum distortion of the head surface is ± 0,05

mm (± 0.002 in). If the measurement exceeds the
specification, replace the cylinder head.

CYLINDER HEAD (CONT'D) If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin.
Cylinder Head Top Clearance
Top Clearance 0,6 - 0,8 mm (0.024 - 0.031 in)
Figure 70-80-27
Valve Guide - Checking
2
Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
70-80-7.)
1
Remove the carbon from the valve guide.
Figure 70-80-29
P-85172
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-27] being checked at T.D.C.
2
Put 4 pieces of 1,5 mm (0.06 in) diameter solder (Item 2)
[Figure 70-80-27] on the top of the piston. Use grease to
hold them in position.
NOTE: Put the solder in position so they do not touch

B-14335
the valves.
Turn the piston to bottom dead center.

Measure the valve stem O.D. (Item 1) [Figure 70-80-29].
Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Cylinder Head Removal Measure the valve guide I.D. (Item 2) [Figure 70-80-29].
Calculate the clearance. If the clearance exceeds the
Turn the crankshaft until the piston exceeds T.D.C. allowable limit, replace the valve and / or valve guide.
Remove the cylinder head.
Figure 70-80-28 Valve Guide I.D. 7,030 - 7,045 mm

(0.2768 - 0.2773 in)
Valve Stem O.D. 6,960 - 6,975 mm
(0.2741 - 0.2746 in)
Clearance Between 0,055 - 0,085 mm
Valve Stem and Guide (0.0022- 0.0033 in)
Allowable Limit 0,10 mm
(0.0039 in)
P-85173
Remove the solder (Item 1) [Figure 70-80-28] and

measure it.

CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide Removal And Installation Figure 70-80-32
Figure 70-80-30
225 mm (8.86”)
20 mm 70 mm (2.8”) 45 mm
(0.79”) (1.8”)
11,7-11,9 mm
(0.461-0.468”) 6,50-6,60 mm
(0.256-0.259”)
5,0 mm 8,50-8,90 mm 20,0 mm
(0.2”) (0.335-0.350”) (0.79”)
6,70-7,00 mm PI-9993
12,5-12,8 mm
(0.264-0.275”) 25,0 mm
(0.98”) (0.493-0.503”)
MC-1364
Grind the valve face to the correct angle using a valve
refacer [Figure 70-80-32].
To remove and replace the valve guide, make the driver
tools as shown in figure [Figure 70-80-30]. Clean the valve seat and combustion chamber.
Figure 70-80-31 Figure 70-80-33
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-31]. recessing with a depth gauge [Figure 70-80-33].
Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-31], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

Reconditioning The Valve And Valve Seat (Cont’d) 1

30° Exhaust
Figure 70-80-34 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-36].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-34].
If the seat surface (b) needs correction, slightly correct
the seat using a 45 degree cutter and then resurface the
Recessing 0,65 - 0,85 mm
seat surface with a 15 degree cutter to get the correct
(0.026 - 0.33 in)
width (Item 2) [Figure 70-80-36].
Allowable Limit (Recessing) 1,20 mm (0.0472 in)
Valve Seat Width
Figure 70-80-35
Intake & Exhaust 3,3 - 3,6 mm
(0.13 - 0.14 in)
Valve Seat And Face Angle
Intake 45 degrees
Exhaust 45 degrees
45° Exhaust
15° Exhaust 45° Intake
15° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-35].

Valve Spring
Figure 70-80-37
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-38].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the
spring [Figure 70-80-37]. Setting Length 31,5 mm (1.24 in)
Setting Load 60,8 N (14.3 lb)
Free Length 35,1 - 35,6 mm (1.39 - 1.40 in)
Allowable Limit 45,9 N (10.3 lb)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-37].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 1,0 mm (0.039 in)

Valve Tappets
Remove the oil pan and oil pump strainer. (See Oil Pan
Remove the idler gear and camshaft. (See Idler Gear

And Camshaft Removal And Installation on Page 70-100-
5.)
1
Figure 70-80-39
1 P-85175
Measure the OD of the tappet (Item 1) [Figure 70-80-41].

tappets.
Tappet OD 9,965 - 9,980mm

(0.3924 - 0.3929 in)
Clearance 0,020 - 0,050 mm
P-85141 Between Tappet (0.00079 - 0.0019 in)
and Tappet
Turn engine with the crankshaft facing up and remove the Bore
valve tappets (Item 1) [Figure 70-80-39]. Allowable limit 0,07 mm (0.003 in)
Figure 70-80-40
P-85142
Measure the ID of the tappet bore (Item 1) [Figure 70-

80-40].
Tappet Bore ID 10,000 -10,015 mm

(0.39370 - 0.39429 in)
Clearance Between 0,020 - 0,050 mm
Tappet (0.00079 - 0.0019 in)
and Tappet Bore

CYLINDER HEAD (CONT'D) Bridge Arm And Bridge Arm Shaft - Checking
Rocker Arm And Shaft - Checking Figure 70-80-43
Figure 70-80-42
1
1
2
P-85177
B-3697
Measure the bridge arm ID (Item 1) [Figure 70-80-43].
Measure the rocker arm I.D. (Item 1) [Figure 70-80-42] If the clearance exceeds the allowable limit, replace the
with an inside micrometer. bridge arm (Item 1) [Figure 70-80-43].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70- Bridge arm ID. 9,050 - 9,065 mm
80-42] with an outside micrometer. (0.3170 - 0.3181 in)
If the clearance exceeds the allowable limit, replace the Figure 70-80-44
bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm

& Shaft 0,016 - 0,045 mm
(0.00063 - 0.0017 in)
(0.0059 in)
Rocker Arm Shaft O.D. 14,973 - 14,984 mm
(0.58949 - 0.58992 in)
Rocker Arm I.D. 15,0 - 15,018 mm
(0.59056 - 0.59125 in) 1
P-85176
Measure the bridge arm shaft OD (Item 1) [Figure 70-80-

44].

bridge arm shaft (item 1) [Figure 70-80-44].
Oil Clearance between 0,018 -0,042 mm

Bridge arm and Bridge (0.0.00071 - 0.0016 in)
arm shaft.
Bridge arm shaft OD. 9,023 - 9,8032 mm
(0.3553- 0.3555 in)

Bridge Arm Shaft - Removal And Installation
Figure 70-80-45
1
P-85972
Remove the used valve bridge arm shaft (Item 1), then
P-85969 clean valve bridge arm shaft mounting hole. Use the
valve bridge arm replacing tool to press in new shaft
[Figure 70-80-46].
Make valve bridge arm shaft replacement tool as shown
above [Figure 70-80-45]. Figure 70-80-47
A 9,50 mm (0.374 in)

1
B 19,0 mm (0.748 in)
2
C 23,2 mm (0.913 in)
D 42,00 - 42,40 mm (1.654 - 1.669 in)
E 12,5 mm dia. (0.492 in dia.) through hole
F 61,0 mm (2.40 in)
G 18,7 mm (0.736 in)
H 30,90 - 31,70 mm (1.217 - 1.248 in)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in) P-85973

Install bridge arm shaft (Item 1) using the valve bridge
shaft replacing tool (Item 2) [Figure 70-80-47] to the
proper depth in [Figure 70-80-48].

CYLINDER HEAD (CONT'D) Push Rod Alignment - Checking
Bridge Arm Shaft - Removal And Installation (Cont’d) Figure 70-80-49
Figure 70-80-48
P-76926
P-85970
Place the push rod on V blocks [Figure 70-80-49].
Set the depth of the bridge arm shaft (Item 1) to 31,1 - Measure the push rod alignment [Figure 70-80-49].
31,7 mm (1.23 - 1.24 in) [Figure 70-80-48].
If the push rod exceeds the allowable limit, replace the
push rod.
Push Rod Allowable Limit 0,25 mm

Alignment (0.0098 in)

CRANKSHAFT AND PISTONS Figure 70-90-3
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

1
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan and oil pump strainer. (See Oil Pan
Figure 70-90-1
P-85143
1 Remove the connecting rod bolts (Item 1) [Figure 70-90-

3].
NOTE: Mark the location of the rod bearings to

prevent them from becoming interchanged.
Installation: Tighten the connecting rod bolts to 69 - 73

Installation: Apply engine oil to the connecting rod bolts

and lightly screw in by hand.
P-85141
Installation: Install the rod bearing with the centrally
lined groove towards the connecting rod, and the non
Figure 70-90-2 grooved side towards the cap.
Top View of Crankcase
Installation: Make sure the marks on the connecting rod
and bearing are aligned and facing the injection pump
when installing the bearing cap.
P-85142
Remove the tappet (Item 1) [Figure 70-90-1] from the

tappet bore (Item 2) using a magnetic tool [Figure 70-90-
2].
Installation: Apply engine oil to the tappet during

installation.
NOTE: Mark the location of the tappets to prevent

them from becoming interchanged.

CRANKSHAFT AND PISTONS (CONT’D) Piston And Connecting Rod - Servicing
Piston And Connecting Rod Removal And Figure 70-90-6

Installation (Cont’d)
1
Figure 70-90-4
P-85145
P-51633 Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2) [Figure 70-
90-6].
Use a hammer handle and push the piston / connecting
rod assembly out of the cylinder bore [Figure 70-90-4]. NOTE: Assemble the piston to the connecting rod
with the mark (Item 2) and the connecting rod
NOTE: Make sure the pistons are marked so they will mark (Item 1) [Figure 70-90-6] facing the
be returned to the same cylinder bore. injection pump side.
Figure 70-90-5
P-85144
Installation: Make sure the marks on the connecting rod

and bearing (Item 1) [Figure 70-90-5] are aligned and
facing the injection pump when installing the bearing cap.
Repeat the procedure to remove the other piston /

connecting rod assemblies from the engine block.

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-8
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-7 2
1 2 3 4 5 6
1
3
7
4 PI-10015
Installation: When installing new rings, assemble the

P-85146 ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
Remove the top ring (Item 1), the second ring (Item 2) 3) [Figure 70-90-8].
and the oil ring (Item 3) [Figure 70-90-7].
Figure 70-90-9
Remove the snap rings (Item 4) and piston pin (Item 7)
[Figure 70-90-7].
Separate the piston (Item 5) from the connecting rod

(Item 6) [Figure 70-90-7].
Installation: Heat the piston in clean engine oil to 80°C

(176°F) and tap the piston pin into position. Place the
piston rings so that there are gaps every 120 degrees
with no gap facing the piston pin in the cylinder.
NOTE: Mark the piston (Item 5) and connecting rod

(Item 6) [Figure 70-90-7] with the same
number to ensure correct installation and
proper cylinder placement. P-47272
Measure the I.D. of the piston pin bore in both horizontal

and vertical directions [Figure 70-90-9].
If the measurement exceeds the allowable limit, replace

the piston.
Piston Bore I.D. 28,0 - 28,013 mm

(1.1024 - 1.1028 in)
(1.104 in)

Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-10
B-3622
Install a piston ring into the lower part of the cylinder

P-47273 bore. Measure the ring gap with a feeler gauge [Figure
70-90-11].
Measure the O.D. of the piston pin (Item 1) [Figure 70- If the gap exceeds the allowable limit, replace the ring.
90-10].
Top Ring Gap 0,25 - 0,40 mm
Measure the I.D. of the connecting rod small end bushing (0.0099 - 0.015 in)
(Item 2) [Figure 70-90-10].
Oil Ring Gap 0,25 - 0,45 mm
(0.0099 - 0.017 in)
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the connecting rod. If it still Allowable Limit 1,25 mm
exceeds the specifications, replace the piston pin. (0.0492 in)
Second Ring Gap 0,30 - 0,45 mm
Piston Pin O.D. 28,006 - 28,011 mm (0.012 - 0.017 in)
(1.1026 - 1.1027 in)
Bushing I.D. 28,031 - 28,046 mm
(1.1036 - 1.1041 in)
Oil Clearance Between 0,020 - 0,040 mm
Piston Pin & Bushing (0.00079 - 0.0015 in)
(0.0059 in)

CRANKSHAFT AND PISTONS (CONT’D) Cylinder Bore - Checking
Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-13
Figure 70-90-12
B-4066
PI-10017
Use a gauge to check the inside measurement of the
cylinder bore [Figure 70-90-13].
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler Figure 70-90-14
gauge [Figure 70-90-12].

ring. If the clearance still exceeds the allowable limit,
replace the piston.
Top Ring 0,050 - 0,090 mm

(0.0020 - 0.0035 in)
Second Ring 0,090 - 0,12 mm
(0.0036 - 0.0047 in)
Oil Ring 0,020 - 0,060 mm
(0.0079 - 0.0023 in) P-37163
Measure the six points as shown in figure [Figure 70-90-

14] to find the maximum wear.
The factory specifications are:
94 - 94,022 mm (3.7008 - 3.7016 in).
The allowable limit is 94,15 mm (3.707 in).
If the cylinder bore is not within specifications, bore and

hone to oversize dimension.

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft Gear Removal And Installation
Connecting Rod Alignment Remove the crankshaft. (See Crankshaft And Bearings
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before Figure 70-90-16
doing this check.
Install the piston pin into the connecting rod. 3
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate. 1
2
Figure 70-90-15 4
2
P-85149
Remove the crankshaft sleeve (Item 1), the crankshaft

gears (Item 2), the seal (Item 3) and the key (Item 4)
[Figure 70-90-16].
Installation: Install a new seal (Item 3) when servicing

[Figure 70-90-16].
B-4067 Figure 70-90-17
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-15].
If the measurement exceeds the allowable limit, replace

the connecting rod.
Rod Alignment 0,05 mm (0.002 in)
1
2
3
P-85148
Installation: Heat the crankshaft sleeve (Item 1) [Figure

70-90-16] and [Figure 70-90-17] to 150 - 200°C (302 -
392°F). Install the crankshaft sleeve onto the crankshaft
using the crankshaft sleeve guide (Item 2) and the
crankshaft replacing tool (Item 3) MEL 1660 [Figure 70-
90-17].
Installation: Install the crankshaft sleeve (Item 1) with

the chamfered surface facing outward [Figure 70-90-17].

Crankshaft Gear Removal And Installation (Cont’D)
Figure 70-90-18
2
0,850 - 1,15 mm (0.0335 - 0.0452 in)
2
1 3
P-85153
Remove crankcase 2 (Item 2) from crankcase 1 (Item 1)

P-85150 [Figure 70-90-20].
Remove the crankshaft (Item 3) [Figure 70-90-20].

Installation: When installing the crankshaft sleeve
(Item 1) allow for a space (Item 2) [Figure 70-90-18] from Figure 70-90-21
the end of the crankshaft to the edge of the crankshaft
sleeve.
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 70-90-19
P-85995
This tool is used for aligning the crankcase 1 and

crankcase 2. Make two of these tools.
A 126,6 mm (4.984 in)

B 49,1 mm (1.93 in)
C 37,5 mm (1.48 in)
D 20 mm (0.79 in)
P-85151 E 14 mm dia. (0.55 in dia.)
F 14 mm dia. (0.55 in dia.)
G 14 mm dia. (0.55 in dia.)
Remove the crankcase mounting screws in order from Z
H 17,5 mm (0.689 in)
to A [Figure 70-90-19].
I 17,5 mm (0.689 in)
J 35 mm (1.4 in)
Installation: Tighten the crankcase mounting bolts from
K 19 mm (0.75 in)
A to J to 138 - 147 N•m (102 - 108 ft-lb)
Installation: Tighten the crankcase mounting bolts from Material (Item 1) [Figure 70-90-21]: SS400
K to Z to 59 - 63 N•m (44 - 47 ft-lb).

Crankshaft And Bearings Removal And Installation

(Cont’d)
1
Figure 70-90-22
P-85156
Apply oil to the thrust bearings and install the crankshaft

1 (Item 1) [Figure 70-90-24].
P-85157
Figure 70-90-25
NOTE: Make sure both crankcases are clean and dry

before assembling. 3
Install the bearings (Item 1) into the crankcase 2 (Item 2)

[Figure 70-90-22].
2
Install the thrust bearings (Item 3) [Figure 70-90-22] with
the groove facing out.
1
Figure 70-90-23
1 4
P-85996
2
Align and install crankcase 2 (Item 2) to crankcase 1
(Item 1) [Figure 70-90-25].
Apply engine oil to the crankcase mounting bolts and

hand tighten from A to J and then K to Z [Figure 70-90-
19].
3
Install the jig (Item 3) [Figure 70-90-25] and tighten to 78
- 90 N•m (58 - 66 ft-lb)
P-85155
NOTE: The jig helps to minimize the level difference
between the crankcase 1 and crankcase 2 at
Install the bearings (Item 2) into the crankcase 1 (Item 1) the flywheel side. The gap must be 0,05 mm
[Figure 70-90-23]. (0.002 in) or smaller.
Install the thrust bearings (Item 3) [Figure 70-90-23] with Tighten the crankcase mounting bolts from A to J to 138 -
the groove facing out. 147 N•m (102 - 108 ft-lb)
Tighten the crankcase mounting bolts from K to Z to 59 -

Carefully apply liquid gasket evenly (Item 4) to the 63 N•m (44 - 47 ft-lb).
crankcase 1 (Item 1) [Figure 70-90-23].
Remove the jig (Item 3) [Figure 70-90-25].

CRANKSHAFT AND PISTONS (CONT’D) Turn the crankshaft at a slow rate to obtain the
misalignment (one half of the alignment measurement).
Crankshaft And Bearings - Servicing
If the misalignment exceeds the allowable limit, replace
Figure 70-90-26 the crankshaft.
Alignment 0,02 mm (0.0008 in)
Figure 70-90-28
1
2
P-85159
3
1
Set a dial indicator with its tip on the end of the
crankshaft (Item 1) [Figure 70-90-26].
P-85160
Measure the side clearance by moving the crankshaft

side to side (Item 2) [Figure 70-90-26]. Place plastigage on the crankshaft (Item 3) [Figure 70-
90-28].
If the misalignment exceeds the allowable limit, replace
the crankshaft. Place crankcase 2 (Item 2) on crankcase 1 (Item 1)
[Figure 70-90-28] and torque the bolts.
Side clearance of Factory Spec. 0,15 - 0,35 mm
crankshaft (0.0059 - 0.013 in) Torque the bolts A to Z [Figure 70-90-19]. (See
Allowable limit 0,50 mm Crankshaft And Bearings Removal And Installation on
(0.020 in) Page 70-90-7.)
Figure 70-90-27 Remove crankcase 2 (Item 2) [Figure 70-90-28] and

measure the amount of the flattening with the scale to
determine the oil clearance.
Crankshaft Factory Spec. 79,977 - 79,990 mm

Journal O.D. (3.1487 - 31.1492 in)
Oil clearance Factory Spec. 0,030 - 0,073 mm
between (0.0012 - 0.0028 in)
crankshaft journal Allowable limit 0,20 mm (0.079 in)
and crankshaft
bearing
A-2763
Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 70-90-27].

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-29
P-37145
Clean the crank pin and crank pin bearing.

P-85161
Put a strip of plastigage [Figure 70-90-30] on the center
of the crank pin.
Reference of undersize dimensions of crankshaft journal
[Figure 70-90-29]. NOTE: Never insert the plastigage into the crank pin
oil hole. Be sure not to move the crankshaft
Undersize 0,2 mm 0,4 mm while the connecting rod screws are
(0.0079 in) (0.016 in) tightened.
Dimension A 2,8 - 3,2 mm 2,8 - 3,2 mm
radius radius Install the connecting rod cap and tighten the connecting
(0.11 - 0.12 in (0.11 - 0.12 in rod screws to the specified torque, and remove the cap
radius) radius) again.
*Dimension 1,0 - 1,5 mm relief 1,0 - 1,5 mm Measure the amount of the flattening with the scale, and
B (0.040 - 0.059 in relief get the oil clearance.
relief) (0.040 - 0.059 in
relief) If the oil clearance exceeds the allowable limit, replace
Dimension C 79,777 - 79,790 79,577 - 79,590 the crank pin bearing.
mm dia. mm dia.
(3.1409 - 3.1413 (3.1330 -3.1334 If the same size bearing cannot be used because of the
in dia.) in dia.) crank pin wear, replace it with an undersized one
referring to the table.
The crankshaft journal must be fine-finished to higher
than ————(0.8-S) Crankpin Factory spec. 49,980 - 49,991 mm
*Holes are to be de-burred and edges rounded with O.D. (1.9678 - 1.9681 in)
relief
1,0 - 1,5 mm (0.040 - 0.059 in) Oil clearance Factory spec. 0,011 - 0,058 mm
between (0.00067 - 0.0018 in)
crank pin and Allowable 0,20 mm (0.0079 in)
crank pin limit
bearing

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-31
P-85162
2
Undersize dimensions of crankpin.
P-37147
Undersize 0,20 mm 0,40 mm
(0.0079 in) (0.016 in)
NOTE: To replace it with a specific STD service part,
make sure the crank pin bearing has the same Dimension A 3,3 - 3,7 mm radius 3,3 - 3,7 mm
ID color as the connecting rod [Figure 70-90- (0.13 - 0.14 in radius
31]. radius) (0.13 - 0.14 in
radius)
ID Connecting rod Crank pin bearing *Dimension B 1,0 - 1,5 mm relief 1,0 - 1,5 mm
Color (0.040 - 0.059 in relief
Large-end inch Class Center wall thick
relief) (0.040 - 0.059 in
dia.
relief)
Blue 53,010 - 53,010 L 1,496 - 1,501
Dimension C 49,780 - 49,791 49,580 - 49,591
mm mm
mm dia. mm dia.
(2.0870 - 2.0874 (0.05890 -
(1.9599 - 1.9602 in (1.9520 - 1.9524
in) 0.05909 in)
dia.) in dia.)
witho 53,000 - 53,010 S 1,491 - 1,496
(0.8-S)
ut mm mm
The crank pin must be fine-finished to higher than ———
Color (2.0867 - 2.0870 (0.05870 -
—
in) 0.05889 in)
*Holes to be de-burred and edges rounded with relief.
1,0 -1,5 mm (0.040 - 0.059 in)

CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal
Remove the flywheel. (See Flywheel Removal And

Remove the housing. (See Housing Removal And

Figure 70-100-1
2
1
P-90121
Remove the eight outside timing gearcase cover

mounting bolts (Item 1) [Figure 70-100-1].
Remove the eight inside timing gearcase cover mounting

bolts (Item 2) [Figure 70-100-1].
Remove the timing gearcase cover (Item 3) [Figure 70-

100-1].

CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation
Figure 70-100-2
P-90004A
A 70,0 mm (2.76 in)

B 8,0 mm (0.31 in)
C 22,0 mm (0.866 in)
D 30,0 mm (1.18 in)
E 87,0 mm dia.
(3.43 in dia.)
F 82,036 - 82,071 mm dia.
(3.2298 - 3.2311 in dia.)
G 77,0 mm dia.
(3.03 in dia.)
H 57,0 mm dia. (2.24 in dia.)
I 35,0 mm dia. (1.38 in dia.)
J 30,0 mm dia. (1.18 in dia.)
K 84,0 mm (3.31 in)
L 3,5 mm (0.14 in)
M 3,0 mm (0.12 in)
N 6,60 - 6,80 mm (0.260 - 0.267 in)
O 8,0 mm (0.31 in)
P 67,0 mm dia. (2.64 in dia.)
Q 4,0 mm dia. (0.16 in) through hole
a Ra = 1.6 a
c Ra = 3.2 a
d 0,80 mm radius (0.031 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
C1.0 Chamfer 1,0 mm (0.039 in)
Make timing gearcase cover guide tool [Figure 70-100-

2].

CAMSHAFT AND TIMING GEARS (CONT’D) b Ra = 1.6 a
Timing Gearcase Cover Installation (Cont’d) c 0,80 mm radius (0.031 in radius)
d 1,5 mm radius (0.059 in radius)
Figure 70-100-3
e 0,20 mm radius (0.0079 in radius)
C0.3 Chamfer 0,30 mm (0.012 in)
Make timing gearcase oil seal replacing tool [Figure 70-

100-3].
Figure 70-100-4
P-85218
P-90006
Make timing gearcase guide screws as shown above

A 118 mm (4.65 in) [Figure 70-100-4].
B 12,0 mm (0.472 in)
Figure 70-100-5
C 0,90 - 1,0 mm (0.36 - 0.039 in)
D 10,0,0 mm (0.394 in)
E 80,0 mm (3.15 in) 2
F 10,0,0 mm (0.394 in)
G 120 mm dia. 1
(4.72 in dia.)
H 100,90 - 101,10 mm dia.
(3.9725 - 3.9803 in dia.)
I 86,966 - 86,988 mm dia.
(3.4239 - 3.4247 in dia.)
J 79,0 mm dia. (3.11 in dia.) 3
K 15,0 mm dia. (0.591 in dia.) P-85999
L 30,0 mm dia. (1.18 in dia.)
M 13,0 mm (0.512 in) Apply engine oil to the timing gearcase oil seal (Item 1)
[Figure 70-100-5].
N 90,00 mm (3.54 in)
O 2,50 mm (0.0984 in) Install timing gearcase guide screws (Item 2) [Figure 70-
100-5].
P 0,35 rad (20 degrees)
Q 0,15 - 0,25 mm (0.0059 - 0.0098 in) Install timing gearcase using the guide (Item 3) [Figure
70-100-5].
a Ra = 3.2 a

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-8
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-6
P-85997B
1
Tighten the seven outside timing gearcase cover
P-85998 mounting bolts (Item 1) [Figure 70-100-8].
Tighten the six inside timing gearcase cover mounting

Apply a liquid gasket (Three Bond 1217H) (Item 1) bolts (Item 2) [Figure 70-100-8].
[Figure 70-100-6] to the two crankcase seams.
Installation: Tighten the timing gearcase cover bolts to
Figure 70-100-7 103 - 117N•m (76 - 86 ft-lb) [Figure 70-100-8].
P-85217
Install timing gearcase oil seal using the timing gearcase

oil seal replacing tool (Item 1) [Figure 70-100-7].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
When the gears are installed, check the backlash of the
gears. Remove the valve tappets. (See Valve Tappets on Page
70-80-12.)
Figure 70-100-9
Figure 70-100-10
1 2 3
1
2
4
P-85205
P-90008
Install a dial indicator to individually check backlash for

cam gear (Item 1), idle gear (Item 2), injection pump gear Rotate entire engine with the crankshaft (Item 1) [Figure
(Item 3) and crank gear (Item 4) [Figure 70-100-9]. 70-100-10] facing up to remove the tappets
Hold one gear while turning the other gear [Figure 70- Remove the three camshaft set bolts (Item 2) and
100-9]. remove the cam (Item 3) [Figure 70-100-10].
If the backlash exceeds the allowable limit, check the oil Remove the idle gear mounting bolts (Item 4) and
clearance of the shaft and gear. If the oil clearance is remove idle gear (Item 5) [Figure 70-100-10].
correct, replace the gear.
Installation: Make sure the timing marks are in correct
Crank Gear & Cam Gear 0,0410 - 0,139 mm alignment when installing the timing gears.
(0.00162 - 0.00547 in)
(0.0087 in)
Cam Gear & Idler Gear 0,0410 - 0,134 mm
(0.00162 - 0.00527 in)
(0.0087 in)
Injection Pump Gear & Idler 0,0410 - 0,134 mm
Gear (0.00162 - 0.00527 in)
(0.0087 in)

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-13
Camshaft - Servicing
Figure 70-100-11
1 2
1
P-85212
2
Measure the camshaft journal (Item 1) and journal (Item

P-85209 2) [Figure 70-100-13].
Calculate the oil clearance. If the clearance exceeds the

Mount a dial indicator and check cam gear (Item 1) end allowable limit, replace the camshaft.
play (Item 2) [Figure 70-100-11].
Cylinder Block Bore 1 35,000 - 35,025 mm
Installation: Check the camshaft end play. If clearance I.D. (1.3780 - 1.3789 in)
exceeds the allowable limit, replace the camshaft retainer
Cylinder Block Bore 2 44,000 - 44,025 mm
plate [Figure 70-100-11].
I.D. (1.7323 - 1.7332 in)
Camshaft Journal 1 O.D. 34,934 - 34,950 mm
Camshaft End Play 0,10 mm (0.0039 in)
(1.3754 - 1.3759 in)
Allowable Limit
Camshaft Journal 2 O.D. 43,934 - 43,950 mm
Figure 70-100-12 (1.7297 - 1.7303 in)
Oil Clearance of Cam- 0,050 - 0,091 mm
shaft Journal (0.0020 - 0.0035 in)
(0.0059 in)
P-47263
Measure the cylinder block bore in the engine block

[Figure 70-100-12].

CAMSHAFT AND TIMING GEARS (CONT’D) Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Camshaft - Servicing (Cont’d)
Camshaft Alignment Allowable Limit 0,01 mm
Figure 70-100-14 (0.0004 in)
2 Idler Gear And Shaft - Servicing

1
Figure 70-100-16
P-85214
2
Measure the cam lobes at their highest point (Item 2)
[Figure 70-100-14].
P-85207
If the measurement is less than the allowable limit,

replace the camshaft (Item 1) [Figure 70-100-14]. Mount a dial indicator and check idle gear (Item 1) end
play (Item 2) [Figure 70-100-16].
Cam Lobe Height Intake 37,50 mm (1.476 in)
Cam Lobe Height Exhaust 37,90 mm (1.492 in) Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
Allowable Limit Intake 37,00 mm (1.457 in)
collar.
Allowable Limit Exhaust 37,40 mm (1.472 in)
Idler Gear End Play 0,15 - 0,25 mm
Figure 70-100-15 (0.0059 - 0.0098 in)
1
P-85213
Put the camshaft (Item 1) in V-blocks. Install a dial

indicator [Figure 70-100-15].

CAMSHAFT AND TIMING GEARS (CONT’D) Make this idle gear bushing replacing tool as shown
above [Figure 70-100-18].
Idler Gear And Shaft - Servicing (Cont’d)
A 196 mm (7.72 in)
Figure 70-100-17
B 25,00 mm (0.984 in)
C 150 mm (5.91 in)
D 34,5 mm dia. (1.36 in dia.)
E 38,075 - 38,100 mm dia. (1.4991 - 1.5000 in dia.)
F 20 mm dia. (0.79 in dia.)
1 2 a 0,0063 mm (0.000248 in)
b 0,0063 mm (0.000248 in)
Figure 70-100-19
1 2
P-85208
Measure idle gear bushing ID (Item 1) and idle gear shaft

OD (Item 2) [Figure 70-100-17].
Idler Gear Shaft O.D. 34,959 - 34,975 mm

(1.3764 - 1.3769 in)
Idler Gear Bushing I.D. 35,025 - 35,050 mm
(1.3790 - 1.3799 in)
Oil Clearance Between 0,050 - 0,091 mm
Idler Shaft & Gear Bushing (0.0020 - 0.0035 in)
P-85210
(0.0039 in)
When removing idle gear bushing, press out bushing as
Installation: If the oil clearance exceeds the allowable shown above (item 1) [Figure 70-100-19].
limit, replace the idle gear bushing.
When replacing idle gear bushing, press in bushing as
Figure 70-100-18 shown above (item 2) [Figure 70-100-19].
P-85211

TURBOCHARGER Testing
Description Remove the turbocharger. (See Removal And Installation

on Page 70-110-2.)
Figure 70-110-1
Radial Clearance
Figure 70-110-2
1
1
P-85976
The turbocharger is placed between the exhaust and

P-76099
intake manifolds. It is driven by hot exhaust gases and
supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The Move the compressor / turbine wheel (up and down / right
location of the turbo is between the engine and the and left) (Item 1) [Figure 70-110-2].
blower housing.
If the wheel contacts the housing, replace the
The oil flows to the turbo by a tubeline (Item 1) and turbocharger assembly with a new one.
returns to the engine block through another tubeline
(Item 2) [Figure 70-110-1]. Check the oil tubelines for leaks.
The turbocharger internal components are not

serviceable.

TURBOCHARGER (CONT’D) Figure 70-110-4
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects 1
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Remove the muffler. (See Removal And Installation on P-85978

Page 70-30-1.)
Remove the air cleaner. (See Housing Removal And Remove the two exhaust manifold cover bolts (Item 1)
Installation on Page 70-40-1.) [Figure 70-110-4].
Figure 70-110-3 Figure 70-110-5
1
1
1
P-85975 P-85979
Disconnect the two oil pipes (Item 1) [Figure 70-110-3]. Remove the eight exhaust manifold bolts (Item 1) [Figure
70-110-4].
Installation: Tighten the two tubelines (Item 1) [Figure
70-110-3] to 16 - 19 N•m (12 - 14 ft-lb) torque. Installation: Tighten the eight bolts (Item 1) [Figure 70-
110-3] to 24 - 27 N•m (17.7 - 19.9 ft-lb) torque.

TURBOCHARGER (CONT’D)
Figure 70-110-6
P-85127
Remove the turbocharger assembly (Item 1) [Figure 70-

110-6].
Installation: During installation replace all gaskets with

new ones.

FLYWHEEL AND HOUSING Make flywheel stop tool as shown above in [Figure 70-
120-2].
Flywheel Removal And Installation
A 144 mm (5.67 in)
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page B 104 mm (4.09 in)
70-10-7.) C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
Remove the drive belt shield. (See DRIVE BELT on Page
30-50-1.) E 12,0 mm dia. (0.472 in dia.)
F 16,0 mm dia. (0.630 in dia.)
Remove the drive belt tension pulley. (See Tensioner G 16,0 mm dia. (0.630 in dia.)
Pulley Removal And Installation on Page 30-50-4.)
H 32,0 mm (1.26 in)
Remove the drive belt. (See DRIVE BELT on Page 30- I 16,0 mm (0.630 in)
50-1.)
Figure 70-120-3
Figure 70-120-1
1 2
P-85218
P-85138
Make flywheel guide bolts as shown above to aid in

Remove the six mounting bolts (Item 1) from the pulley removal and installation of flywheel [Figure 70-120-3].
(Item 2) [Figure 70-120-1].
Remove the pulley (Item 2) [Figure 70-120-1].
Figure 70-120-2
P-85215

FLYWHEEL AND HOUSING (CONT’D) Figure 70-120-5
Flywheel Removal And Installation (Cont’d)
Figure 70-120-4
P-85140A
Install two bolts (Item 1) [Figure 70-120-5] into the

P-85074 threaded holes on the flywheel and tighten to remove
flywheel.
Install flywheel stop tool (Item 1) [Figure 70-120-4]. Figure 70-120-6
Remove two flywheel bolts and replace them with the

flywheel guides bolts to aid in removal (Item 1) [Figure
70-120-3].
Remove the seven mounting bolts (Item 2)[Figure 70- 1

120-4] from the flywheel.
Installation: Apply engine oil to the bolts and tighten to

98,1 - 107 N•m (72.4 - 79.5 ft-lb) torque.
NOTE: Do not use a impact wrench. Serious damage

will occur. There is one positioning pin in the
crankshaft gear and it is installed in the
flywheel. P-85140
Install two guide bolts (Item 1) [Figure 70-120-6] to aid in

installation of the flywheel.

FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation
Ring Gear Removal And Installation Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
Figure 70-120-7 70-10-7.)
Remove the drive belt shield. (See DRIVE BELT on Page

30-50-1.)
Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-50-4.)
Remove the drive belt. (See DRIVE BELT on Page 30-

50-1.)
Remove the starter. (See Removal And Installation on

Page 60-40-1.)
1 Remove the flywheel. (See Flywheel Removal And

P-48850 Installation on Page 70-120-1.)
Figure 70-120-8
The ring gear (Item 1) [Figure 70-120-7] on the flywheel
is an interference fit. Heat the ring gear enough to
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. 1
Clean the new ring gear and heat it to a temperature of 2

232 - 260°C (450 - 500°F)
1
Fit the ring on the flywheel and be sure the gear is seated
correctly.
P-85137
Remove the four mounting bolts (Item 1) and the housing

(Item 2) [Figure 70-120-8].


EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
3
12
11
1
7 5
13
2
7
9
15
10
9
14
P-85105
The items listed below refer to Page 70-130-1 [Figure

70-130-1].
1. Thermo Valve 9. Cooled EGR Gas

2. Mechanical EGR Valve 10. To The Intake Manifold
3. Cylinder Head 11. Fresh Air
4. Reed Valve 12. Cooled EGR Gas Merges With Fresh Air
5. EGR Cooler 13. Exhaust Gas
6. Intake Manifold 14. Coolant Inlet
7. Boost Pressure 15. Coolant Outlet
8. Coolant Temperature

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Cold Engine Coolant Temperature Test
(CONT'D)
Start the engine and run at low idle.
Testing
Start Service Analyzer and select [Monitor].
There are two tests for checking the EGR system. Both
tests will need to be performed and the coolant Select [Engine Temperature].
temperature must be monitored through the Service
Analyzer.
The Cold Engine Coolant Temperature Test will need to

WARNING
be performed with the engine coolant below 55°C
(131°F). The Hot Engine Coolant Temperature Test will AVOID BURNS
need to be performed with the engine coolant above Some surfaces of the Exhaust Gas Recirculation
70°C (158°F). system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing.

WARNING W-2716-0208
AVOID INJURY OR DEATH NOTE: Verify the engine temperature is below 55°C
When the engine is running during service, the (131°F). If the engine temperature is above
steering levers or joysticks must be in neutral and 55°C (131°F), let the engine cool down and
the parking brake engaged. restart the Cold Engine Coolant temperature
W-2717-0208 Test.
NOTE: Monitor the engine coolant temperature using

the Service Analyzer.
MACHINE FALLING OR MOVING CAN CAUSE

Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
1
1.)
Open the rear door.
Connect the Service PC (See SERVICE PC (LAPTOP

COMPUTER) on Page 60-150-1.)
P-85108
Measure the surface temperature of the EGR system

WARNING (Item 1) [Figure 70-130-2] with an Infrared
Thermometer.
When an engine is running in an enclosed area, fresh If the engine coolant temperature is below 55°C (131°F)
air must be added to avoid concentration of exhaust and the surface temperature of the EGR system is 150°C
fumes. If the engine is stationary, vent the exhaust (302°F) or below, the EGR system is OK, Continue with
outside. Exhaust fumes contain odorless, invisible the Hot Engine Coolant temperature Test.
gases which can kill without warning. If the surface temperature of the EGR system reads
W-2050-0807 150°C (302°F) or above continue this Cold Engine
Coolant Temperature Test.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-130-5
(CONT'D)
Testing (Cont’d)
Figure 70-130-3
P-85108

(Item 1) [Figure 70-130-5] with an Infrared
P-85984 Thermometer.
With the engine coolant temperature above 70°C (158°F)

Disconnect the boost hose (Item 1) [Figure 70-130-3] and the surface temperature of the EGR system 150°C
from the EGR valve. (302°F) or above, the EGR system is OK.
Figure 70-130-4 If the surface temperature of the EGR system is 150°C

(302°F) or below continue this Hot Engine Coolant
Temperature Test.
Figure 70-130-6
P-85108

Thermometer. P-85980
If the surface temperature of the EGR system declines,

the thermo valve has failed. Disconnect the intake hose (Item 1) [Figure 70-130-6].
If the surface temperature of the EGR system stays

above 150°C (302°F), the EGR valve has failed.
Hot Engine Coolant Temperature Test
Verify the engine temperature is above 70°C (158°F), if

the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
continue with the Hot Engine Coolant Temperature Test.

(CONT'D)
Testing (Cont’d)
Figure 70-130-7
P-85108

P-85984 Thermometer.
If the surface temperature of the EGR system increases,

Disconnect the EGR hose (Item 1) [Figure 70-130-6]. the thermo valve has failed.
Figure 70-130-8 If the surface temperature of the EGR system is 150°C

(302°F) or below, the EGR valve has failed.
1
2
P-85981
Connect a hose (Item 1) directly between the intake

manifold (Item 2) and the EGR valve (Item 3) [Figure 70-
130-8].

(CONT'D)
1 1
2
1
WARNING
4
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting 3
diagnostic tests.
1
Allow the engine to cool before servicing.
W-2716-0208 P-85110
Allow the engine to cool before working on the EGR Remove the four EGR cooler mounting bolts (Item 1) and
system. the EGR system assembly (Item 2) [Figure 70-130-11].
Figure 70-130-10 Installation: Replace the gaskets (Items 3 and 4)

[Figure 70-130-11] with new ones.
Figure 70-130-12
1
3
P-85982
2
Disconnect and cap the EGR valve coolant hoses (Item
P-85113
1) [Figure 70-130-10].
Disconnect the boost pressure hose (Item 2) [Figure 70- NOTE: The gasket (Item 3) [Figure 70-130-11] and
130-10]. [Figure 70-130-12] is marked with the letter
“F” and must be installed downward.

(CONT'D)
Disassembly And Assembly 4
Figure 70-130-13 3
6
4
8 5
4
2
1 7
6 1
5 P-85111
3
2
4 Remove the two mounting bolts (Item 1) from the EGR
valve (Item 2) and EGR valve flange (Item 6) [Figure 70-
P-85112 130-14].
Remove the two mounting bolts (Item 3) from the reed

Remove the two mounting bolts (Item 1) from the EGR valve (Item 5) [Figure 70-130-14].
cooler flange (Item 2) [Figure 70-130-13].
Remove and replace the gaskets (Item 4) [Figure 70-
Remove and replace the gasket (Item 3) [Figure 70-130- 130-14].
13].
Installation: When reassembling replace with new
Remove the four bolts (Item 4) from the EGR cooler (Item gaskets.
5) and the EGR valve (Item 7) [Figure 70-130-13].
Remove and replace the gasket (Item 6) [Figure 70-130-

13].
Remove the thermo valve (Item 8) [Figure 70-130-13].
Installation: When reassembling replace with new

gaskets.
NOTE: If the thermo valve is dropped it must be

replaced with a new one.
Installation: Tighten the thermo valve to 30 - 39 N•m (22

- 28 ft-lb) torque.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-4
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-7
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Compressor Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-12
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-19
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schraeder® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1


AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-3.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-3.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-3.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-3.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-3.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-3.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Dessicant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas

b-16691

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
1
Figure 80-10-1
2
P-89545
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P-89538 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3,7 MPa (36,9
P-85824 bar) (535 psi).
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
Figure 80-10-5 4
3
1 2
P-90420A
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-92602 10-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat and A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-7] is used to push air through the heater and
evaporator coils and into the cab.
P-92659
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

Components (Cont'd)
Figure 80-10-8
1
1
2
3
4 P-89545
Pressure Switch: The pressure switch (Item 1) [Figure

P-92638 80-10-10] will disengage the compressor clutch at high
pressure readings over 2,6 MPa (26,5 bar) (384 psi) on
the high side, or at very low pressure of 193,1 kPa (1,9
Control Panel: The panel (Item 1) [Figure 80-10-8] has bar) (28 psi) or less on the high side, which indicates loss
three separate components. of refrigerant.
Fan Switch: This is a four position rotary switch (Item 2)

[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-9
P-90353
Heater Valve: The heater valve (Item 1) [Figure 80-10-9]

is used to control the amount of engine coolant that flows
to the heater coil.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment WARNING

Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-12
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
P16399
equipment, knowledge, and experience to service
refrigeration equipment.
In servicing A/C and heater systems you will be exposed W-2373-0611
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Recirculation Filter (Earlier Models)
Filters Figure 80-20-2
Fresh Air Filters
Figure 80-20-1 1
3
2
P-90490A
2
1
The recirculation filter is located behind the operator’s
seat inside the operator cab. Flip the clamps (Item 1)
holding the filter up and remove the filter (Item 2) [Figure
P-90489A P-90492A 80-20-2].
Shake the filter or use a vacuum to clean. This can be

The fresh air filters are located behind the side windows done several times before replacement is required.
outside the operator cab. (Right side shown) Remove the
clamping knob (Item 1) and filter cover (Item 2) [Figure Install the filter into the opening and flip the clamps down
80-20-1]. to hold the filter in place.
Shake the filter (Item 3) [Figure 80-20-1] or use low Recirculation Filter (Later Models)
pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter, Figure 80-20-3
filter cover and clamping knob.
1
P100755
The recirculation filter is located behind the operator’s

seat inside the operator cab. The filter cover is held in
place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-3] to remove.
Rinse the filter elements with water or use a vacuum to

clean. Do not use solvents.
Line up the clips on the filter cover with the slots provided
and push the cover into place.

REGULAR MAINTENANCE (CONT’D) Figure 80-20-5
Compressor Drive Belt Adjustment
The air conditioning belt is a special maintenance free

type that is pretensioned over the pulleys. This belt
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts.
Compressor Drive Belt Replacement

1
Figure 80-20-4
P-85993
Use a prybar at the two leverage points (Item 1) [Figure

1 80-20-5] to move the air conditioning pump until the
bottom air conditioning pump mounting bolt (Item 2)
[Figure 80-20-4] can be installed.
Tighten the three mounting bolts (Items 1 and 2) [Figure

80-20-4].
2 Close the rear door.
Condenser
P-85942A
The condenser should be cleaned with the oil cooler and
the radiator.
NOTE: The engine is shown removed for visual
clarity. Air Conditioning Lubrication
Loosen the top air conditioning pump mounting bolts Run the air conditioning for about five minutes every
(Item 1) [Figure 80-20-4]. week to lubricate the internal components.
Remove the bottom air conditioning pump mounting bolt

(Item 2) [Figure 80-20-4].
Move the air conditioning pump toward the engine as far

as it will go and remove the belt from the pulleys.
Inspect the pulleys for wear.
Install new belt.

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

REGULAR MAINTENANCE (CONT’D) Later Models
Evaporator / Heater Coil Raise the operator cab. (See Raising on Page 10-30-2.)
Earlier Models Figure 80-20-8
Figure 80-20-6
P100756
Unhook cover latches (Item 1) [Figure 80-20-8] and

P-90419A remove the cover.
Figure 80-20-9
Remove cover screws (Item 1) [Figure 80-20-6] and
remove the cover.
Figure 80-20-7 1
P100757
2
Use low pressure air or water to remove debris from the

P-90420A heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-9].
Use low pressure air or water to remove debris from the Install the cover and lower the operator cab. (See
heater coil (Item 1) and evaporator (Item 2) [Figure 80- Lowering on Page 10-30-3.)
20-7].
Install the cover and lower the operator cab. (See

Lowering on Page 10-30-3.)

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly Repair or adjust.
connected and seals are not damaged.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation / thermostat
components. thermostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 rpm are:
High pressure side pressure: 1,4 - 1,8 MPa (14,5 - 18,3 bar) (210 - 265 psi)
Low pressure side pressure: 103,4 - 227,5 kPa (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective The high and low pressure side gauge pressures Replace compressor.
compressor. equalize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Adjust thermostat’s
malfunction. temperature setting or probe
placement or replace
thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
performance. operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.

Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.

Troubleshooting Tree
P-90410

Troubleshooting Tree (Cont’d)
P-90411

P-90412

P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F PSIG TEMP F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80

Temperature / Pressure Chart (Cont’d)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add -13 - -12°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90°F

90°F
+40°F
130°F condenser temperature=200 psig
Conditions and pressures will vary from system to system. Check with MCC for system specifications.

TROUBLESHOOTING (CONT'D) Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
Poor A/C Performance 60-1.)
Start the loader, lock the park brake, and engage the A/C Check the A/C evaporator coil for dirt or mud and clean if
system with the blower fan on High. Run the loader at full necessary. (See Removal And Installation on Page 80-
throttle for approximately 15 minutes, with the loader cab 110-1.)
door closed.
Check the engine coolant to see if it is bypassing the
Figure 80-30-1 heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-18.)
P-90356
Figure 80-30-2
N-22411
Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 2,2 - 11,6°C

(45 - 53°F.) depending on the amount of humidity in the
air and ambient temperature.
If louver temperature is too high. (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower for proper operation, or noise, and

replace if necessary. (See Removal And Installation on
Page 80-130-1.)

HVAC Repair And Leaks
Figure 80-30-3
P-90361
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT’D) Figure 80-30-6
Electrical System
Check to see if the compressor clutch is engaging.

1
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN OR press the
RUN Button, without starting the loader.
Figure 80-30-4
P-90357
Locate the loader harness and the compressor clutch

wire (Item 1) [Figure 80-30-6].
2
1 Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.
Figure 80-30-7
P-92638
Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON
position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
P-90358
1 With a multi meter, check the resistance to the

compressor clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor

clutch.
P-85412
If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.
Open the rear door (tailgate).

Electrical System (Cont’d)
Figure 80-30-8
P-90360
1
Using a multi meter check the loader wiring harness

P-90358 (Item 1) [Figure 80-30-10] for voltage.
The voltage should be around 12 volts.

With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, check the
harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-30-11
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Figure 80-30-9
1
P-90360
If there is voltage at the harness, check the resistance at

2
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, check for low refrigerant

1 P-90361 level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

TROUBLESHOOTING (CONT’D) If there is a resistance value, check the blower.
Electrical System (Cont’d) Figure 80-30-14
Figure 80-30-12
P-90363
P-90363
Disconnect the blower wiring connector (Item 1) [Figure
80-30-14] from the loader wiring harness.
Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
1
2 P-90362
1
Check the loader harness (Item 1) [Figure 80-30-15] for
P-90362 voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

Check the loader harness (Item 1) [Figure 80-30-13] for harness for broken wires.
voltage. The voltage should be 12 volts.
If there is voltage at the wiring harness, check the
If there is no voltage at the wiring harness, check the resistance to the blower at the blower wiring connector
harness for broken wires. (Item 2) [Figure 80-30-15].
If there is voltage at the wiring harness, check the If there is no resistance value replace the blower. (See
thermostat (Item 2) [Figure 80-30-13] for resistance. Removal And Installation on Page 80-130-1.)
The resistance value of the thermostat should be 10 Ohm If there is a resistance value check the climate controls at
at 20°C (68°F). the control panel inside the loader cab.
If there is no resistance value, replace the thermostat.


Electrical System (Cont’d)
Figure 80-30-16 C
H
B
1 M
N-22288
If there is voltage at the wiring harness, check the blower

P-90364 switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame
[Figure 80-30-18].
Figure 80-30-17
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the

blower switch.
If the above resistance tests are good, check the A/C

P-90365 switch.
Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.
Check the loader harness for voltage. The voltage should

be 12 volts.


TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Electrical System (Cont’d) If a resistance value is found, check the potentiometer.
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does

not work, check the potentiometer.
1
Figure 80-30-21
1
P-90367
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.
Check the harness for voltage. The voltage should be 12

P-90366
volts.
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Figure 80-30-20 Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be 12 volts.

1
2
N-22289
If there is voltage at the wiring harness, check the A/C

switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no

resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-20].

Electrical System (Cont'd)
Figure 80-30-22
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0
K Ohm.
If there is voltage at the wiring harness, check the Check the resistance between the wire terminal C and
potentiometer [Figure 80-30-22] for resistance. wire terminal B frame [Figure 80-30-24] should be
around 10 K Ohm.
The resistance should be 10K Ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
P-90368
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Raise the lift arms and install an approved lift arm
Figure 80-30-25
Figure 80-30-27
2 3
1 1
P-90369
P-90364A
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-25] Push the A/C switch (Item 1) to the OFF position, turn the
clockwise to the full Heater position. blower switch (Item 2) to position 1, then turn the
temperature control (Item 3) [Figure 80-30-27]
Figure 80-30-26 counterclockwise to the full A/C position, with the loader
ignition switch OFF.

A C
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
N-22290
Check the resistance between the wire terminal A and

wire terminal B frame [Figure 80-30-26] should be 1
around 10 K Ohm.
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 80-30-26] should be
around 0 K Ohm.
P-90371
If the resistance is not found replace the potentiometer.

Check the heater hose (Item 1) [Figure 80-30-28] for
temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replace.

TROUBLESHOOTING (CONT’D) Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
Heater Valve Not Opening Or Closing shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
Raise the lift arms and install an approved lift arm loader. The heater valve should rotate. Place a mark on
support device. (See Installing on Page 10-20-1.) the loader shaft.
Figure 80-30-29 Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-30-29]

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

2 3 loader, so the heater valve can be clearly seen. Watch
1 the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
P-90364A starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

Push the A/C switch (Item 1) to the OFF position, turn the function. (See Electrical System on Page 80-30-12.)
blower switch (Item 2) to position 1 and turn the
temperature control (Item 3) [Figure 80-30-29] to the Replace the heater valve. (See Removal And Installation
High A/C position, with the loader ignition switch OFF. on Page 80-140-1.)

Figure 80-30-30
P-90370
NOTE: The HVAC assembly is removed for photo

clarity.

SYSTEM CHARGING AND RECLAMATION Follow the steps displayed on the refrigerant identifier
screen.
Refrigerant Identification
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
WARNING and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.

If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
gas.
W-2371-0611
and properly and safely disposed of.
If R134a is found, evacuate the system.

Figure 80-40-1
N-23024
NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.
Connect the Refrigerant Identifier to the low pressure

hose.
Connect the Refrigerant Identifier to its power source.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-3
Reclamation And Charging With Recovery / Charging

Unit
Figure 80-40-2
N-22291
IMPORTANT: Only trained technicians should

perform the reclaiming and recharging.
2
WARNING
P-90372
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
Locate the low pressure port (Item 1), and high pressure blindness if it contacts the eyes and may cause
port (Item 2) [Figure 80-40-2]. serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
WARNING • NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of R-134a to the system must be done by a
refrigerant can cause severe injuries to eyes. In competent refrigeration dealer who has the proper
contact with a flame, R-134a refrigerant gives a toxic equipment, knowledge, and experience to service
gas. refrigeration equipment.
W-2371-0611 W-2373-0611
Use an approved recovery / charging unit [Figure 80-40-

3] to evacuate the system.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Unit (Cont'd)
Figure 80-40-4
N-22292
Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P-90374
NOTE: The A/C system holds 0,68 kg (1.5 lb) of
refrigerant.
Figure 80-40-5
Figure 80-40-7
P-90373
N-22381
Connect the reclaimer to the loader A/C charge ports

(Item 1) [Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 2) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 3) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.

COMPRESSOR
Removal And Installation WARNING

device. (See Installing on Page 10-20-1.) In the event of a leak, wear safety goggles. Escaping
Raise the operator cab. (See Raising on Page 10-30-2.) contact with a flame, R-134a refrigerant gives a toxic
gas.
Evacuate the A/C system. (See Reclamation And W-2371-0611
Charging With Recovery / Charging Unit on Page 80-40-
2.) Figure 80-50-3
Open the rear door.
Figure 80-50-1
1
1 P-89543
Remove the compressor hoses (Item 1) [Figure 80-50-3]

from the compressor.
P-90357
Installation: Tighten the compressor hoses to 29,8 N•m
(22 ft-lb) torque.
Disconnect the loader harness (Item 1) [Figure 80-50-1]
from the compressor clutch wire. Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
Figure 80-50-2
Figure 80-50-4
1
2 1
P-89538
P-89534
Remove the compressor mount bolt (Item 1) and the belt Remove the compressor mount bolts and nuts (Item 1)
(Item 2) [Figure 80-50-2]. [Figure 80-50-4].
Remove the compressor from the loader.

Installation: Tighten the compressor mount bolt to 46

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
Oil RECLAMATION on Page 80-40-1.)
Figure 80-50-5 Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200

1 rpm.
Remove the compressor from the loader. (See Removal

P-90486
The compressor (Item 1) [Figure 80-50-5] is factory filled

with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check

or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
• When ever the evaporator, condenser or receiver-

drier is replaced.
• Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 100 oil should be used, and never

mix R-12 and R-134a Oils.
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check
Figure 80-50-6
1
P-90486
NOTE: After draining the oil through the drain hole

P-90487 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.
Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-50-9
P-16534A
Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole 1
[Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.
P-90487
Add new compressor oil through the suction side

Installation: Add 150 - 170 cc's of PAG 100 oil.
NOTE: The suction port on the compressor is marked

with an SUC and is the larger port on the
compressor.

CONDENSER Figure 80-60-2
Remove the rear grille. (See Removal And Installation on 1

Page 50-60-1.)
Remove the refrigerant from the A/C system. (See

Unit on Page 80-40-2.)
P-89546
Figure 80-60-1

routes from the condenser to the receiver / dryer.
Cap and plug the hose and the condenser fittings with
1 the proper A/C caps and plugs.
Figure 80-60-3
P-85824 1
Remove the two brackets (Item 1) [Figure 80-60-1].
WARNING
P-89548

refrigerant can cause severe injuries to eyes. In Disconnect the hose (Item 1) [Figure 80-60-3] that
contact with a flame, R-134a refrigerant gives a toxic routes from the condenser to the compressor.
gas.
W-2371-0611
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Remove the condenser.

RECEIVER / DRIER Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Receiver / Drier Removal And Installation
Cap and plug the hoses and the receiver / drier fittings
WARNING NOTE: When replacing a receiver / drier in an A/C

system 30 cc (1 fl oz) of PAG 100 oil must be
added to the system when recharging.
Figure 80-70-2
W-2059-0598
Remove the rear grille. (See Removal And Installation on

Page 50-60-1.)

Reclamation And Charging With Recovery / Charging 1
WARNING P-90493
In the event of a leak, wear safety goggles. Escaping Note the flow direction on the receiver / drier (Item 1)
refrigerant can cause severe injuries to eyes. In [Figure 80-70-2] for proper installation.
gas.
W-2371-0611
Figure 80-70-1
P-90488
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.

RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-5
Figure 80-70-3
1
N-22205
P-92665
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver /
drier (Item 2) [Figure 80-70-3]. Figure 80-70-6
Figure 80-70-4
N-22206
P-89521
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
Remove the two mount bolts (Item 1) [Figure 80-70-4] 3,7 MPa (36,9 bar) (535 psi).
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.
The pressure relief valve is a secondary protection

device in the A/C system, with the pressure switch
shutting down the system at 2,6 MPa (26,5 bar) (384 psi).
NOTE: If a pressure relief valve is found open, check

the A/C system for problems. Replace the
complete receiver / drier unit.

RECEIVER / DRIER (CONT’D)
Pressure Switch Removal And Installation
Figure 80-70-7
P-90361
Disconnect the loader wire harness (Item 1) [Figure 80-

70-7] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0611
Figure 80-70-8
P-90488
Remove the pressure switch (Item 1) [Figure 80-70-8]

from the A/C high pressure hose.
Remove the pressure switch from the loader.

RECEIVER / DRIER (CONT’D)
Schraeder® Valve Removal And Installation
Figure 80-70-9
N-22166
The schraeder® valve (Item 1) [Figure 80-70-9] is

located in the A/C high pressure hose and is located
under the pressure switch.

Remove the pressure switch.
With a schraeder® valve removal tool, remove the valve

from the hose.

EVAPORATOR / HEATER UNIT Figure 80-80-3
Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40- 1
2.)
2
Figure 80-80-1 2
P-90421
NOTE: Support the evaporator / heater unit before

1 1 removing the mounting hardware.
Figure 80-80-4
P-90363
3
Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1].
2
Figure 80-80-2
3 1
P-90422
1 Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Cap and plug the hoses and the expansion valve fittings
Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)

P-90423 torque.

NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the Remove the two nuts (Item 3) [Figure 80-80-4].
system.
Remove evaporator / heater unit from the loader.
Remove the two hoses (Item 1) [Figure 80-80-2].

THERMOSTAT The EDT has the following protection built in:
1. Over temperature
Description
2. Over current from clutch output
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil 3. Voltage (Above and below operational limits or
temperature and cycles the compressor clutch to reverse voltage)
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before start 5. Temperature sensor open and short detection
up to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 2°C (35.6°F). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor
temperature is below -2°C (28.4°F), the EDT will turn off
Temperature At A/C start up 2x per second
the clutch and status LED.
sensor open and
short detection
Figure 80-90-1
Compressor Continuous 3x per second
clutch short to
battery
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

THERMOSTAT (CONT’D) Figure 80-90-4
NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the 1
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P-92613
Figure 80-90-2
Remove the thermostat probe (Item 1) [Figure 80-90-4]

from the A/C evaporator coil.
Figure 80-90-5
1 2
P-92606
Remove the nine screws (Item 1) and cover (Item 2)

[Figure 80-90-2].
P-92609
Figure 80-90-3
Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-5].
P-92603
Remove the three screws (Item 1) and left cover (Item 2)

[Figure 80-90-3].

EXPANSION VALVE Figure 80-100-2

1

1
Evacuate the A/C system. (See Reclamation And
2.)
2
1
WARNING P-90416
In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
gas. Remove the four screws (Item 1) and the cover (Item 2)
W-2371-0611
[Figure 80-100-2].
Figure 80-100-1 Figure 80-100-3
1
2
1
1
P-92659 P-90417
Remove the two A/C hoses (Item 1) [Figure 80-100-1] Remove the five screws (Item 1) and the cover (Item 2)
from the expansion valve. [Figure 80-100-3].
Installation: Tighten the two A/C hose fittings to 29,8

Cap and plug the hoses and the expansion valve fittings

EXPANSION VALVE (CONT'D)
Figure 80-100-4
P-90418
Remove the two evaporator fittings (Item 1) [Figure 80-

100-4] from the expansion valve.
Installation: Tighten the two evaporator fittings to 29,8

Remove the two mount bolts (Item 2) [Figure 80-100-4].
Remove the expansion valve from the loader.
Cap and plug the evaporator tubelines (Item 1) [Figure

80-100-4] and the expansion valve fittings with the proper
A/C caps and plugs.
Figure 80-100-5
N-22085
The expansion valve [Figure 80-100-5] is replaced as a

complete unit.

EVAPORATOR COIL Figure 80-110-2
1
1
2
Evacuate the A/C system. (See Reclamation And 1
2.)
NOTE: The evaporator / heater unit is removed for

photo clarity. 1
P-90417
WARNING Remove the five screws (Item 1) and the cover (Item 2)
[Figure 80-110-2].
In the event of a leak, wear safety goggles. Escaping Figure 80-110-3

gas.
W-2371-0611
Figure 80-110-1
1
1
P-90418
Disconnect the two evaporator fittings (Item 1) [Figure

2 80-110-3] from the expansion valve.
1
P-90416
Installation: Tighten the two evaporator fittings to 29,8
NOTE: The evaporator / heater unit is removed for Cap and plug the evaporator tubelines (Item 1) [Figure
photo clarity. 80-110-3] and the expansion valve fittings with the proper
A/C caps and plugs.
Remove the four screws (Item 1) and the cover (Item 2)
[Figure 80-110-1].

EVAPORATOR COIL (CONT'D)
Figure 80-110-4
2
2
3
P-90420A
Remove the thermostat probe (Item 1) [Figure 80-110-4]

from the evaporator coil.
Remove the two retaining clips (Item 2) [Figure 80-110-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil (Item 3) [Figure 80-110-4].
Figure 80-110-5
P-90424
Inspect the evaporator coil [Figure 80-110-5] for leaks,

Clean with low pressure water or air.

HEATER COIL Figure 80-120-3
Remove the evaporator coil (If equipped with A/C). (See 2

Remove the heater valve. (See Removal And Installation

on Page 80-140-1.) 1
NOTE: The evaporator / heater unit is removed for

photo clarity.
3
Figure 80-120-1
P-90440
Remove the three screws (Item 1) and cover (Item 2)

[Figure 80-120-3].
1 2
Remove the tie strap and move the wire harness (Item 3)
[Figure 80-120-3] off to the side.
Figure 80-120-4
1
P-90419A
2 1
Remove the nine screws (Item 1) and the cover (Item 2)
[Figure 80-120-1].
Figure 80-120-2 1
2
1
P-90445
1
Remove the five screws (Item 1) and cover (Item 2)
3
[Figure 80-120-4].
P-90439
Remove the three screws (Item 1) and cover (Item 2)

[Figure 80-120-2].
Remove the two screws (Item 3) [Figure 80-120-2].

HEATER COIL (CONT'D)
Figure 80-120-5
P-90441
Remove the bolt, spacer, and nut (Item 1) [Figure 80-

120-5].
Remove the heater coil from the unit.
Figure 80-120-6
P-90443
The heater coil [Figure 80-120-6] can be cleaned with

low pressure air or water.

BLOWER FAN Disassembly And Assembly
Remove the evaporator / heater unit. (See Removal And

Remove the heater coil. (See Removal And Installation 2

on Page 80-120-1.)
Figure 80-130-1
1 1
2
P-90458
1 1 Remove the eight screws (Item 1) [Figure 80-130-2]

from the blower wheel cover.
2
the resistor.
P-90457
Figure 80-130-3
Remove the two screws (Item 1) [Figure 80-130-1].
Remove the blower fan (Item 2) [Figure 80-130-1] from 1

the evaporator / heater unit.
2
P-90465
Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].
Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

BLOWER FAN (CONT'D) Figure 80-130-6
Figure 80-130-4
P-90463
1 Check the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
NOTE: Mark the wires for proper installation.
Remove the two wires (Item 1) [Figure 80-130-4] from

the blower motor.
Figure 80-130-5
1 1
P-90461
Remove the blower wheel outside clamp (Item 1) [Figure

80-130-7] from the blower wheel.
P-90460
Remove the screw (Item 1) [Figure 80-130-5] from the

bottom side of the blower motor.
Remove the blower motor from the blower housing.

BLOWER FAN (CONT'D)
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-
8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.

HEATER VALVE Figure 80-140-2

3 4
Raise the lift arms and install an approved lift arm support 1
NOTE: The heater valve is not serviceable and must

be replaced as a complete assembly.
Remove any tie-straps that hold the heater hoses.

2
NOTE: The evaporator / heater unit is shown
removed for photo clarity. P-90415
Figure 80-140-1
with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-

2].
1
Remove the heater hose from the heater valve.
Remove the nut (Item 2) [Figure 80-140-2] from the

3 heater valve mount.
2 Remove heater hose clamp (Item 3) and the heater valve
(Item 4) [Figure 80-140-2] from the evaporator / heater
P-90414 unit.

with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-

1].
Remove the heater hose.
Disconnect the loader wiring harness (Item 2) [Figure

80-140-1] from the heater valve.
Remove the nut (Item 3) [Figure 80-140-1] from the

heater valve mount.

SPECIFICATIONS
(T650) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
SPEC-01 T650 Service Manual

SPEC-02 T650 Service Manual
(T650) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard track and 74 inch Heavy Duty Construction And Industrial
bucket and may vary with other bucket types. All dimensions are shown in millimeters. Respective imperial dimensions
are given in inches enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
2228 mm
(87.7 in)
1851 mm
(72.9 in) 1880 mm
(74 in)
1532 mm
(60.3 in)
97°
42°
4026 mm
(158.5 in)
870 mm
(34.2 in)
3149 mm
(124 in)
2447 mm
2065 mm (96.3 in)
(81.3 in)
31°
30.6°
1499 mm
207 mm (59 in)
(8.1 in)
2752 mm
(108.4 in)
3474 mm
(136.8 in)
NA1661
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 T650 Service Manual

(T650) LOADER SPECIFICATIONS (CONT’D)
Performance
ROLLER SUSPENSION SOLID-MOUNTED

UNDERCARRIAGE (OPTIONAL) UNDERCARRIAGE
Rated Operating Capacity 1066 kg (2350 lb) 1166 kg (2570 lb)
with 200 Pound Frame Mounted 1111 kg (2450 lb) 1211 kg (2670 lb)
Counterweight Kit
with 300 Pound Frame Mounted 1145 kg (2525 lb) 1245 kg (2745 lb)
Counterweight Kit
Tipping Load 3045 kg (6714 lb) 3331 kg (7343 lb)
Operating Weight 4707 kg (10378 lb) 4282 kg (9440 lb)
Breakout Force - Lift 3084 kg (6800 lb) 2903 kg (6400 lb)
Breakout Force - Tilt 2631 kg (5800 lb) 2495 kg (5500 lb)
Push Force 3302 kg (7280 lb) 2903 kg (6400 lb)
Travel Speed
- Single Speed Loader 0 - 10,6 km/h (0 - 6.6 mph) 0 - 10,6 km/h (0 - 6.6 mph)
- Two-Speed Loader (Option)
Low Range 0 - 9,8 km/h (0 - 6.1 mph) 0 - 9,8 km/h (0 - 6.1 mph)
High Range 0 - 17,2 km/h (0 - 10.7 mph) 0 - 17,2 km/h (0 - 10.7 mph)
Engine
Make / Model Kubota / V3307-DI-TE3 Interim Tier IV

Fuel / Cooling Diesel / Liquid
Horsepower
- ISO 9249 EEC / SAE J1349 Net 52,4 kW (70.3 hp) @ 2400 rpm
- ISO 14396 Gross 54,6 kW (73.2 hp) @ 2400 rpm
- SAE 1995 Gross 55,4 kW (74.3 hp) @ 2400 rpm
Torque
- ISO 9249 EEC / SAE J1349 Net 253,1 N•m (186.7 ft-lb) @ 1600 rpm
- SAE 1995 Gross 264,4 N•m (195.0 ft-lb) @ 1600 rpm
Low Idle rpm 1250 - 1450
High Idle rpm 2525 - 2650
Number of Cylinders 4
Displacement 3,3 L (203 in3)
Bore / Stroke 94 mm / 120 mm (3.70 in / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Drive System
Main Drive Fully hydrostatic, rubber track drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic drive motors
Tracks (Tension) Grease cylinder and spring

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 Controls (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control; additional foot operated speed control pedal with SJC
option, key-type start switch or optional keyless start panel or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Glow plugs automatically activated as needed by Instrument Panel
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel
Hydraulic System
Pump Type Engine driven, gear type

Pump Capacity - Standard 87,1 L/min (23.0 U.S. gpm)
Pump Capacity - High-Flow Option 115,5 L/min (30.5 U.S. gpm)
System Relief at Quick Couplers 23,8 MPa - 24,5 MPa (238 - 245 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 76,2 mm (3.00 in)
Tilt Cylinder (2) 76,2 mm (3.00 in)
Rod Diameter: Lift Cylinder (2) 44,5 mm (1.75 in)
Stroke: Lift Cylinder (2) 633,2 mm (24.93 in)
Control Valve - Standard 3-Spool, open center, manually operated with spring detent for lift float and
electrically controlled auxiliary spool
Control Valve - ACS and SJC 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 3.9 Seconds
Lower Lift Arms 2.6 Seconds
Bucket Dump 2.3 Seconds
Bucket Rollback 1.7 Seconds

Electrical System
Alternator Belt driven, 90 amps, open frame

Battery 12 volts, 950 cold cranking amps @ -18°C (0°F),
180 Minute reserve capacity @ 25 amps
Starter 12 volts, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, General Warning.
Indicators:
BICS™ Functions, Two-Speed, 3-Point Shoulder Belt, Turn Signals, Engine
Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown,
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;
System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.
Capacities
Fuel 103,1 L (27.2 U.S. gal)

Engine Oil with Filter Change 11,4 L (12.0 qt)
Engine Cooling System
with Heater 11,4 L (3.0 U.S. gal)
without Heater 11,7 L (3.1 U.S. gal)
Hydraulic / Hydrostatic Reservoir 10,2 L (2.7 U.S. gal)
Hydraulic / Hydrostatic System 45,0 L (11.9 U.S. gal)
Hydrostatic Drive Motor (Each) 180 mL (6.1 U.S. fl oz)
Tracks
Standard 320 mm (12.6 inch) Rubber, C-Pattern

Optional 450 mm (17.7 inch) Rubber, C-Pattern
Ground Pressure
ROLLER SUSPENSION SOLID-MOUNTED

UNDERCARRIAGE (OPTIONAL) UNDERCARRIAGE
Standard Track - 320 mm (12.6 in) 0,044 MPa (0,44 bar) (6.3 psi) 0,040 MPa (0,40 bar) (5.8 psi)
Optional Track - 450 mm (17.7 in) 0,031 MPa (0,31 bar) (4.5 psi) 0,028 MPa (0,28 bar) (4.1 psi)

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 that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
9,0 - 10,2 12,4 - 13,6
0.250
N•m (80 - 90) (110 - 120)
(in-lb) 20,3 - 22,6 24,2 - 27,1
0.3125
(180 - 200) (215 - 240)
34 - 38 47 - 54
0.375
(25 - 28) (35 - 40)
54 - 61 81 - 88
0.4375
(40 - 45) (60 - 65)
88 - 95 122 - 136
0.500
(65 - 70) (90 - 100)
122 - 136 170 - 190
0.5625
(90 - 100) (125 - 140)
170 - 190 240 - 260
0.625
(125 - 140) (175 - 190)
300 - 330 410 - 450
0.750
(220 - 245) (300 - 330)
450 - 490 645 - 710
0.875
(330 - 360) (475 - 525)
645 - 710 985 - 1085
1.000
N•m (475 - 525) (725 - 800)
(ft-lb) 880 - 975 1425 - 1600
1.125
(650 - 720) (1050 - 1175)
1200 - 1360 2000 - 2200
1.250
(900 - 1000) (1475 - 1625)
1630 - 1830 2720 - 2980
1.375
(1200 - 1350) (2000 - 2200)
2040 - 2240 3530 - 3870
1.500
(1500 - 1650) (2600 - 2850)
2720 - 2980 4680 - 5150
1.625
(2000 - 2800) (3450 - 3800)
3390 - 3730 5830 - 6500
1.750
(2500 - 2750) (4300 - 4800)
4270 - 4750 7450 - 8300
1.875
(3150 - 3500) (5500 - 6100)
5150 - 5700 8800 - 9800
2.000
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
4 - 5 N•m
M 5 x 0.8
(3 - 4 ft-lb)
8 - 9 N•m 8 - 12 N•m
M 6 x 1.0
(6 - 7 ft-lb) (6 - 9 ft-lb)
8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
M 8 x 1.25
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
M 10 x 1.25
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
M 12 x 1.25
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
M 14 x 1.25
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-30-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-30-
1].
Figure SPEC-30-2
O-ring Boss
Tightening Torque
x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.
Figure SPEC-30-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
P-85926
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-30-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-30-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.

CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart

ALPHABETICAL INDEX
(T650) LOADER SPECIFICATIONS CRANKSHAFT AND PISTONS . . . . . .70-90-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
ACCESS PANEL (INSIDE) (SJC) . . . . 50-121-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
AIR CONDITIONING SYSTEM FLOW . 80-10-2 DIAGNOSTIC SERVICE CODES . . . . .60-90-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-60-1
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-50-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 ELECTRICAL / HYDRAULIC CONTROLS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 (ACS) . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
BOBCAT CONTROLLER (SJC) (DRIVE) ELECTRICAL / HYDRAULIC CONTROLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
BOBCAT CONTROLLERS (GATEWAY AND ELECTRICAL SYSTEM INFORMATION
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
BOBCAT INTERLOCK CONTROL SYSTEM EMERGENCY EXIT . . . . . . . . . . . . . .10-190-1
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BOB-TACH (HAND LEVER) . . . . . . . . 10-130-1 ENGINE COOLING SYSTEM . . . . . . .70-50-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 ENGINE LUBRICATION SYSTEM . . .10-110-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-131-1 ENGINE SPEED CONTROL (SJC) S/N
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 A3P011522 & BELOW AND S/N A3P111118 &
BELOW . . . . . . . . . . . . . . . . . . . . . . . . .70-21-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
ENGINE SPEED CONTROL (SJC) S/N
BUCKET POSITION VALVE . . . . . . . . 20-100-1 A3P011523 & ABOVE AND S/N A3P111119 &
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1 ABOVE . . . . . . . . . . . . . . . . . . . . . . . . .70-22-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1
CAMSHAFT AND TIMING GEARS . . 70-100-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-30-1 EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 EXHAUST GAS RECIRCULATION (EGR)
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
CONTROL HANDLE / LEVER (ACS) . 50-111-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CONTROL HANDLE / LEVER (SJC) . 50-112-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
CONTROL HANDLE / LEVER . . . . . . 50-110-1 FLYWHEEL AND HOUSING . . . . . . .70-120-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-101-1 FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
CONTROL PANEL SETUP . . . . . . . . 60-180-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONTROL PANEL . . . . . . . . . . . . . . . 50-100-1 FRONT AUXILIARY HYDRAULIC COUPLER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
CONTROL PEDALS AND LINKAGES (ACS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1 FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1
CONTROL PEDALS AND LINKAGES . 50-90-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CONTROL SYSTEM (ACS) . . . . . . . . 60-130-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-50-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1
INDEX-01 T650 Service Manual

HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1 OPERATOR SEAT (SUSPENSION) . . 50-30-1
HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1 PASSWORD SETUP (DELUXE
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1 INSTRUMENTATION PANEL) . . . . . . 60-190-1
HYDRAULIC / HYDROSTATIC FILTERS PASSWORD SETUP (KEYLESS START
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
HYDRAULIC / HYDROSTATIC FLUID PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-160-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1 REAR AUXILIARY DIVERTER VALVE
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
HYDRAULIC CONNECTION REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-30-1 RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
HYDRAULIC CONTROL VALVE (ACS) OR REGULAR MAINTENANCE . . . . . . . . 80-20-1
(SJC) . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
REMOTE START TOOL (SERVICE TOOL) KIT
HYDRAULIC CONTROL VALVE (STANDARD) - 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
REMOTE START TOOL KIT-MEL1563 10-60-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1
RIGHT SIDE LOWER PANEL . . . . . . 50-170-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1
SEAT BAR SENSOR . . . . . . . . . . . . 60-110-1
HYDRAULIC SYSTEM INFORMATION 20-10-1
SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
HYDROSTATIC DRIVE MOTOR (TWO
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-200-1
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
HYDROSTATIC PUMP (SJC) . . . . . . . .30-41-1 SERVICE MANUAL REVISION . . . . . . SMR-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-40-1 SERVICE PC (LAPTOP COMPUTER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
HYDROSTATIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SPARK ARRESTER MUFFLER . . . . 10-150-1
LEFT SIDE LOWER PANEL . . . . . . . .50-160-1 SPEED SENSORS (SJC) . . . . . . . . . . 60-80-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 STEERING DRIFT COMPENSATION 60-161-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 STOPPING THE ENGINE AND LEAVING THE
LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1
LIFTING AND BLOCKING THE LOADER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16
TORQUE SPECIFICATIONS FOR BOLTS
LOADER STORAGE AND RETURN TO . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-170-1
TOWING THE LOADER . . . . . . . . . . . 10-50-1
LUBRICATING THE LOADER . . . . . .10-140-1
TRACK MAINTENANCE . . . . . . . . . . 40-30-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1
TRACK UNDERCARRIAGE COMPONENTS
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-30-1 (ROLLER SUSPENSION) . . . . . . . . . 40-21-1
MAINTENANCE CLOCK . . . . . . . . . .60-200-1 TRACK UNDERCARRIAGE COMPONENTS
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 (SOLID-MOUNTED) . . . . . . . . . . . . . . 40-20-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .70-30-1 TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
OIL COOLER . . . . . . . . . . . . . . . . . . . .20-90-1 TRANSPORTING THE LOADER ON A
OPERATOR CAB . . . . . . . . . . . . . . . . .10-30-1 TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . .50-20-1 TROUBLESHOOTING . . . . . . . . . . . . 80-30-1

TURBOCHARGER . . . . . . . . . . . . . . . 70-110-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1

ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: T650 - 1

Date: 15 July 2009
Product: Bobcat Loader
Model: T650
Manual No: 6987172 (7-09)
The following Sections are a revision to the above Service Manual.
COVER
10-30
30-20
40-21
70-10
SPEC-10
SMR-1 T650 Service Manual

ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 August 2009
Model: T650
Manual No: 6987172 (8-09)
T650 Service Manual (P/N 6987172) Dated 8-09 contains updated service information which replaces the previous
T650 Service Manual (P/N 6987172) Dated 7-09.

ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 September 2009
Model: T650
Manual No: 6987172 (9-09)
COVER
20-10
20-20
30-10

ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 October 2009
Model: T650
Manual No: 6987172 (10-09)
COVER 60-160
FOREWARD 60-190
60-191
10-30 60-200
10-140 60-220
10-180
10-190 70-40
20-80 SPEC-10
ALPHABETICAL INDEX
50-01
50-20
50-80
50-150
50-160
50-170
50-180
60-01
60-50
60-90
60-130
60-140
60-141
60-142
60-150

SERVICE MANUAL
ROUTE TO
REVISION ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER

Date: 15 December 2009
Model: T650
Manual No: 6987172 (12-09)
COVER
10-100
20-120
50-70
50-91
50-120
60-50
60-60
60-130
70-10
70-20
70-21 ADDED
70-70
SPEC-10
SPEC-40
ALPHABETICAL INDEX

SERVICE MANUAL
ROUTE TO
REVISION ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER

Date: 15 June 2010
Model: T650
Manual No: 6987172 (6-10)
FRONT COVER
10-110
10-120
10-150
20-21
20-61
50-20
50-112
60-90
70-90
SPEC-40

SERVICE MANUAL
ROUTE TO
REVISION ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER

Date: 15 December 2010
Model: T650
Manual No: 6987172 (12-10)
T650 Service Manual (P/N 6987172) Dated 12-10 contains updated service information which replaces the
previous T650 Service Manual (P/N 6987172) Dated 6-10.

ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 August 2011
Model: T650
Manual No: 6987172 (8-11)
COVER 40-20
FOREWARD 40-21
10-01 50-01
10-20 50-40
10-40 50-41
10-60 50-60
10-70 50-150
10-90
10-120 ELECTRICAL SCHEMATICS
10-140
10-150 60-01
10-160 60-10
60-70
20-01 60-80
20-21 60-90
20-60 60-110
20-61 60-150
60-161
30-01 60-180
30-20 60-190
30-21 60-200
30-30 60-210
30-40
30-41
30-50

70-10
70-60
70-70
70-90
80-01
80-20
80-70
SPEC-10
ALPHABETICAL INDEX

Service Manual T650 Compact Track Loader: S/N A3P011001 & Above S/N A3P111001 & Above

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Service Manual

T650 Compact Track Loader

S/N A3P011001 & Above

6987172 (8-11) Printed in U.S.A. © Bobcat Company 2011

CORRECT CORRECT CORRECT

P-90216 NA1711 NA1715

WRONG WRONG WRONG

NA1714 NA1710 NA1712

NA1722 NA1725 B-6589

1-1 T650 Service Manual

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

1-3 T650 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-5 T650 Service Manual

3. The seat belt must be 11. Bob-Tach wedges and

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

1-7 T650 Service Manual

22. Check for any field

1-8 T650 Service Manual

1-9 T650 Service Manual

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

1-10 T650 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

1-11 T650 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

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrester exhaust system regularly to

Battery gas can explode and cause serious injury. Use

1-12 T650 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Know where fire extinguishers and first aid kits are

1-13 T650 Service Manual

Always use the serial number of the loader when Figure 3

Loader Serial Number

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

Module 1 - Model / Engine

Explanation of loader Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

2. The five digit Production Sequence Number identifies