x Bobcat. Service Manual T2556, T2566 Telescopic Handler 72556: S/N A8FR11001 & Above T2566: S/N A8G311001 & Above .60868764.EN (12-07) Revisod (08-12) Printed in Belgium © Bobeat Company 2012 of 010 Dealer Copy -- Not for Resale‘128944 104 ON ~ Adog s9leaq 21010MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator's Handbook and A TNA TN CEE 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 CORRECT Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!" Carefully read the message that follows. 50216 Dito sevice the Bobeat ‘VersaHANDLER without instructions. , CORRECT lg WRONG Wwatee , / lo K ye 3 x 3 <3 3 ce IS 8-10062 s.score |S Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER | fequired daily. Aafieiaule taste nese: ting, ANE scom up uniess boomers > component or a part faiure can held by an approved boom stop. & cause boom to drop. Do not go Replace if damages. 6 lunder boom when raised unless 4 Never modify equipment or add ‘supported by an approved boom ‘attachments not approved by Stop. Roplace i damaged. Bobcat Company. $ 5 — WRONG WRONG Bescon i Have good ventilation when Keep body jewelry and clothin Leadacid batteries produce Acer gitige tes — Asean hoary soning A aie aspen ase pars, Slectrical contact not parts and AA Keop arcs, parka, flames, and A Wear aust masie when gringing exnaust, lighted. tobacco” away” from Painted parts, Toxie dustand gas 44 Wear “eye protection to guard batteries. tan be produced. ‘from battery acid, compressed AA Batteries contain acid which ‘Avold exhaust fume leaks which Springs, fulds under ‘pressure urns eyes or skin on contact, ‘an Kill without warning. Exhaust and flying debris. when engines Wear protective clothing. acid System must be tightly sealed. fre. running or tools are used. contacts body, flush well with Use eye protection approved for water. For eye contact flush wall type of welding. and. get Immediate "medical attention. Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner] operator withaut any specie technical veining. Mainienance procedures wich ere. nol ia the ion & laintenance Manual must be performed ONLY BY QUALIFIED ‘genuine Bobcat replacement parts. BCAT SERVICE PERSONNEL. Always use Msw2-0409 of 010ajesey 19) 10N ~ Adog s9}28q Nf 4of910CONTENTS SAFETY & MAINTENANCE . = 10-01 HYDRAULIC SYSTEM sees cee cote ee ee tere ee sees s, 20-01 HYDROSTATIC SYSTEM = 30-01 DRIVE SYSTEM 2.20.00. oe e eee ee eee eect ete et eee eens 40-01 MAINFRAME . . . . ceeeee . 60-01 ELECTRICAL SYSTEM & ANALYSIS. . . ceeeee - 60-01 ENGINE SERVICE - . . . coves -- 70-01 HEATING, VENTILATION, AIR CONDITIONING .... 0.2.20... 0020e0e eee eeee eee 80-01 SPECIFICATIONS SPEC-01 ALPHABETICAL INDEX . . . ceeeee INDEX-01 501010 13 Dealer Copy -- Not for Resaleajesey 19) 10N ~ Adog s9}28q Nf 14 61010FOREWORD FOREWORD 2.220.020 eee ee cece eect eee ene eee eee 17 SAFETY INSTRUCTIONS . . . ceeeee 2219 FIRE PREVENTION Maintenance Operation Electrical ... Hydraulic System Fueling . Starting Spark Arrester Exhaust System Welding And Grinding Fire Extinguishers SERIAL NUMBER LOCATION . . . . cove cece eee 2. 4-12 Telescopic Handler Serial Number . . weeeee 2. 1-12 Engine Serial Number . . . oe 2 4-12 Other Serial Numbers . . cones 2. 1-12 DELIVERY REPORT 0.0.00... 000 e cee ee cece e teen eee ee et eee eee 1-13 TELESCOPIC HANDLER IDENTIFICATION | . wees oe tA Tet 910 15 Dealer Copy -- Not for Resaleajesey 19) 10N ~ Adog s9}28q Nf 16 ao1o10ete. FOREWORD This manual is for the Bobcat telescopic handler mechanic It provides, necessary servic adjustment procedures for the Bobcat telescopic handler and its component parts and systems, Ref Operation & Maintenance Manual for operating instructions. starting procedure. daily checks, and fer Ageneral inspection of the following items must be made after the telescopic handler has had service or tepair: 1. Check that ROPS/FOPS (including right side window) is in good condition and is not modified. 2. Check that ROPS mounting hardware is tightened and is Bobcat approved. 3. The seat belt must be correctly installed, functional and in good condition, 4. Check boom stop, replace if damaged 5. Machine signs (decals) must be legible and in the correct location, 6. Joystick control lever and foot pedals must return to neutral. 7. Check for correct function of the work lights. 2o1010 10. The parking brake must function corey |e) Enclosure door latches must open and close freely. & Attachment locking pins must function correctly and be in good condition. Bob-Tach e wedges and linkages (if equipped) must function correctly and be in good condition . Safety treads must be in good conaltion [ats .. Check for correct function of inclator lamps and gauges fe Check hydraulic fluid level, engine oil level and fuel “4 6 supply. = D > . Inspect for fuel, oil or hydraulic fluid leaks. =D é é FW VH.0308 SM. "72556, 72566 Ser Dealer Copy -- Not for Resale15. 16. 47. 18. 19, 20. Lubricate the telescopic handler. Check the condition of the battery and cables. Inspect the air cleaner for damage or leaks. Check the condition of the element. Check the electrical charging system, heck tires for wear and pressure. Use only approved tires. Inspect for loose or broken parts or connections. sooto10 20. 20. 2 23 18 Check for any field modification not completed. Operate the machine and check all functions. Check for correct function of the Lateral Operator Restraint ¥ i System (LORS) if equipped. | (QJ 7 Check function or condition of all equipped options and 2 accessories (examples: back- see up alarm, fre extinguisher, | rotating beacon, front stabilizers, etc.). Recommend to the owner that all necessary corrections be made before the machine is returned to service. FW VH-0308 SM "72556, 72566 Service Manual Dealer Copy -- Not for ResaleSAFETY INSTRUCTIONS Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. Instructions are necessary before operating ot servicing machine. Read and understand the Operation & Maintenance Manual, Operator's Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. 1w-2008.0807 IMPORTANT ‘This notice Identifies procedures which must be followed to avoid damage to the machine. 2010-0284 A. DANGER ‘The signal word DANGER on the machine and in the manuals indicates a hazardous situation which, if not avoided, will result in death or serious injury. 1002-1107 ‘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 Horio The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments: +The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition, + The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and ‘service procedures. tis a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer. + Machine signs (decals) instruct on the safe operation land care of your Bobcat machine or attachment. The ‘signs and their locations are shown in the Operation & Maintenance Manual. Repiacement signs are available from your Bobcat dealer. + An Operator's Handbook fastened to the operator cab. It's brief instructions are convenient to the ‘operator. The handbook is availabe from your dealer © in an English edition or one of many other languages. g See your Bobcat dealer for more information one translated versions. for + The AEM Safety Manual delivered with the machine 5 gives general safety information. +The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop- type service and repair work. Dealer Copy ~ Ne + The Telescopic Handler Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com, This course is intended to provide rules and practices of correct operation of the Telescopic Handler. + The Telescopic Handler Safety Video is available from your Bobcat dealer or at www.training.bobcat.com ‘or www.bobeat.com. 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. SI VH EMEA-0409 SM "72556, 72566 Service ManualSAFETY INSTRUCTIONS (CONT) Cutting or drilling concrete containing sand or rock containing quartz can result in exposure to silica dust. Use a respirator, water spray or other means to control dust. s2ot910 FIRE PREVENTION “ Maintenance ‘The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is 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 The operator's area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fre hazards and overheating. All fuels, most lubricants and some coolants mixtures are. flammable, Flammable fluids that are leaking or spilled ‘onto Not surfaces or onto electrical components. can eause a fire. Operation Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases. Electrical G8 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. SIVH EMEA-0409 SM "72556, 12566 Service Manual Dealer Copy -- Not for ResaleFIRE PREVENTION (CONT'D) 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 outed and have adequate support and secure clamps. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use petrol or diesel fuel for cleaning parts. Use commercial non-flammable solvents, ®@R Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors. Fu Starting Ro not use ether or starting fluids on any engine that has ‘glow plugs. These starting aids can cause explosion and injure you or bystanders. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting, Spark Arrester Exhaust System ‘The spark arrester exhaust system is designed to control the emission of hot particles from the engine and exhaust 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). sa0f910 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 arts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced. Dust generated from repairing non-metallic 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. Dealer Copy -- Not for Resale SI VH EMEA.0409 SM "72556, 72566 Service ManualSERIAL NUMBER LOCATION Always use the serial number of the telescopic handler when requesting service information or when ordering parts, Telescopic Handler Serial Number ‘The front, on the right side of the frame [Figure 1] s4oto10 Engine Serial Number Figure 2 ‘The engine serial number can be found on the water pump [Figure 2] in front of you when opening the engine cover. Always use the full number when ordering replacement parts. Other Serial Numbers ‘Some components can also have serial numbers. Always Use these serial numbers when requesting parts. 142 "72556, 12566 Service Manual Dealer Copy — Not for ResaleDELIVERY REPORT Figure 3 nae ‘The Delivery Report must be completed by the dealer and signed by the owner or operator when the telescopic handler is delivered. An explanation of the form must be given to the owner. Make sure itis fully complete [Figure 31. 1sof910 "72556, 72566 Service Manual Dealer Copy — Not for ResaleTELESCOPIC HANDLER IDENTIFICATION DESIGNATION TTelescopie boom Cabine air iter Fuel tank Mirror ‘Operator Cab Battery compartment Boom stop (option) Engine exhaust Tights Working lights Engine cover Rotating beacon, Pallet forks seot910 "72556, 12566 Service Manual Dealer Copy — Not for Resale‘SAFETY & MAINTENANCE LIFTING AND BLOCKING THE TELESCOPIC HANDLER . - 10-10-41 Procedure . + 10-10-1 OPERATOR CAB (ROPS / FOPS) ae cee 10-20-41 Cab Door : . . coves 10-20-2 Cab Door Window . ~ 10-20-2 TRANSPORTING THE TELESCOPIC HANDLER -s- ++. ONA TRAILER 10-30-1 Loading And Unloading... . . : 10-30-1 Fastening . . oe . cece 10-30-1 TOWING THE TELESCOPIC HANDLER . - 10-40-1 Procedure + 10-401 AIR CLEANER SERVICE ........ ceo bee ee eee eee e es 10-60-41 Replacing Filter Element... . : a woos 10-60-1 ENGINE COOLING SYSTEM .. . . veces 10-70-1 Cleaning oe . cece 10-70-1 Removing And Replacing The Coolant +. 10-701 Checking Level - 10-70-3 FUEL SYSTEM ... : . . cece 10-80-1 Fuel Specifications . : - coos 10-80-1 Biodiesel Blend Fuel : : : on 10-80-1 Filling The Fuel Tank : : a cesses 10-80-2 Secondary Fuel Filter - . oe . oe 10-80-2 Primary Fuel Filter (Pre-Filter) ~ 10-80-3 Removing Air From The Fuel System . ~ 10-80-4 ENGINE LUBRICATION SYSTEM ...... . = 10-90-1 ‘Checking And Adding Engine Oil . + 10-90-1 Engine Oil Chart : : coe 10-90-1 Removing And Replacing Oil And Filter _- . cece 10-90-2 HYDRAULIC / HYDROSTATIC SYSTEM . we ++ 10-10-41 ‘Checking And Adding Fluid . - oe oe es a 10-100-1 Hydraulic / Hydrostatic Fluid Chart... a ++ 10-10-41 Removing And Replacing Hydraulic Fluid 10-100-2 Removing And Replacing Hycraulic/ Hydrostatic Filter veceeeee 10-100-3, Hydraulic Tank Breather oe 10-100-3 ATTACHMENT CARRIER . . oe . oe 10-110-1 Inspection And Maintenance... 0... oes v eevee eee eeeeeee entrees 10-110-1 AXLES (FRONT AND REAR) ~ 10-120-1 Checking Oil Level (Planetary Carrier) o bevee cee, 10642041 Removing And Replacing Oil (Planetary Camrier) oo... 2... ee eeeeeee cess 10-120-1 sot 910 10.01 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleChecking And Adding Oil (Front Differential)... - 10-120-2 Removing And Replacing Oil (Front Differential) . + 10-120-2 Checking And Adding Oil (Rear Differential) - 10-120-3 Removing And Replacing Oil (Rear Differential) . + 10-120-3 Checking And Adding Oil (Front Drop Box) ©. 10-120-4 Removing And Replacing Oil (Front Drop Box) . . » 10-120-4 LUBRICATING THE TELESCOPIC HANDLER - 10-1304 Lubrication Locations - . oe oe cece 10-130-1 TIRE MAINTENANCE ... . : : ce eee eee. 10-1404 Wheel Nuts _ . . . oe eee ee. - 10-140-1 Rotating . » 10-140-1 Mounting - 10-140-1 APPROVED BOOM STOP 2.2.0... 02.000 eceeeece este eecee este eetenes 10-150-1 Installing The Approved Boom Stop . on bocce vets eee sees 10-1504 Removing The Approved Boom Stop a a vocee cence, 1015041 ENGINE COVER : . . . veeee ees. 10-1604 Opening And Closing . - - wecece esse. 10-1601 TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . - 10-170-1 Storage een Soe vveteetteteveeeees veces. 10-4704 Return To Service... : : : coeeee eee, WONTON STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER ......... 10-180-1 Procedure . . . . . ce veee ees 10-1804 EMERGENCY EXIT . - 10-190-1 Rear Window .. - 10-190-4 sgotoi0 10-02 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleLIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2 HANDLER Procedure Always park the machine on a level surface. FI NMIEGUINe Put jackstands under the front and rear axle before running the engine for service. Failure to use jackstands can allow the machine to fall or move and injury or death. w.2461.0303 ire 10-10-41 Put the floor jack under the centre of the rear axle. Lift the telescopic handler and install jackstands [Figure 10-10- 2. STOP the engine. Put the floor jack under the centre of the front axle. Lift the telescopic handler and install jackstands [Figure 10-10-1] sot 910 t0-10-1 "72556, 72566 Service Manual Dealer Copy ~ Not for Resalemootoi0 x Bobcat Cae = é 10-102 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleOPERATOR CAB (ROPS / FOPS) Figure 10-20-1 S728 The telescopic handler has an operator cab (ROPS and FOPS) (Item 1) [Figure 10-20-1] to protect the operator from rollover and falling objects. Check with your dealer it the operator cab has been damaged. Never operate without right window. The seat belt must be worn for roll over protection. ROPS / FOPS - Roll Over Protective Structure per SAE 1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449 (FOPS Level Il). A WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Do not operate without right window. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in serious injury or death. w.2906.0211 21 0f 910 10-20-1 72556, 12566 Servic Dealer Copy -- Not for ResaleOPERATOR CAB (ROPS / FOPS) (CONT'D) Cab Door Figure 10-20-2 Figure 10-20-3, The cab door can be opened from the outside of the cab using the latch (Item 1) [Figure 10-20-2] and opened from the inside of the cab when you squeeze the latch (Item 1) [Figure 10-20-3] (as shown). ‘The cab door can be locked (Item 2) [Figure 10-20-2] with the start key. 1910 Cab Door Window Figure 10-20-4 Tum the handle (Item 1) [Figure 10-20-4] (as shown). Push open the window fully unti it latches against the cab. igure 10-20-5 Pull the lever (item 1) [Figure 10-20-5] inside the cab to disengage the latch and close the window. 10-202 72556, 72566 Service Manual Dealer Copy — Not for ResaleTRANSPORTING THE TELESCOPIC HANDLER ON A. TRAILER Loading And Unloading igure 10-30-1 The telescopic handler must be loaded backward on the trailer. The rear of the trailer must be blocked or supported (Item 1) [Figure 10-30-1] when loading or unloading the telescopic handler to prevent the front end of the trailer ‘rom raising up. Be sure the transport and towing machines are of adequate size and capacity. For the weight of the telescopic handler. (See Performance Specifications on Page SPEC-10-2.) A 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. .w-2060-0807 mot 910 Fastening Figure 10-30-2 10-30-1 Fasten the telescopic handler to the transport machine to prevent if from moving during sudden stops or when 3 going up or down slopes. + Block the wheels (Item 1) [Figure 10-30-2]. + Fasten the machine frame to the transport machine 3 (tes 2 anu 3) [Figure 10-30-2] 7 > + Attach the forks or bucket attachment to the transport & machine (Item 4) [Figure 10-30-2] 3 & g S 3 "72556, 72566 Service Manualof 910 = ae Bobcat. 10-302 "72556, 12566 Service Manual Dealer Copy ~ Not for Resale‘TOWING THE TELESCOPIC HANDLER Procedure The telescopic handler can be towed a short distance such as removing it from mud or loading onto a transport machine, A WARNING UNEXPECTED MACHINE MOVEMENT CAN CAUSE ‘SERIOUS INJURY OR DEATH + Block wheels to prevent roll away before adjusting screws to bypass the park brake system. + Return adjustment screws to the operating position before operating the machine. W-2800-0908 Block the wheels to prevent the machine from rolling. Releasing The Brake Dises ‘The brakes are engaged by spring pressure and released by hydraulic pressure. The park brake must be released manually before towing. Only the front axle has brakes. ‘The following procedure describes how to release tne brakes: Figure 10-40-1 2501910 10-40-1 Figure 10-40-2 DEACTIVATE - ACTIVATE ap LITE, Si At each end of the central part of the front axle are two bolts (see (Item 1) [Figure 10-40-1] and (Item 1) [Figure 10-40-2]). When screwed in, these bolts will remove the spring pressure that engages the brake discs. [Figure 10-40-2] shows the function of such a bolt inside the axle, i icine wan Saad er NTH oS ‘one side of the front axle then the two bolts on the other 3 side: for Re Loosen the locking nuts (Item 2) [Figure 10-40-1} of the bolts and create some clearance for the bolts. Ne Turn the two bolts (Item 1) [Figure 10-40-1] IN, 90° at a > ‘ime, alternating between the two bolts until the bolts are & ‘firmly seated ler Ci Repeat this on the two opposite side bolts on the front axle. 3 ‘The brakes are now released for towing the machine. Please note that the machine will not be able to brake nti the bolts are returned to their original position. "72556, 72566 Service Manual‘TOWING THE TELESCOPIC HANDLER (CONT'D) Procedure (Cont'd) Figure 10-40-3, Raise the engine cover. Tur the tow valve (Item 1) [Figure 10-40-3] ‘counterclockwise 90° to TOWING POSITION. ‘Tow the telescopic handler at a slow speed eof 910 Engaging The Brake Discs WME UNEXPECTED MACHINE MOVEMENT CAN CAUSE ‘SERIOUS INJURY OR DEATH + Block wheels to prevent roll away before adjusting screws to bypass the park brake system. + Return adjustment screws to the operating position before operating the machine. w-2e00.0908 Block the wheels to prevent the machine from rolling, After towing is completed, tum the tow valve (Item 1) [Figure 10-40-3] clockwise 90° to the OPERATING POSITION. Figure 10-40-4 ‘To reactivate the park brake, release the four bolts (see (Item 1) [Figure 10-40-4] on the front axle to their original position (turn the two bolts out, 90° at a time, until no resistance can be felt. Repeat this procedure for the ‘opposite side two bolts). Make sure that all four bolts have been turned out until they can easily be loosened by hand. Tighten the locking nuts (Item 2) [Figure 10-40-4]. This will allow the park brake piston to be active again. 10-402 "72556, 12566 Service Manual Dealer Copy — Not for Resale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 telescopic handler. Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. RW NAUNTIN CRE solcywarings andinetucion inthe mantalg when making rapa, 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-EN-0903) ‘SERVICE SCHEDULE HOURS TT] ITEM SERVICE REQUIRED 10 | 50] 100 | 260] s00] 12 Engine OF TEE The OU GWOT an wT oH a5 ROTO. yarauac Fd Tock Thi Tvol and add as noted [Arbculaion Pins Tavicato wil vam based mulipurpose Gass afaly Signs, Safely Toadand [Chock or darvagod signs (ocasy,safoy woad and WTO, ROpaCOT aires |oamaged or worn, [Faeroe Tan Te SedenoaT COATT WATT [Ras ang ans [eine tr too nt and Tg aT aS TOT oat Bat Teck The condiion a The Seat Bal [Frakes [Check for function. Service as necessary. [Bacup Narn (reauppedy Treck for Tunicfon- Replace as necessary [Tres Trock Yor woar or Jamage Tila To cored pressure. Bo Sure aI TOS We nat to tho samo prossure. Uso only approved tres. [Enaine Ar Fifer And Ar System — [Check condition indicate, replace clement when fequrea and empty GUST cup as naoded. Chock ai system for oaks, Engine Cooing Syston Toan debris Wom of cook, radalor and ar condiionor condonsor hoc ceolant level cold a rearewt Adil reerxad coolant ax. needed (See| ERSINE COoEiNG SYSTEM check cooing system fr fas Pee Dine SAT TERT arnt wh i Bad rap em Rear, attach. Frame Pivots), Tit Lit Cy, Boom Prot Tatescope Boom She CaDTCaTS Wi HITT DSSOT THUPUTpOSG GORSO. CHO Woot DOCS Tor adustmont or repiacoment VaTaUC GSES, TUBES ana [Check condo ct hoses, TUBEWTES Gnd COMETS. REAR Gf TOSSES aS [connections needed Isatery Tock GOETOH1O ENOL A GSUTOG WaTGT as HOGA. Wheat Nae Tock whoa! nut Torquo, Tighten as noodod (S00 Newn [2IT WET o [AIC and Ar Cond Bal WT oquppeaT | Chock ba Tonson and aust es noodod. ry [Dearing Tabricate door Rings with Miu bavod MUNGUIDSGS GTCaES Engine OW and Gr [Replace the ong oi and ior Soo SPECIFICATIONS Tor coro Jcapacty. Use 8 genuine Bobcat ter. ca [Enoine NirFer Replace the outer Wier element. Use a genuine Bobcat er rey [Fuel Fite secondary [Replace the secondary fel iter element. Use a genuine Bobcat Wer re [Fuel Fifer primary plac te primary Tod fier (pe ita lemon Use genuine Bobox Me lal Rydrauic Hydrostatic Fld Per [Replace fe hydraulic Wor clement Use a genuine Bobcat Mor ey yarauke Tank Breathor [Replace the hyoraulc tank breahor Fycraube Fad and Fier [Replace the hydraulic Wand and Wer cement See SPECIFICATIONS: Front and Rear Axle Fla Replace the axle fad See SPECIFICATIONS. i a TSSOP BOG Wear BGS [CR RTOT WaT BAT RTT as MOOT ROTRCD HS TOOT Pivot Pins and BUSTITOS Teck Tor wear On He POT pis ana BUSTITDS. Engine valve si Teck and axust as needed [Enaine Cooianr Teck Tees PTaCION Of AATEC CIN FT FT COG SSE and replaco with promixod coolant Every 2 yours IH] Check wheel nuttorque every 8 hours forthe fist 24 hours. [2] Perform service frst time, then as indicated in chart. [B]_cheok evel [4] Replace tua frst time, then as indicated in char. [B]Orevery 12 months. 2701 910 10-50-1 "72556, 72566 Service Manual Dealer Copy -- Not for Resaleeof oi0 = ae Bobcat. 10-502 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleAIR CLEANER SERVICE Replacing Filter Element Figure 10-60-1 Replace the large (outer) fter element only when the red ring shows in the window of the condition indicator ({tem 1) [Figure 10-60-1]. NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [Figure 10-60-1]. Start the engine. If the red 1g does not show, do not replace the filter clement. Replace the inner filter every third time the outer fer is replaced or when the red ring still shows in the indicator ‘window after the outer filter has been replaced. mooto10 10-60-1 Loosen the filter housing clamps (Item 1) [Figure 10-60- 2). Release the fastener and remove the cover (Item 2) [Figure 10-602}. Figure 10-60-3 Dealer Copy — Not for Resale Pull the element straight out [Figure 10-60-3} NOTE: Make sure all sealing surfaces are free of dirt and debris. Install a new outer element. Install the dust cover and fasten [Figure 10-60-2]. Connect the filter housing clamps. 72556, 12566 ServicAIR CLEANER SERVICE (CONT'D) Replacing Filter Element (Cont'd) Inner Filter Remove the outer element. NOTE: Make sure all sealing surfaces are free of dirt and debri Figure 10-60-4 Remove the inner fier (Item 1) [Figure 1060-4] and inotall a new element. Install the outer element. Install the dust cover and fasten [Figure 10-60-2}, Connect the filter housing clamp (Item 1) [Figure 10-60- 2, motoi0 10-602 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleENGINE COOLING SYSTEM Check the cooling system every day to prevent over- heating, loss of performance or engine damage. A WARNING ‘AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the followi i + When fluids are under pressure. + Flying debris or loose material is present. + Engine is running. + Tools are being used. 20r9.0907 Cleai Figure 10-70-1 Open the engine cover (Item 1) [Figure 10-70-1], Figure 10-70-2 at of910 10-70-1 Use low air pressure or water pressure to clean the radiator, oil cooler and intercooler [Figure 10-70-2] Removing And Replacing The Coolant A WARNING AVOID BURNS. Do not remove radiator cap when the engine is hot. You can be seriously burned. w.2070-1203, Open the engine cover. Figure 10-70-3 Remove the cap (Item 1) [Figure 10-70-3] from the coolant reservoir. Dealer Copy — Not for Resale Remove the fan shield. "72556, 72566 Service ManualENGINE COOLING SYSTEM (CONT'D) Removing And Replacing The Coolant (Cont'd) Figure 10-70-4 Remove the engine block drain plug (Item 1) [Figure 10- 70-4]. Open the drain valve (Item 2) [Figure 10-70-4] and drain all of the coolant into a container. Dispose of used coolant in an environmentally safe manner. Close the drain valves. NOTE: The cooling system is factory filled with ethylene glycol (EG) coolant. DO NOT mix ethylene glycol with propylene glycol. ‘Add premixed coolant to the reservoir if the coolant level is low. Use a refractometer to check the condition of ethylene alycol in your cooling system. the radiator with the premixed coolant. Install the radiator cap. ‘Add coolant fo the reservoir. The coolant level must be between the MIN and MAX marks (Item 2) [Figure 10- 70-3] on the coolant reservoir. Follow the following steps when using concentrated coolant instead of a ready-to-use premix: + mix the coolant in a separate container: 4,3 L (one gallon and one pint) of ethylene glycol mixed with 3,8 L (one gallon) of water is the correct mixture of coolant to provide a -37°C (-34°F) freeze protection. + Add premixed coolant, 47% water and 53% ethylene glycol to the coolant tank until the coolant level Teaches the MIN marker on the tank (Item 1) [Figure 10-70-3}, sof910 10-702 Run the engine until itis at operating temperature. Stop the engine. Check the coolant level (COLD) in the reservoir when cool ‘Add coolant to the reservoir as needed. 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. n. Adding full strength ious premature engine damage. baraeos07 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleENGINE COOLING SYSTEM (CONT'D) Checking Level (Open the engine cover. Check the coolant level in the coolant reservoir. Figure 10-70-5 The coolant level must be between the MIN and MAX marks (Item 1) (Figure 10-70-5] on the coolant reservoir when the engine is cold eu 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 ing point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. 2124-0497 motoi0 10-70-3 72556, 12566 Servic Dealer Copy -- Not for ResaleMotoi0 = ae Bobcat. 10-704 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleFUEL SYSTEM Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is one suggested blending guideline which should prevent fuel gelling problems in cold temperatures: ‘TEMPERATURE No.2 | NO. “SC (ASF) 100% [0% Down to -29°C (-20°F) 50% | 50% Below 20°C (20°F) 0% | 100% At a minimum, Low Sulfur (600 ppm sulfur) Diesel Fuel must be used in this machine: “The following fuels can also be used in this machine: + Ultra Low Sulfur (15 ppm sulfur) Diese! Fuel. + Biodiesel Blend Fuel - Must contain no more than five percent biodiesel mixed with low sulfur or ultra low sulfur petroleum based diesel. This is commonly marketed as BS blended diesel fuel. BS blended diesel fuel must meet ASTM D975 (US Standard) ot EN500 (EU Standard) specifications. asof 910 10-80-1 Biodiesel Blend Fuel Biodiesel blend fuel has unique qualities that should be considered before using in this machine: + Cold weather conditions can lead to plugged fuel ‘system components and hard starting. + Biodiesel blend fuel is an excellent medium for ‘microbial growth and contamination which can cause ‘corrosion and plugging of fuel system components. + Use of biodiese! blend fuel can result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines. + Shorter maintenance intervals can be required, such ‘as cleaning the fuel system and replacing fuel fers and fuel ines. + Using biodiesel blended fuels containing more than five percent biodiesel can affect engine life and cause deterioration of hoses, tubelines, injectors, injector pump and seals. Apply the following guidelines if biodiesel blend fuel is used: + Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank. ‘+ ensure that the tuel tank cap 1s securely ugnteneg. + Biodiesel blend fuel can damage painted surfaces, Temove all spilled fuel from painted surfaces immediately. + Drain all water from the fuel filter daily before operating the machine. Dealer Copy -- Not for Resale + Do not exceed engine oil change interval. Extended cil change intervals can cause engine damage. + Before machine storage; drain the fuel tank, refill wth 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 3 months. "72556, 72566 Service ManualFUEL SYSTEM (CONT'D) Filling The Fuel Tank WMI AVOID INJURY OR DEATH ‘Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. w.2003-0807 Figure 10-80-4 Remove the fuel fil cap (Item 1) [Figure 10-80-1], Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO ‘SMOKING! Install and tighten the fuel fil cap [Figure 10-80-1]. aot 910 10-802 Secondary Fuel Filter See the service schedule for the service interval when to replace the secondary fuel fitter. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-80-2 Remove the fiter element (Item 1) [Figure 10-80-2]. Clean the area around the filter housing. Install the new fiter element with a new seal, and hand tighten, Remove air from the fuel system. (See Removing Air From The Fuel System on Page 10-80-4.) FINA ASUTI Ce) AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, ‘sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. w.2103.0508 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleFUEL SYSTEM (CONT'D) Figure 10-80-5, Primary Fuel Filter (Pre-Filter) Removing Water ire 10-80-3, Hold the fitter assembly (Item 1) and remove the screw {Item 2) [Figure 10-80-5] Figure 10-80-6 Open the drain valve (Item 1) [Figure 10-80-3] on the fuel pre-filter bottom cover to remove water from the filter. When clean fuel drains from the water separator, tighten the drain valve (Item 1) [Figure 10-80-3] by hand pressure. Replacing Filament See the service schedule for the service interval when to replace the fuel fier. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-80-4 Dealer Copy — Not for Resale Remove the filter element (Item 1), bow! (Item 2) and bottom cover (Item 3) [Figure 10-80-6] from the fiter housing, Clean the area around the filter housing and reinstall using a new fier element (Item 1) [Figure 10-80-8}. Remove air from the fuel system. (See Removing Air From The Fuel System on Page 10-80-4.) Open the drain valve (Item 1) [Figure 10-80-8] on the bottom cover of the fuel primary fiter and allow the fluid to drain into a container. Tighten the drain valve (Item 1) [Figure 10-80-4] by hand pressure. a7of910 10-80-3 "72556, 72566 Service ManualFUEL SYSTEM (CONT'D) Removing Air From The Fuel System Figure 10-80-7 ‘After replacing the fiter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine. ‘Turn the Start key switch to the Preheat position (Item 1) [Figure 10-80-7] (this will activate the electrical pump relay). Leave the Start key switch in the Run position (Item 2) [Figure 10-80-7] for 3 minutes. Crank the engine with the accelerator pedal released (low idle position) until the engine starts. Run the engine at low idle for approximately 5 seconds then cycle the accelerator pedal rapidly from the low idle position to the high idle position 3 times. The time taken to cycle the accelerator pedal to be typically one to 3 seconds. This will assist in displacing any residual ‘rapped air in the fuel injection pump. ‘Check for fuel leaks in the fuel system. WMS AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, ‘sparks or lighted tobacco away from fuel and oi Failure to use care around combustibles can cause explosion or fire. w2103.0508 agoto10 10-804 7 MEGS AVOID INJURY OR DEATH 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 "72556, 12566 Service Manual Dealer Copy — Not for ResaleENGINE LUBRICATION SYSTEM Checking And Adding Engine Oil Check the engine oil level every day before starting the engine for the work shift Figure 10-90-1 Open the engine cover and remove the dipstick (Item 1) [Figure 10-90-1], Keep the oil level between the marks on the dipstick (Inset) [Figure 10-90-1] Use a good quality motor oil that meets API Service Classification of Cl-4 or better. (See Oil Chart, [Figure 10-90-2}) aotoi0 10-90-1 Engine Oil Chart Figure 10-90-2 ENGINE OIL, RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE ‘CRANKCASE) TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION Cl-4 OR BETTER) [1] Synthetic Oil - Use recommendation from Synthetic ‘Ol Manutacturer. Use good quality engine oil that meets API Service Classification of Cl-4 or better. (See Oil Chart, [Figure 10-90-2},) Dealer Copy -- Not for Resale "72556, 72566 Service ManualENGINE LUBRICATION SYSTEM (CONT'D) Removing And Replacing Oil And Filter See the service schedule for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page 10-50-1.) Run the engine until itis at operating temperature. Stop the engine. Figure 10-90-3, Remove the access panel at the rear of the engine compartment. Route the hose (Item 1) [Figure 10 00 3] out through the access hole. Remove the cap. Drain the oil into a container and recycle or dispose of used oil in an environmentally safe manner. Install cap and put the drain hose into the engine ‘compartment, install the access cover WUT ‘AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, ‘sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause Figure 10-90-4 Open the engine cover. (See Opening And Closing on Page 10-160-1.) Remove the oil fer (Item 1) [Figure 10-90-4] Clean the filter housing surface. Put clean oil on the new oil fer gasket. Install the filter and hand tighten. Figure 10-90-5, Remove the filer cap (Item 1) [Figure 10-90-5], Put oil in the engine. For capacity, (See Fluid Capacities ‘on Page SPEC-10-4.) For type, (See Engine Oil Chart explosion or fire, 90. w2103.0508 0" Page 10-90-1.) Install fil cap, start the engine and let it run for several minutes Stop the engine, and check for leaks at the oi filter. Remove the dipstick (Item 2) [Figure 10-90-5] and check the oil level. Add oll as needed i tis not at the top mark ‘on the dipstick 401910 10-902 172556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC / HYDROSTATIC SYSTEM Checking And Adding Fluid Use only recommended fluid in the hydraulic system. (See Hydraulic / Hydrostatic Fluid Chart on Page 10-100- 1) Stop the machine on a level surface. Lower the boom all the way, ‘Stop the engine. Figure 10-100-1 Check the fluid level at the sight gauge (Item 1) [Figure 10-100-1], Figure 10-100-2 Remove the fil / breather cap (Item 1) [Figure 10-100-2] and add hydraulic fluid. at o1910 10-1004 Hydraulic ! Hydrostatic Fluid Chart Figure 10-100-3, HYDRAULIC / HYDROSTATIC FLUID RECOMMENDED ISO VISCOSITY GRADE (VG) ‘AND VISCOSITY INDEX (VI) TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE [1] VG 100; Minimum VI 120 [2] VG 46; Minimum Vi 140 [3] Synthetic Fluid; VG 46; Minimum VI 150 [4] BOBCAT Hydraulic / Hydrostatic Fluid Use only revomnmenved fluid in Ure hydiaulie system, [Figure 10-100-3]. (See Specifications on Page SPEC- 50-1.) Dealer Copy ~ Not for Resale "72556, 72566 Service ManualHYDRAULIC / HYDROSTATIC SYSTEM (CONT'D) Removing And Replacing Hydraulic Fluid WMI ‘AVOID INJURY OR DEATH 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 or eyes, mediate medical attention from a physician familiar with this injury. w.2072.0907 A WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, ‘sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. ww2109-0500 Figure 10-100-4 Remove the fill/ breather cap (Item 1) [Figure 10-100-4]. 4201910 40-1002 Figure 10-100-5, Remove the reservoir drain plug (Item 1) [Figure 10-100- 5] behind the right front wheel and drain the fluid into a container, Recycle or dispose of the fluid in an environmentally safe manner. Reinstall the drain plug and tighten ‘Add fluid until itis at the centre ofthe sight gauge (Item 1) [Figure 10-400-5), Install the fil cap. 172556, 72566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC / HYDROSTATIC SYSTEM (CONT'D) Hydraulic Tank Breather Removing And Replacing Hydraulic / Hydrostatic See the service schedule for the correct replacement Filter interval. (See SERVICE SCHEDULE on Page 10-50-1.) See the service schedule for the correct service intervals. Open the engine cover. (See Opening And Closing on (See SERVICE SCHEDULE on Page 10-50-1.) Page 10-160-1.) Figure 10-100-6 Figure 10-100-8 2 g Unscrew the plug (Item 1) [Figure 10-100-6] by hand. Remove and discard the breather (Item 1) [Figure 10- a 100-8}. S Figure 10-100-7 2 Install the new fil breather. 3 > = 5 é & 3 3 6 Remove the cartridge (Item 1) [Figure 10-100-7] from the oil filter. NOTE: Be careful to keep impurities from getting into the hydraulic / hydrostatic system. Put the new cartridge in the ot fier. ‘Top up the oil if necessary. Inspect the seal and replace if necessary. Replace the plug. 4301910 10-1003, "72556, 72566 Service ManualAso 910 x Bobcat Cae = é 10-1004 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleATTACHMENT CARRIER Inspection And Maintenance Figure 10-111 The telescopic handler mounting hooks (Item 1) [Figure 10-1101] must not be damaged. Check for cracked or broken hooks. Figure 10-110-2 The stop blocks (Item 1) [Figure 10-110-2] must not be damaged. Check for bent or broken stop blocks. 4501910 10-1104 Figure 10-110-3, The telescopic handler attachment locking pins (item 1) [Figure 10-110-3] must move freely. The pins must not be bent or the ends deformed. Figure 10-110-4 jealer Copy — Not for Resale The pins must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-110-4] Lubricate the attachment carrier. SCHEDULE on Page 10-50-1.) (See SERVICE "72556, 72566 Service Manual46 01910 = ae Bobcat. 10-1102 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleAXLES (FRONT AND REAR) Checking Oil Level (Planetary Carrier) Figure 10-120-1 Put the machine on a level surface with the plugs (Item 1) [Figure 10-120-1] positioned as shown. Remove the plugs (Item 1) [Figure 10-120-1]. The oil level should be at the bottom edge of the plug hole. ‘Add gear lube through the hole (tem 1) [Figure 10-120- 1 if the oil level is below the hole. For capacity. (See Fluid Capacities on Page SPEC-10-4.) For type, (See ‘Specifications on Page SPEC-50-1,) Install and tighten the plug. Repeat the procedure for the other side. a7 910 10-1204 Removing And Replacing Oil (Planetary Carrier) (See SERVICE SCHEDULE on Page 10-50-1.) for the correct service interval. Figure 10-120-2 Put the machine on a level surface with the plug (Item 1) [Figure 10-120-2] positioned as shown. Remove the plug (Item 1) [Figure 10-120-2] and drain into a container. Recycle or dispose of the used lubricant in an environmentally safe manner. lot for Resale Reposition the plug hole and add gear lube until the lube = level is at the bottom edge of the plug hole (Item 1) ! [Figure 10-120-1]. For capacity, (See Fluid Capacities on 2 Page SPEC-10-4_) For type, (See Specifications on Page & ‘SPEC-50-1,) Dealer Install and tighten the plug. Repeat the procedure for the other side. "72556, 72566 Service ManualAXLES (FRONT AND REAR) (CONT'D) Checking And Adding Oil (Front Differential) See the service schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-120-3, Put the machine on a level surface. Remove the plug (Item 1) [Figure 10-120-3}. The oil level should be at the bottom edge of the plug hole. ‘Add oll through the hole i oll evel Is below the hole (item 1) Figure 10.470.3] For capacity, (See Fluid Capacities on Page SPEC-10-4.) For type, (See Specifications on Page SPEC-50-1.) Install and tighten the plug. 49.1910 10-1202 Removing And Replacing Oil (Front Differential) See the service schedule for the correct service interval, (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-120-4 With the machine on a level surface remove the plug (item 1) [Figure 10-120-4] and drain into a container. Recycle or dispose of the used lubricant in an ‘environmentally safe manner. ‘Add oil through the hole (Item 1) [Figure 10-120-3] until oil level is below the hole. For capacity, (See Fluid Capavilies un Paye SPEC-10-8.) Fur ype, (See. ‘Specifications on Page SPEC-50-1.) Install and tighten the plug, 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleAXLES (FRONT AND REAR) (CONT'D) Checking And Adding Oil (Rear Differential) Figure 10-120-5 Put the machine on a level surface. Remove the plug (Item 1) [Figure 10-120-5]. The oil level should be at the bottom edge of the plug hole. Add oil through the hole if oil level is below the hole. For capacity, (See Fluid Capacities on Page SPEC-10-4,) For type, (Gee Specifications on Page SPLC-30-1.) Install and tighten the plug. 49 01910 10-1203 Removing And Replacing Oil (Rear Differential) Figure 10-120-6 See the service schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1.) With the machine on a level surface remove the plug {Item 1) [Figure 10-120-6] and drain into 2 container. Recycle or dispose of the used lubricant in an environmentally safe manner. for Resale ‘Add cil through the hole (item 1) [Figure 10-120-5] until = oil level is below the hole. For capacity, (See Fluid S Capacities un Paye SPEC-10-8) Fur type, (See 4 Specifications on Page SPEC-50-1.) > Install and tighten the plug 6 & 3 3 3 72556, 12566 Service ManualAXLES (FRONT AND REAR) (CONT'D) Checking And Adding Oil (Front Drop Box) Figure 10-120-7 Remove the plug (Item 1) [Figure 10-120-7]. The oil level ‘should be at the bottom edge of the plug hole. ‘Add oil through the hole (item 1) [Figure 10-120-7] ifthe cll level is below the hole. For capacity, (See Fluid Capacities on Page SPEC-10-4) For type, (See Specifications on Page SPEC-50-1.) Inctall and tighten the plug. Removing And Replacing Oil (Front Drop Box) Figure 10-120-8 With the machine on a level surface, remove the plug (Item 1) [Figure 10-120-8] and drain into a container. Recycle or dispose of the used lubricant in an ‘environmentally safe manner. Add oil through the hole (item 1) [Figure 10-120-7] until oil level is below the hole. For capacity, (See Fluid Capacities on Page SPEC-10-4.) For type, (See Specifications on Page SPEC-50-1.) Install aid Gghten the play, sooto10 10-1204 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleLUBRICATING THE TELESCOPIC HANDLER Lubrication Locations Lubricate as specified in the service schedule for the best Performance of the machine. (See SERVICE ‘SCHEDULE on Page 10-50-1.) Record the operating hours each time you lubricate so that itis performed at the correct interval Always use a good quaiiy lithium based multipurpose grease. Apply lubricant until extra grease shows. Lubricate the following locations on the telescopic handler: Figure 10-130-1 Axle Pivots - Top and bottom (Item 1) [Figure 10-130-1] all four wheels. Figure 10-130-2 Axle Oscillation - Rear Axle (Item 1) [Figure 10-130-2] 54 of 910 10-1304 Figure 10-130-3, Attachment Carrier Pivot (tem 1) [Figure 10-130-3] (Both Sides). Figure 10-130-4 Dealer Copy — Not for Resale Tilt Cylinder Base End (Item 1) [Figure 10-130-4], 72556, 72566 Service ManualLUBRICATING THE TELESCOPIC HANDLER (CONT'D) Lubrication Locations (Cont'd) Figure 10-130-5 Tilt Cylinder Rod End (Item 1) [Figure 10-130-5] Figure 10-130-6 Lift Cylinder Base End, Slave Cylinder Base End (Item 1) [Figure 10-130-6). s20f910 10-1302 Figure 10-130-7 NOTE: Raise the boom and install the approved boom stop before lubricating the boom and slave cylinders, (See Installing The Approved Boom Stop on Page 10-150-1.) Lift Cylinder Rod End (Item 1), Slave Cylinder Rod End (Item 2) [Figure 10-130-7). Figure 10-130-8 Boom Pivot (Item 1) [Figure 10-130-8] (Four Places). 172556, 72566 Service Manual Dealer Copy — Not for ResaleLUBRICATING THE TELESCOPIC HANDLER Figure 10-130-11 (CONT'D) Lubric ation Locations (Cont'd) Figure 10-130-9 Boom Slide [Figure 10-130-9] (Four Places). Figure 10-130-10 Cab Door Hinges (Item 1) [Figure 10-130-10] (Upper). saofo10 10-1303, ‘Cab Door Hinges (Item 1) [Figure 10-130-14] (Lower). Dealer Copy ~ Not for Resale "72556, 72566 Service ManualS401 910 10-1304 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleTIRE MAINTENANCE. Wheel Nuts Figure 10-140-1 (See SERVICE SCHEDULE on Page 10-50-1.) [Figure 10-140-1] for the service interval to check the wheel nuts. The correct torque is 360 Nem (266 ft-lb) torque. Rotating Check the tires regularly for wear, damage and pressure, (See Traction on Page SPEC-10-3.) for the correct tire presoure. Rear tires usually wear faster than front tres. To keep the ‘wear even, move the front tires to the rear and rear tires to the front. Itis important to keep the same size tires on each side of the telescopic handler. If different sizes are used, each tire will be tuning at a different rate and cause excessive ‘wear. The tread bars of all the tires must face the same direction. Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capacity. Check for the correct pressure before operating the telescopic handler. ss 01910 10-1404 Mounting WOT When the engine is running during service, the Travel Direction Lever must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W.2397-0301 Tires are to be repaired only by an authorized person using the correct procedures and type of equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage. ‘The rim flange must be cleaned and free of rust, The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire. ‘Avoid excessive pressure which can rupture the tire and ‘cause serious injury or death. During inflation of the tire, check the tire pressure ‘frequently to avoid over infiation. "72556, 72566 Service Manual Dealer Copy -- Not for Resalese of 910 10-1402 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleAPPROVED BOOM STOP If the boom is raised for service or maintenance, use the + following procedure to install and remove the approved boom stop. . Installing The Approved Boom Stop + Put the telescopic handler on a flat, solid and level surface. + With the operator in the seat, the seat belt fastened, Travel Direction Control in neutral and the parking brake engaged, start the engine and raise the boom and stop the engine. Figure 10-150-1 + Remove the boom stop (Item 1) [Figure 10-150-1] from the storage postion Figure 10-150-2 + Install the pins and secure with fasteners [Figure 10- 150-2) ‘+ Start the engine and lower the boom slowly [Figure 10-1502] so that the boom stop is held securely. 5701910 10-1504 Removing The Approved Boom Stop Start the engine and raise the boom. Stop the engine. Remove the fasteners, pins and boom stop. Dealer Copy — Not for Resale "72556, 72566 Service Manualsof 910 e-{ 10-1502 172556, 72566 Service Manual Dealer Copy — Not for ResaleENGINE COVER Opening And Closing Figure 10-160-1 Pull the latch handle (Item 1) [Figure 10-160-1] out and rotate counterclockwise. Raise the engine cover to provide access for maintenance. soof910 10-1601 Dealer Copy — Not for Resale "72556, 72566 Service Manualsof 910 &- 10-1602 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleTELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE Storage Sometimes it can be necessary to store your Bobcat telescopic handler for an extend period of time. Below is a list of items to perform before storage. + Thoroughly clean the telescopic handler including the engine compartment. + Lubricate the telescopic handler. + Replace worn or damaged parts. + Park the telescopic handler in a dry protected shelter. + Lower the boom all the way and put the attachment (i equipped) flat on the ground. + Put grease on any exposed cylinder rods. + Put fuel stabilizer in the fuel tank and run the engine 1a few minutes to circulate the stabilizer to the pump and fuel injectors. If biodiesel blend fuel has been used, perform the following: Drain the fuel tank, refill with 100% petrolcum dicacl fuel, add fuel stabilizer and run the engine for at least 30 minutes. + Drain and flush the cooling system. Refill with remixed coolant. + Replace all fluids and filters (engine, hydraulic / hydrostatic). + Replace air cleaner, heater and air conditioning fiters. + Putall 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. sr ot10 Return To Service After the Bobcat telescopic handler has been in storage, it is necessary to follow a list of items to return the telescopic handler to service. 10-1704 Check the engine and hydraulic fluid levels; check cootant level. Install a fully charged battery Remove grease from exposed cylinder rods. Check all belt tensions. Be sure all shields and guards are in place. Lubricate the telescopic handler. Check tire inflation and remove blocks from under frame. Remove cover from exhaust pipe opening. Resale Start the engine and let run for a few minutes while 5 Iheering the incinment panels and eysteme fs ‘correct operation. Operate machine, check for correct function. Stop the engine and check for leaks. Repair as needed. Dealer Copy — Ni "72556, 72566 Service Manuale20f910 &- 10-1702 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleSTOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER Procedure + Stop the telescopic handler on solid, flat and level ground. + Putthe Travel Direction Control Lever and Joystick in neutral. + Engage the parking brake. (See the Operation & Maintenance Manual for the correct procedure.) Figure 10-180-1 + Retract and lower the boom and attachment flat on the ground [Figure 10-180-1] + Tum the key switch to STOP and unfasten the seat ett + Use grab handles, safety tread and steps when getting off. DO NOT JUMP eaof 910 10-1804 WUT Before you leave the operator's position: + Put the travel Direction Control Lever and the Joystick in neutral. Engage the parking brake. + Retract and lower the boom and attachment flat ‘on the ground, + Stop the engine. Raise the restraint bar (if equipped). SEE THE MACHINE OPERATION & MAINTENANCE MANUAL FOR MORE INFORMATION. w.2037-0607 Dealer Copy -- Not for Resale "72556, 72566 Service Manual6401910 &- 10-1802 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleEMERGENCY EXIT Rear Window Figure 10-190-1 Turn the handle (see picture inset) [Figure 10-190-t] and push the rear window open. Exit through the rear window opening, #5 01910 10-1904 Dealer Copy — Not for Resale "72556, 72566 Service Manuales of 910 &- 10-1902 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC SYSTEM HYDRAULIC SYSTEM INFORMATION . ... - 20-10-1 Glossary Of Hydraulic / Hydrostatic Symbols . : + 20-10-1 Troubleshooting Chart . : : coos 20-10-4 Tightening Procedures .. 20-10-5 LIFT CYLINDER . - 20-20-1 Removal And Installation . . . . oe 20-20-1 Parts Identification a veces 20-20-6 Disassembly .. . : - - coos 20-20-7 Assembly . . oe . cece (20-20-11 BUCKET POSITIONING CYLINDER ... . ~ 20-30-1 Removal And Installation ©. 20-30-1 Parts Identification... we : + 20-30-6 Disassembly ..... veces voce eee vette ester eeteeeseeeess es 20-30-7 Assembly . . a : coe 20-30-11 EXTENSION CYLINDER . . veces 20-40-1 Cylinder Group Removal And Installation - . cee 20-40-1 Upper Tubeline Removal . . . +. 20-40-3 Upper Tubeline installation . - 20-40-5 Extension Cylinder Removal And Installation . vec ceees sees 2040-7 Tubeline Tray Disassembly . . . coos 20-40-9 Tubeline Tray Assembly... - - wees 20-40-10 Parts Identification : : : on 20-40-13, Disassembly .. . : a a coos 20-40-14 Assembly . . oe . cece (20-40-18 TILT CYLINDER - 20-60-1 Removal And Installation + 20-50-1 TILT CYLINDER .. vee 20-50-2 Parts Identification : : : coe 20-50-3 Disassembly .. - . oe oe wees 20-50-4 Assembly : : . : coos 20-50-9 STEERING CYLINDER (FRONT) . oe wees 20-60-1 Removal we oe 20-60-1 Installation 20-60-2 Disassembly .. . : a a cece 20-60-4 Assembly . . oe . cece 20-60-5 STEERING CYLINDER (REAR) . oe cece 20-61-1 Removal .. - we ~ 20-61-1 Installation ©. 20-61-2 Disassembly ~ 20-61-4 Assembly + 20-61-6 #701910 20.01 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleDRIVE BOX Parts Identification 20-70-1 20-70-1 Disassembly . 20-70-2, Assembly : : 20-70-6 Special Tools : : : - coveee se. 20-70-9 MAIN RELIEF VALVE .. . . . . vceee eee 20-80-41 Testing And Adjustment : 20-80-1 Removal And Installation . oe . ee eeee-.- 20-80-2 QUICK-TACH CYLINDER . . . ve veee ees 20-9041 Removal And Installation . oe . wees ee... 20-90-17 Parts Identification. 20-90-3, Disassembly . 20-90-4 Assembly 20-90-7, PORT RELIEF VALVES 220000 e eee ee ence eee e ss 20-1004 Adjustment Procedure : a a co cee cess 20-1004 STEERING MODE VALVE BLOCK .. . . ve vcee ees 20-1104 Removal And Installation . oe oe cece 20-110-1 Parts Identification «00... bons . veces 20-110-3 Disassembly ... - 20-110-4 Solenoid Testing... 2... : Device eee voeeee ss 20-1106 Assembly .. . . . : coves es 20-110-6 BRAKE VALVE . . . . . ceveee ss 20-1204 Removal And installation : a . ve eeee ees 20-1201 Disassembly And Assembly . oe oe wees sees ++. 20-120-2 GEAR PUMP - 20-130-4 Removal And Installation Parts Identification » 20-130-1 = 20-130-3 Disassembly And Assembly . = 20-130-4 FAN MOTOR .. . - - : wee ee es 20-1404 Removal And Installation : - a cece eee eee 20-1401 Parts Identification cee - 20-140-5 Disassembly And Assembly ..... - - cee eee ees» 20-140-6 HYDRAULIC FLUID RESERVOIR 20-150-1 Removal And Installation : - - cece eee eee, 20-1504 STEERING VALVE oe . 2+ 20-160-1 Removal And Installation : cece eee e ees 20-160-1 Parts Identification - 20-160-2 Disassembly .. ~ 20-160-3 Inspection . 20-160-9 '20-160-10 Assembly 9.01910 20.02 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE - 20-170-1 Troubleshooting Chart (Controllers) : » 20-170-1 Telescoping Valve Section Troubleshooting 20-170-2 Auxiliary Valve Section Troubleshooting . 20-170-6 ‘Troubleshooting Chart (Control Valve) 20-170-10 Removal And Installation .. = 20-170-11 Parts Identification 20-170-15 Disassembly And Assembly . 20-170-16 End Housing Disassembly And Assembly 20-170-17 Telescoping Valve Section Disassembly And Assembly . + 20-170-18 Auxiliary Valve Section Disassembly And Assembly 20-170-30 Lifting Valve Section Disassembly And Assembly 20-170-41 Tilting Valve Section Disassembly And Assembly .. . 20-170-46 Inlet-Outlet Valve Section Disassembly And Assembly. 20-170-52 JOYSTICK oo eee ence e tet ee eee 20-180-1 Removal And Installation. - 20-180-1 PARKING BRAKE _ (20-190-1 Valve Removal And Installation 20-190-1 Valve Disassembly And Assembly (20-190-2 PILOT PRESSURE LOCKOUT VALVE .. - 20-200-1 Testing : - 20-200-1 Removal And Installation... 20-200-2 Disassembly And Assembly . 20-200-3 ACCUMULATOR 20-210-1 Removal And Installation (20-210-1 ‘TOW VALVE » 20-220-1 Removal And Installation » 20-220-1 Disassembly And Assembly 20-220-2 FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE 20-230-1 Removal And Installation . (20-230-1 Disassembly And Assembly . 20-230-2 FLOW CONTROL VALVE (20-240-1 Removal And Installation .. 20-240-1 69 of 910, 20.03 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleTooto10 = ae Bobcat. 20.04 "72556, 12566 Service Manual Dealer Copy ~ Not for Resaleonyen onssand eounsie ON any sun oyoeds esau. 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(3AOV GNV 100S1448V N/S) 9597. OLLVINAHOS OFINWUGAH ooo12 9b 3A WA fowmouviinwauny @ «4 sr) a se) 2 0992 08g ~ aN WA "BIN3Y LO NGWNOUWIAVOUNY @) anwaxosvo @ enna ouvisoxa ywous2e08 Moesovcsa Wovens gamvn ©esas ae = (Bnoaw anv tonsaty WS! 9HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic / Hydrostatic Symbols Dealer Copy — Not for Resale GLOSSARY OF HYDRAULIC/HYDROSTATIC SYMBOLS fontrat Hud 1 Gnaieation ef Temperature) Grain Line Idrein or bleed |ine - jermometen = MECHANICAL CONNECTIONS ~ Double > The arrows in the dicmond CONNECTED JUNCTION OF OIL LINES: Wo} Neries electric signet with pom] nao rash, 1208 See Mana Trot a10Glossary Of Hydrauli HYDRAULIC SYSTEM INFORMATION (CONT'D) I Hydrostatic Symbols (Cont'd) GLOSSARY OF SYMBOL DESCRIPTION CYLINDER: Equipment to convert hydroulic energy into linear energy ond in which the fluid pressure operates alternately in bath directions (forword ond backward strokes) TSF dousce acting wyonaucic evcinoen, UNEQUAL DISPLACE Wite single piston rod DOUBLE ACTING HYORAULIC CYLINDER UNEQUAL DISPLACEMENT and CUSHION (ON ONE END ~ With single siston rod = PUMP: To convert mechanical into hydraulic energy energy —Q— Fixen capacity visPLaceMenT HYDRAULIC PUMP ~ Wath one Giectien ef flow 6B — vaRiawee CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC PUNE in feo drections of tisw Toisrectioneh MOTOR: To conver! hydreulic eneroy into rotary mechanical energy OH fixe0 capacity pisPLaceMeNtT BIDIRECTIONAL HYDRAULIC MOTOR - with two directrons Bf flow (bidireetionel} HYDRAULIC/HYDROSTATIC SYMBOL CONTROL SYMBOLS DESCRIPTION MECHANISMS CONTROL VALVE WITH DETENT {Wolds Volve in Position! — device for mentomning 2 given position {mechenicel) CONTROL VALVE ACTIVATED BY A PULL BUTTON (ronuel) CONTROL VALVE ACTIVATED BY A PUSH-PULL BUTTON (manual) CONTROL VALVE ACTIVATED BY A LEVER (manual) CONTROL VALVE ACTIVATED BY A PEDAL (marucil CONTROL VALVE WITH SPRING URN (machenicai) CONTROL VALVE ACTIVATED BY AN FLECTRIC SOLENOID (ecirieal) CONTROL VALVE ACTIVATED BY PILOT PRESSURE (indirect control, pilot aetuates by pplication of pressure) [rez Tot o10 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC SYSTEM INFORMATION (CONT'D) Glossary Of Hydraulic / Hydrostatic Symbols (Cont'd) SYMBOL DESCRIPTION NON-RETURN VALVE, SHUTTLE VALVE® Volve which allows free flow in one direction only NON-RETURN VALVE (Check Volve) ~ Used as Replenishirg Volve, Lood Check Valve or Anticavitation Volve ~ Opens Hf the Iniel pressure is higher than the Outlet pressure Often eontoins inlernol spring whieh hos NO Significont pressure value on on in SPRING LOADED VALVE (Byposs Valve) ~ Opens if the Inlet pressure is greater thea the Quilel pressure plus the spring pressure VALVE = 11 ia possibie 10 open in the valve by pilot pressure SHUTTLE VALVE port is closed providing for the opening (fully or more flow paths (represented by severol squores) 4 LJ PATHS olf CONTROL VALVE (Two Position! controlled by on electric solenoid (with eetun spring) controlled by pressure (with return spring) Toot910 PILOT CONTROLLED NON-RETURN The Inlet port InS——J!9 connected to fhe higher pressure CT is culametically connected 10 the out Ouilet pert while the other Inlet DIRECTIONAL CONTROL VALVE: Valve restricted) or the closing of one or TWO PORTS and CLOSED FLOW SOLENOID ACTIVATED DIRECTIONAL PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (Two Position) ~ GLOSSARY OF HYDRAULIC/HYDROSTATIC SYMBOLS SYMBOL DESCRIPTION PRESSURE CONTROL VALVE: Valve ensuring the conirol of pressure a RELIEF VALVE - When the Intet pressure overcomes the opposing force af Ihe spring, the valve opens permitting tlow from the Outle! per! RELIEF/REPLENISHING VALVE or RELIEF /ANTICAVITATION VALVE ~ When the Inlet proseure overcomes the oppesing force fof the spring, the valve: opens permiting flow trom the Outlet gort = Allows free flow in ihe opposite direction | zl =I DUAL PRESSURE RELIEF VALVE - our _L J), When the inlet pressure TAI! cvercomes the opposing rorce TT Gt ine spring, the valve opens permitting flew tram Ine outlet por! Pilot pressure provides @ Second pressure velve FLOW CONTROL VALVE: Valve controlling the flow in one or both directions t- ONE WAY RESTRICTOR VALVE (Non-Return Valve with Restriction! ~ Uni cllowing free flow in one irection but restrieved flow in the olher direction TOW VALVE ~ Normally in closed position -><+ 20-10-3 Feary "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC SYSTEM INFORMATION (CONT'D) Troubleshooting Chart N WARNING The following troubleshooting chart is provided for assistance in locating and correcting problems which até 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 Styetments can cause injury or death. only w.2004-1265 PROBLEM CAUSE [The hydraulic system wil not operate. 236 [The hydraulic furd temperature warning ight comes ON when hydraulies are i loperating. [Stow hycraulie system action Fydraulc action is not moth [Boom goes up slowly at full engine rpm. [The boom comes down wih the fever n neural positon, KEY TO CORRECT THE CAUSE 7. The Maid level is not correct The hydraulic pump has damage. 3. Relief valve is not at the correct pressure. Suction leak on the inlet side of the hydraulic pump. %. Fluid is cold. Wrong viscosity fluid. (See Section SPEC-OT) 8. Using the machine for more than Is rated sapachy. “TTaternal Teak Tn the WA eylindar External leak from the cylinder(s) ‘3. Damaged lit spool. agotoi0 20-404 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC SYSTEM INFORMATION (CONT'D) Tightening Procedures er When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12000-0888 To tighten the hydraulic fittings, tubelines etc. (See HYDRAULIC CONNECTION SPECIFICATIONS on Page ‘SPEC-40-1.) for the correct procedure and torque. I NUE 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 1s not received immediately. 1.2145, 0200 atofoi0 20-10-5 "72556, 72566 Service Manual Dealer Copy ~ Not for Resaleagofo10 = ae Bobcat. 20-406 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleLIFT CYLINDER Removal And Installation Figure 20-20-1 Raise the boom and support onto adequate stands [Figure 20-20-1], Figure 20-20-2 Remove the rear cover (Item 1) [Figure 20-20-2] from the machine. aot aio 20-20-1 Figure 20-20-3, Remove the rod end pivot pin retainer pin (Item 1) [Figure 20-20-3]. Figure 20-20-4 2 3 3 g a Ss 3 2 1 > 2 3s S 5 3 3 a ‘Support both cylinders using a cinch strap (item 1) [Figure 20-20-4]. "72556, 72566 Service ManualLIFT CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-20-5 Remove the upper pivot pin using a pin removal tool (item 1) [Figure 20-20-5} A. WARNING Eye and boay protection Is required when welding or grinding. Wear approved goggles, helmet and clothing. Failure to wear eye and body protection can result in serious injury. w.2000-1285 NOTE: If a nut must be welded onto the pin for removal the following three steps must be performed. aot o10 20-202 Figure 20-20-6 4. Rotate the battery disconnect switch (Item 1) [Figure 20-20-6] to the right to disconnect the power supply from the battery. Figure 20-20-7 2. Protect the side window (Item 4) and frame opening (Item 2) [Figure 20-20-7] from sparks, "72556, 12566 Service Manual Dealer Copy — Not for ResaleLIFT CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-20-8 3. Wrap the eylinder rod with 2 damp welding blanket (item 1) [Figure 20-20-8] to prevent damage. Figure 20-20-9 Lift and support the cylinders using a hoist and lifting strap (Item 1), Remove the cinch strap (Item 2) [Figure 20-209] IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean, Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. |-2008.0888 asof 910 20-20-83 Figure 20-20-10 Lower both cylinders onto a wood block (Item 1) [Figure 20-20-10) Figure 20-20-14 2 3 3 g a Ss 3 2 > 2 3s S 5 3 3 a Remove the two hoses (Item 1) [Figure 20-20-10] from the load lock. NOTE: Mark the hoses for correct installation. "72556, 72566 Service ManualLIFT CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-20-12 Remove the two hoses (item 1) [Figure 20-20-12] from the cylinder. Figure 20-20-13, Remove the base end pivot pin retainer bolt (Item 1) [Figure 20-20-13}. agof 910 20-204 Figure 20-20-14 Remove the base end pivot pin Item 1) [Figure 20-20- 14], Figure 20-20-15, Lift and remove both cylinders [Figure 20-20-15], NOTE: Protect the side window from possible damage. "72556, 12566 Service Manual Dealer Copy — Not for ResaleLIFT CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-20-16 Remove the bolt and nut (lem 1) [Figure 20-20-15] and separate the lift cylinder and bucket positioning cylinder. a7 of 910 20-20-5 Dealer Copy — Not for Resale "72556, 72566 Service ManualLIFT CYLINDER (CONT'D) Parts Identification Dealer Copy -- Not for ResaleLIFT CYLINDER (CONT'D) Disassembly Use the following tools to disassemble the cylinders: MEL1074-0-ring Seal Hook MEL1353-Cylinder Gland Nut Wrench Figure 20-20-17 2 Sr, Pane Put the cylinder in a vise [Figure 20-20-17]. Remove the four bolts (Item 1) and remove the load lock (item 2) [Figure 20-20-18} Figure 20-20-19 Carefully peen the lock ring from the head gland [Figure 20-20-19] Figure 20-20-20 Loosen the head gland [Figure 20-20-20] a9 of 910 20-20-7 "72556, 72566 Service Manual Dealer Copy — Not for ResaleLIFT CYLINDER (CONT'D) Figure 20-20-23 Disassembly (Cont'd) Figure 20-20-21 Remove the set screw (Item 1) [Figure 20-20-23] from the piston. Figure 20-20-24 Remove the rod assembly (Item 1) [Figure 20-20-24] from the housing, Figure 20-20-22 ‘Support the cylinder rod on a wood block and remove the piston [Figure 20-20-24]. Put the rod end of the cylinder in a vise [Figure 20-20- 22. m1 910 20.208 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleLIFT CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-20-25 Figure 20-20-27 [Figure 20-20-25] from the piston. Figure 20-20-26 Remove the two wear rings (Item 1) and seal (Item 2) piston. Figure 20-20-28 a i‘ Remove the O-ring (Item 1) (Figure 20-20-27] from the 2 P2810 the rod. Remove the expander O-ring (Item 1) [Figure 20-20-26]. ororo10 20-209 Remove the head gland (Item 1) [Figure 20-20-28] from "72556, 72566 Service Manual Dealer Copy — Not for ResaleLIFT CYLINDER (CONT'D) Figure 20-20-31 Disassembly (Cont'd) Figure 20-20-29 Remove seal (item 1) wear ring (Item 2) and wiper (Item 3) [Figure 20-20-30] from the head gland, Remove the two O-rings (Item 1) [Figure 20-20-29] from the head gland. Figure 20-20-30 Remove the wear ring (Item 1) [Figure 20-20-30}, mai910 20-20-10 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleLIFT CYLINDER (CONT'D) Assembly Use the following tools to assemble the cylinders: MEL1353-Cylinder Gland Nut Wrench MEL 1033-Rod Seal installation Too! Wash the cylinder parts in solvent and dry with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Lubricate all O-rings and seals with hydraulic fluid during installation. Always use nev O-rings and seals. Figure 20-20-32 Install the wiper (Item 1), wear ring (Item 2) and seal (item 3) [Figure 20-20-32] in the head gland. jure 20-20-33, P2869 Install the wear ring (Item 1) [Figure 20-20-33], sofo10 20-20-11 Figure 20-20-34 Install the centre seal (Item 1) [Figure 20-20-34), NOTE: The groove in the seal must point away from the wiper seal (Item 4) [Figure 20-20-32}. Figure 20-20-35, Dealer Copy — Not for Resale Install the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-20-35] "72556, 72566 Service ManualLIFT CYLINDER (CONT'D) ‘Assembly (Cont'd) Figure 20-20-36 O Install the head gland (Item 1) [Figure 20-20-36] onto the rod. Figure 20-20-37 P2917 Install the O-ring (Item 1) [Figure 20-20-36] in the piston. Figure 20-20-38 cS Install the expander O-ring (Item 1) [Figure 20-20-38] on the piston. Figure 20-20-39 Install the two wear rings (Item 1) and seal (Item 2) [Figure 20-20-39] onto the piston, onoro10 20-20-12 "72556, 12566 Service Manual Dealer Copy — Not for ResaleLIFT CYLINDER (CONT'D) Figure 20-20-42 Assembly (Cont'd) Figure 20-20-40 Install and tighten the set screw (Item 1) [Figure 20-20- 42). Figure 20-20-43 Clean off any old residue, and apply LOCTITE® 243 o equivalent to the threads on the rod {Figure 20-20-40} Figure 20-20-41 2 3 3 g a Ss 3 2 1 > 2 3s S 5 3 3 a Install the rod assembly (Item 1) [Figure 20-20-43] into Pamet the housing. Install the piston (Item 1) [Figure 20-20-41] on the rod. 95 01910 20-20-13, "72556, 72566 Service ManualLIFT CYLINDER (CONT'D) Figure 20-20-46 ‘Assembly (Cont'd) Figure 20-20-44 Install the load lock (Item 1) onto the eylinder and tighten the four bolts (Item 2) [Figure 20-20-46}. Tighten the head gland [Figure 20-20-44] Figure 20-20-45, Peen the lock ring into the groove in the head gland [Figure 20-20-45}. 6 of 910 20-20-14 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleBUCKET POSITIONING CYLINDER Removal And Installation Figure 20-30-1 Raise the boom and support on adequate stands [Figure 20-30-41] Figure 20-30-2 Remove the rear cover (Item 1) [Figure 20-30-2] from the machine. Figure 20-30-3, Remove the rod end pivot pin retainer pin (Item 1) [Figure 20-30-3]. 2 3 3 g a Ss 3 2 1 > 2 3s S 5 3 3 a ‘Support both cylinders using a cinch strap (item 1) [Figure 20-30-4]. 71910 20-30-1BUCKET POSITIONING CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-30-5 Remove the upper pivot pin using a pin removal tool (item 1) [Figure 20-30-5} A. WARNING Eye and boay protection Is required when welding or grinding. Wear approved goggles, helmet and clothing. Failure to wear eye and body protection can result in serious injury. w.2000-1285 NOTE: If a nut must be welded onto the pin for removal the following three steps must be performed. 99 01910 Figure 20-30-6 4. Rotate the battery disconnect switch (Item 1) [Figure 20-30-6] to the right to disconnect the power supply from the battery, Figure 20-30-7, 2. The side window (item 1) and frame openings (Item 2) [Figure 20-30-7] must be protected from sparks. 20-302 Dealer Copy — Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-10 Removal And Installation (Cont'd) Figure 20-30-8 Lower both cylinders onto a wood block (Item 4) [Figure 20-30-10) 3. The cylinder rod must be wrapped with a damp welding blanket (Item 1) [Figure 20-30-8] to prevent damage. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can auickiv damage the system. Figure 20-30-9 Figure 20-30-14 Lift and support the cylinders using a hoist and lifting strap (Item 1), Remove the cinch strap (Item 2) [Figure 20-30-9]. Remove the two hoses (Item 1) [Figure 20-30-14] from the load lock. NOTE: Mark the hoses for correct installation. moto10 20-30-83BUCKET POSITIONING CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-30-12 Remove the two hoses (item 1) [Figure 20-30-12] from the cylinder. Figure 20-30-13, Remove the base end pivot pin retainer bolt (Item 1) [Figure 20-30-13}. 40001 910, Figure 20-30-14 Remove the base end pivot pin (Item 1) [Figure 20-30- 14], Figure 20-30-15 Lift and remove both cylinders [Figure 20-30-15], NOTE: Protect the side window from possible damage. 2030-4 Dealer Copy — Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Removal And Installation (Cont'd) Figure 20-30-16 Remove the bolt and nut (lem 1) [Figure 20-30-16] and separate the lft cylinder and bucket positioning cylinder. 401 of 910, 20-30-5 Dealer Copy — Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Parts Identification 1. Bushing 2. Grease Fitting 3. Housing 4. Wear Ring 5. Expander O-ring 6 Seal 7. Set Screw 8 Piston 9. O-ring 10. Back-up Ring 11. Head Gland 12. Wiper Seal 13. Rod 162: 10201910 20-306 Dealer Copy -- Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Disassembly Use the following tools to disassemble the cylinder MEL1353 - Cylinder Gland Nut Wrench MEL1074 - O-ring Seal Hook Clean the outside of the bucket positioning cylinder before disassembly. Figure 20-30-17 Put the oylinder in a vice [Figure 20 30 47]. Figure 20-30-18 Carefully peen the lock ring from the head gland [Figure 20-30-18], 103.1910, Figure 20-30-19 Remove the head gland [Figure 20-30-19}. Figure 20-30-20 Dealer Copy — Not for Resale Remove the rod assembly (Item 1) [Figure 20-30-20) from the housing. 20-30-7BUCKET POSITIONING CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-30-21 Put the rod end of the cylinder in a vise [Figure 20-30- 24] Figure 20-30-22 Support the cylinder rod on a wood block and remove the sset screw (Item 1) [Figure 20-30-22] from the piston. Figure 20-30-23, Remove the piston assembly (item 1) [Figure 20-30-23] from the rod. Figure 20-30-24 Remove the two wear rings (Item 1) and seal (Item 2) [Figure 20-30-24] from the piston. 404 910, 20-308 Dealer Copy -- Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-30-25 , or Remove the expander O-ring (Item 1) [Figure 20-30-25]. Figure 20-30-26 Remove the O-ring (Item 1) [Figure 20-30-26] from the piston, Figure 20-30-27 Remove the head gland (item 1) [Figure 20-30-27] from the rod Figure 20-30-28 Remove the centre seal (Item 1) and outer wear ring {Item 2) [Figure 20-30-28] 405 0f 910, 20-309 Dealer Copy — Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-30-29 Remove any residue from the threads on the cylinder rod [Figure 20-30-31], Remove the outer wear ring (Item 1) and wiper (Item 2) [Figure 20-30-29]. Figure 20-30-30 PaZS6I Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-30-30). 408. 910, 20-30-10 Dealer Copy ~ Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Assembly Use the following tools to assemble the cylinder: MEL1353-Cylinder Gland Nut Wrench MEL 1033-Rod Seal installation Too! Clean all parts in solvent and dry with compressed air, Inspect all parts for nicks, scratches or other damage, Replace any damaged parts. Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation. Figure 20-30-32 Install the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-30-32] onto the head gland. ire 20-30-33 Install the wiper (Item 1) and wear ring (Item 2) [Figure 20-30-33]. 107 of 910 Figure 20-30-34 Install the wear ring (Item 1) [Figure 20-30-34). Figure 20-30-35 Install the centre seal (Item 1) [Figure 20-30-35] NOTE: The groove in the seal must point away from the wiper seal (Item 4) [Figure 20-30-33]. 20-30-11 Dealer Copy — Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) ‘Assembly (Cont'd) Figure 20-30-36 Install the head gland (Item 1) [Figure 20-30-36] onto the rod. Figure 20-30-37 Install the O-ring (Item 1) [Figure 20-30-37] in the piston. Figure 20-30-38 Install the expander O-ring (Item 1) (Figure 20-30-38] ‘onto the piston, Figure 20-30-39 Install the two wear rings (Item 1) and seal (Item 2) [Figure 20-30-39]. 408. 910, 20-30-12 Dealer Copy -- Not for ResaleBUCKET POSITIONING CYLINDER (CONT'D) Assembly (Cont'd) Figure 20-30-40 Install the set screw (item 1) [Figure 20-30-42) into the piston and tighten. Figure 20-30-43 Install the piston (Item 1) [Figure 20-30-40] onto the rod. Figure 20-30-41 s g g ae Ss 3 G . 2 > 2 § IS 5 o 3 Io Pa Install the rod assembly (tem 1) [Figure 20-30-43} into ‘the housing. Apply LOCTITE® 243 or equivalent to the set screw (tem 1) [Figure 20-30-41]. 40901910, 20-30-13,BUCKET POSITIONING CYLINDER (CONT'D) ‘Assembly (Cont'd) Figure 20-30-44 Tighten the head gland [Figure 20-30-44] Figure 20-30-45, Carefully peen the lock ring over and into the nut [Figure 20-30-45) 11001910, 20-30-14 Dealer Copy — Not for ResaleEXTENSION CYLINDER Cylinder Group Removal And Installation Remove the inner boom. (See Removal on Page 50-40- 1) Figure 20-40-1 Remove the bolt (Item 1) and washer (Item 2) [Figure 20-40-1] from one side of the cylinder pin. Installation: Tighten the bolt to 255 - 285 N-m (188-210 felb) torque. Figure 20-40-2 Remove the pin assembly (Item 1) [Figure 20-40-2] from the opposite side. 111 of 910 20-40-1 Figure 20-40-3, Remove the two bolts (Item 1) [Figure 20-40-3] from the top ofthe inner boom. Installation: Tighten the bolts to 24 N-m (18 flb) torque. Figure 20-404 Remove the two hoses (Item 1) [Figure 20-40-4] from the tubelines. "72556, 72566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Figure 20-40-7 Cylinder Group Removal And Installation (Cont'd) Figure 20-40-5 Remove the electrical harness (if equipped) (Item 1) from the connector housing (Ite 2) [Figure 20-40-7], NOTE: Mark the connector housing for correct Remove the two hoses (Item 1) [Figure 20-40-5] from siskalaton. the bulkhead fittings. Figure 20-40-8 Figure 20-40-6 Remove tie-straps (if equipped) (Item 1) [Figure 20-40-8] Remove the two hoses electrical connector (Item 1) and pull the electrical harness into the boom. [Figure 20.40-6] from the auxiliary valve. 11201910, 20-402 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleEXTENSION CYLINDER (CONT'D) Cylinder Group Removal And Installation (Cont'd) Figure 20-40-9 For ease of installation, temporarily tie a rope onto the two hoses (Item 1) and electrical hamess (Item 2) [Figure 20-40-9]. Figure 20-40-10 Remove the extension cylinder assembly from the boom [Figure 20-40-10} 11301910, 20-40-3 Upper Tubeline Removal Figure 20-40-14 ‘Support the extension cylinder on a work surface. Remove the tie-straps (Item 1) [Figure 20-40-11] from the electrical hamess. Figure 20-40-12 Dealer Copy — Not for Resale Roll up the electrical harness (Item 1) [Figure 20-40-12] and temporarily tie to the existing hoses. "72556, 72566 Service ManualEXTENSION CYLINDER (CONT'D) Upper Tubeline Removal (Cont'd) Figure 20-40-13, Remove the two tie-straps (Item 1) [Figure 20-40-13] from the hoses (both sides). Figure 20-40-14 Loosen the tubeline clamp mounting bolts (item) [Figure 20-40-14}. NOTE: Mark the location of the tubelines for correct assembly. 11401 910, 20-40-4 Figure 20-40-15, Slide the tubeline bracket assembly (Item 1) forward. Remove the four hoses (Item 2) [Figure 20-40-15] from the tubelines. NOTE: Mark the hoses for correct assembly. igure 20-40-16 Remove the bolt (Item 1) [Figure 20-40-16] from the rod end of the cylinder. Lift and remove the tubelines from the top of the cylinder. "72556, 12566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Figure 20-40-19 Upper Tubeline Installation Figure 20-40-17 Slide the tubeline bracket back. Measure the distance Pare from the tubeline nut (item 1) to the tubeline clamp (Item [oe | yirigure 20-40-19} Set the tubeline assembly onto the extension cylinder The correct measurement must be 50,8 mm (2.00 in) for and install the bolt (Item 1) and tighten to secure the all four tubelines. tubeline clamp bracket (Item 2) [Figure 20-40-17] to the fod end of the cylinder. Tighten the tubeline clamps. Figure 20-40-18 Slide the tubeline bracket (Item 1) forward. Install the four hoses (Item 2) [Figure 20-40-18] on the tubelines. 115 0910, 20-40-5 "72556, 72566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Figure 20-40-22 Upper Tubeline Installation (Cont'd) Figure 20-40-20 Figure 20-40-23, Figure 20-40-24 ‘Secure the hoses to the tubeline bracket (both sides) with ‘wo tie-straps (Item 1) [Figure 20-40-22]. ‘Secure the electrical harness to the inner tubeline using Measure the distance from the front of the tubeline bracket (Item 1) [Figure 20-40-20] to the back of the 152-203 mm (6-8 in) tubeline clamps (Item 1) [Figure 20-40-21]. The correct measurement must be 1244,6 mm (49 in) for all four tubelines, To move and adjust the tubeline clamps (Item 1) loosen the bolts (Item 2) [Figure 20-40-24]. When the tubeline clamps are in the correct position, tighten the bolts. 11801 910, 20-40-86 raps (Item 1) [Figure 20-40-23] approximately every "72556, 12566 Service Manual Dealer Copy -- Not for ResaleEXTENSION CYLINDER (CONT'D) Figure 20-40-26 Extension Cylinder Removal And Installation Figure 20-40-24 Remove the two tubelines (Item 1) from the load lock (item 2) [Figure 20-40-26} Figure 20-40-27 Remove the six tie-straps (lem 1) [Figure 20-40-24] securing the electrical harness to the hose. Figure 20-40-25 wo) Dealer Copy — Not for Resale Install 2 hoist (Item 1) [Figure 20-40-27] to lift and Pareeo support the extension cylinder. Remove the three bolts (Item 1) and tubeline clamps (item 2) from the cylinder. Remove the bracket (Item 3) [Figure 20-40-25), 117 910, 20-40-7 "72556, 72566 Service ManualEXTENSION CYLINDER (CONT'D) Extension Cylinder Removal And Installation (Cont'd) Figure 20-40-28 Remove the bolt (ltem 1) and tubeline clamp (Item 2) [Figure 20-40-28] from both sides of the cylinder. Figure 20-40-29 Para Slide the extension cylinder through the tubelines [Figure 20-40-29] and remove the cylinder. NOTE: It can be necessary to reposition the lifting strap. 11801910, 20-408 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleEXTENSION CYLINDER (CONT'D) Tubeline Tray Disassembly Figure 20-40-30 Remove the four hoses (Item 1) [Figure 20-40-32] from the tubelines. NOTE: Mark the hoses for correct assembly. Remove all tie-straps (Item 1) [Figure 20-40-30] securing the electrical harness to the hoses. Figure 20-40-33 Figure 20-40-31 Dealer Copy — Not for Resale Straighten the two tabs (Item 1) (both ends) and remove the cover (Item 2) [Figure 20-40-33], Remove the two bolts (Item 1) and tubeline mounting brackets (Item 2) (Figure 20-40-34]. 11901910, 20-40.9 "72556, 72566 Service ManualEXTENSION CYLINDER (CONT'D) Tubeline Tray Assembly Tubeline Tray Disassembly (Cont'd) Figure 20-40-36 Figure 20-40-34 Remove the tie-strap (Item 1) from both ends of the electrical harness (Item 2) [Figure 20-40-34] Remove the electrical hamess. Figure 20-40-35, Place the tubelines (ltem 1) and (Item 2) next to each other on the left side of the tray (Item 6) [Figure 20-40- 36] and [Figure 20-40-37]. NOTE: The notch (Item 3) [Figure 20-40-36] represents the front of the tray. Remove the tubelines (Item 1) [Figure 20-40-35]. Place the tubelines (Item 4) and (Item 5) next to each ‘other on the right side of the tray (Item 6) [Figure 20-40- 36] and [Figure 20-40-37] 120 0f 910 20-40-10, "72556, 12566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Tubeline Tray Assembly (Cont'd) Figure 20-40-38 Place the electrical harness (Item 1) in the centre of the ‘two tubelines on the right side and secure using a tie- strap (Item 2) [Figure 20-40-38] on each end of the tubelines. Figure 20-40-39 With the tubelines held in position, install the tray cover (item 1) on the tray. Bend the two tabs (Item 2) [Figure 20-40-39] on each end of the tray cover. 121 910, 20-40-11 Install the hose / hamess assembly (Item 1) [Figure 20- 40-40] on the tubelines on the right side of the tray. NOTE: The hose (Item 2) must be connected to the outside tubeline (Item 3) [Figure 20-40-40]. Apply LOCTITE #271 onto the bolt Item 4) and instal the hose bracket (Item 5) [Figure 20-40-40] NOTE: Do not overtighten the bolt or damage will be done to the tubelines below. Install @ liestap (Item 0) [Figure 20-40-40] on the electrical hamess, "72556, 72566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Tubeline Tray Assembly (Cont'd) Figure 20-40-41 Install the hose assembly (Item 1) [Figure 20-40-41] on the two tubelines on the left side of the tray. NOTE: The hose (Item 2) must be connected to the inside tubeline (Item 3) [Figure 20-40-41]. ‘Apply LOCTITE #271 onto the bolt (Item 4) and install the hose bracket (Item 5) [Figure 20-40-44]. NOTE: Do not overtighten the bolt or damage will be done to the tubelines below. Figure 20-40-42 Install_new tie-straps (Item 1) [Figure 20-40-42] approximately every 152 - 203 mm (6 - 8 in) to secure the electrical harness to the hose. 1220f 910 20-40-12 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleEXTENSION CYLINDER (CONT'D) Parts Identification Housing Relief Valve yaar 910 20-40-13, "72556, 72566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Disassembly Use the following tool to disassemble the cylinder: MEL1074-O-ring Seal Hook Clean the outside of the extension cylinder before disassembly. Mark the outside of the extension cylinder for ease of assembly. Figure 20-40-43, Put the cylinder in a vise [Figure 20-40-43], Figure 20-40-44 8 ~~ P2600 oS Remove the two fittings (Item 1) and relief valves (Item 2) [Figure 20-40-44). 124 of 910 20-40-14 Figure 20-40-45 Carefully peen the lock ring from the head gland [Figure 20-40-45], Figure 20-40-46 Loosen the head gland [Figure 20-40-46] "72556, 12566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-40-47 Remove the rod assembly (Item 1) [Figure 20-40-47] from the housing. Figure 20-40-48 Put the rod end of the cylinder in a vise [Figure 20-40- 43} Figure 20-40-49 20005 ‘Support the eylinder rod on a wood block [Figure 20-40- 49} jure 20-40-50 Dealer Copy -- Not for Resale Loosen the set screw (Item 1) [Figure 20-40-50] 12501910, 20-40-15 "72556, 72566 Service ManualEXTENSION CYLINDER (CONT'D) Figure 20-40-53, Disassembly (Cont'd) Figure 20-40-54 Jo Remove the expander O-ring (Item 1) [Figure 20-40-53]. Figure 20-40-54 Remove the piston assembly (Item 1) [Figure 20-40-51] from the rod, Figure 20-40-52 Remove the O-ring (Item 1) [Figure 20-40-54] from the piston, Remove the two wear rings (Item 1) and seal (Item 2) [Figure 20-40-52] from the piston. 12601910, 20-40-16 "72556, 12566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Figure 20-40-57 Disassembly (Cont'd) Figure 20-40-55 Re [=e] 2) [Figure 20-40-57) Remove the head gland (Item 1) [Figure 20-40-55] from the rod, Figure 20-40-56 P2015 Remove the wiper (Item 1) and seal (Item 2) [Figure 20- 40-56] from the head gland. 127 910, 20-40-17 P2004 fe the two O-rings (Item 1) and back-up ring (Item Dealer Copy ~ Not for Resale "72556, 72566 Service ManualEXTENSION CYLINDER (CONT'D) Figure 20-40-60 Assembly Use the following tools to assemble the cylinder: Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and damage. Replace any worn or damaged parts. Always install new seals and O-rings. Lubricate all O- rings and seals with clean hydraulic fluid before installation, Figure 20-40-58 cylinder rod, Figure 20-40-64 PaO Install the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-58] on the head gland. Figure 20-40-59 Install the wiper (Item 1) and seal (Item 2) [Figure 20-40- 59]. 128 of 910 20-40-18, Install the head gland (Item 1) [Figure 20-40-60] onto the Install the O-ring (Item 1) [Figure 20-40-61] in the piston, "72556, 12566 Service Manual Dealer Copy — Not for ResaleEXTENSION CYLINDER (CONT'D) Assembly (Cont'd) Figure 20-40-62 Install the expander O-ring (Item 1) [Figure 20-40-62}. Figure 20-40-63 of Install the two wear rings (Item 1) and seal (Item 2) [Figure 20-40-63] onto the piston. P08 12901910, Figure 20-40-64 Install the piston (item 1) [Figure 20-40-64] on the rod and hand tighten. Dealer Copy — Not for Resale 20-40-19 jure 20-40-65 Tighten the set serew (Item 1) [Figure 20-40-65} 172556, 72566 Service MenualEXTENSION CYLINDER (CONT'D) ‘Assembly (Cont'd) Figure 20-40-66 Install the rod assembly (Item 1) [Figure 20-40-66] into the housing. Figure 20-40-67 25001 Tighten the head gland [Figure 20-40-67]. Figure 20-40-68 Peen the lock ring into the groove in the head gland [Figure 20-40-68), ire 20-40-69 Install the two fittings (Item 1) and two relief valves (Item 2) [Figure 20-40-69]. 12001910, 20-40-20, "72556, 12566 Service Manual Dealer Copy — Not for ResaleTILT CYLINDER Removal And Installation Remove the quick-tach assembly. (See Removal And Installation on Page 50-90-1.) igure 20-50-1 Raise the boom approximately 460 mm (1.5 ft) and install ‘a wood block under the boom [Figure 20-50-1]. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean, Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 1.200.088 Figure 20-50-2 Remove the two hoses (Item 1) [Figure 20-50-2] from the tubelines. 131 of 910 20-50-1 NOTE: Mark the hoses for correct installation. Figure 20-50-3 Install a lifting ring (Item 1) [Figure 20-50-3] and hoist to the top of the cylinder. Figure 20-50-4 Dealer Copy —Not for Resale If equipped with secondary auxiliary hydraulics remove the tubeline (Item 1) [Figure 20-50-4], "72556, 72566 Service ManualTILT CYLINDER Figure 20-50-7 Removal And Installation (Cont'd) Figure 20-50-5 Lower the cylinder from the boom and remove [Figure 20-50-7]. Remove the pivot pin retainer bolt (Item 1) [Figure 20-50- 5}. Figure 20-50-6 Remove the pivot pin [Figure 20-50-6], 1201910 20-502 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleTILT CYLINDER (CONT'D) Parts Identification 1. Bushing 2. Grease Fitting 3. Housing 4. Relief Cartridge 5. Wear Ring 6. Expander O-ring 7. Seal 8. Lock Ring Piston 10. Snap Ring 11. Cushion Sleeve 12. O-ing Rod 14. Head Gland saa 910, 20-50-3 Ee] "72556, 72566 Service Manual Dealer Copy — Not for ResaleTILT CYLINDER (CONT'D) Figure 20-50-10 Disassembly Use the following tool to disassemble the cylinder: MEL1074-O-ring Seal Hook MEL1075-Adjustable Gland Wrench Figure 20-50-8 Remove the relief cartridge (Item 1) [Figure 20-50-10] Figure 20-50-11 Put the cylinder in a vise [Figure 20-50-8], Figure 20-50-9 Remove the set screw (Item 1) [Figure 20-50-11] Remove the two hoses (Item 1) [Figure 20-50-9] from the eylinder. NOTE: Mark the location of the hos assembly. for correct 14401910, 20-50-4 "72556, 12566 Service Manual Dealer Copy — Not for ResaleTILT CYLINDER (CONT'D) Figure 20-50-14 Disassembly (Cont'd) Figure 20-50-12 Put the rod end of the cylinder in a vise [Figure 20-50- wae] 14 Loosen the head gland [Figure 20-50-12]. anata Figure 20-50-13 2 3 3 3 2 3 3 z 1 > 2 8 8 ran |S S Taam] Support the oyinder rod on a wood block [Figure 20-50- 415). Remove the rod assembly (Item 1) [Figure 20-50-13]. 42501910, 20-50-5 "72556, 72566 Service ManualTILT CYLINDER (CONT'D) Figure 20-50-18 Disassembly (Cont'd) Figure 20-50-16 Remove the lock ring (Item 1) [Figure 20-50-16]. Figure 20-50-19 Figure 20-50-17 Remove the two wear rings (Item 1) and seal (Item 2) [Figure 20-50-18] from the piston. Remove the expander O-ring (Item 1) [Figure 20-50-19]. Remove the piston (Item 1) [Figure 20-50-17] from the rod. 426.01 910, 20-506 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleTILT CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-50-20 Remove the O-ring (Item 1) [Figure 20-50-20] from the inside of the piston. Figure 20-50-21 Remove the head gland (Item 1) [Figure 20-50-24] from the rod. 137 of 910, Figure 20-50-22 Paat08 Remove the O-rings (Item 1) [Figure 20-50-22] from the head gland. Figure 20-50-23 Dealer Copy -- Not for Resale Remove the seal (Item 1) [Figure 20-50-23] from the head gland. "72556, 72566 Service ManualTILT CYLINDER (CONT'D) Figure 20-50-26 Disassembly (Cont'd) Figure 20-50-24 Pane Remove the snap ring (Item 1) [Figure 20-50-26}, Figure 20-50-27 Remove the expander O-ring (Item 1) [Figure 20-50-24] Figure 20-50-25 PRET Remove the cushion sleeve (Item 1) [Figure 20-50-27] from the head gland. Remove the wiper (Item 1) and seal (Item 2) [Figure 20- 50-25] from the head gland. 12801 910, 20-508 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleTILT CYLINDER (CONT'D) Assembly Use the following tool to assemble the cylinder: MEL1075-Adjustable Gland Nut Wrench Clean all the parts in solvent and dry with compressed alr. Inspect all parts for wear and damage. Replace any worn or damaged parts. Always install new seals and O-rings. Lubricate all O- rings and seals with clean hydraulic fluid before installation. Figure 20-50-28 Install the cushion sleeve (Item 1) [Figure 20-50-26] into the head gland, Figure 20-50-29 Pama Install the snap ring (Item 1) [Figure 20-50-29), 120 of 910 20-509 Install the wiper (iter 1) and seal (Item 2) [Figure 20-50- 30] into the head gland. Figure 20-50-34 Install the expander O-ring (Item 1) [Figure 20-50-31]. "72556, 72566 Service Manual Dealer Copy - Not for ResaleTILT CYLINDER (CONT'D) Assembly (Cont'd) Figure 20-50-32 Install the seal (Item 1) [Figure 20-50-32] into the head > Figure 20-50-33, Install the two O-rings (Item 1) [Figure 20-50-33] onto the head gland. 14001 910, 20-50-10, Figure 20-50-34 . Pac Install the head gland (Item 1) [Figure 20-50-34] onto the rod. Figure 20-50-35 Install the O-ring (Item 1) [Figure 20-50-35] inside the piston. "72556, 12566 Service Manual Dealer Copy -- Not for ResaleTILT CYLINDER (CONT'D) Assembly (Cont'd) Figure 20-50-36 Install the expander O-ring (Item 1) [Figure 20-50-36] conto the piston. Figure 20-50-37 om a Install the two wear rings (Item 1) and seal (Item 2) [Figure 20-50-37]. 141 of 910, 20-50-11 Figure 20-50-38 Clean off any old residue, and apply Loctite® #242 or ‘equivalent to the threads on the rod [Figure 20-50-38]. Figure 20-50-39 Install the piston (Item 1) [Figure 20-50-39] onto the rod and tighten. "72556, 72566 Service Manual Dealer Copy — Not for ResaleTILT CYLINDER (CONT'D) Figure 20-50-42 Assembly (Cont'd) a Figure 20-50-40 ZS a Tighten the head gland [Figure 20-50-42] Figure 20-50-43 Install the lock ring (Item 1) {Figure 20-50-40]. Figure 20-50-44 PASO Apply Loctite® #243 or equivalent to the set screw (Item 1) [Figure 20-50-43]. Install the piston / rod assembly (Item 1) [Figure 20-50- 44] into the housing, saret 910 20-50-12 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleTILT CYLINDER (CONT'D) Assembly (Cont'd) Figure 20-50-44 Install the set screw (Item 1) [Figure 20-50-44] Figure 20-50-45 Install the relief cartridge (Item 1) [Figure 20-50-45) 14st 910, Figure 20-50-46 Install the two hoses (Item 1) (Figure 20-50-46}, Dealer Copy ~ Not for Resale 20-50-13, "72556, 72566 Service Manual144 of 10 x Bobcat Cae = é 20-50-14 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleSTEERING CYLINDER (FRONT) Removal Figure 20-60-1 Remove the three bolts (Item 1) and remove the centering sensor (Item 2) from the front steering cylinder ((tem 3) [Figure 20-60-1] Figure 20-60-2 Loosen and remove the tie rod nut (Item 1) from the tie rod end (Item 2) [Figure 20-60-2]. Figure 20-60-3, Remove the tie rod (Item 1) from the steering case {tem 2) [Figure 20-60-3] by means of a puller. Figure 20-60-4 Dealer Copy — Not for Resale Disconnect the left and right tie rods (Item 1) from the piston (Item 2) [Figure 20-60-4] 145 01 910, 20-60-1 "72556, 72566 Service ManualSTEERING CYLINDER (FRONT) (CONT'D) Installation jure 20-60-7 Removal (Cont'd) Figure 20-60-5, Lubricate the seats of the seals and install the steering cylinder (Item 1) [Figure 20-60-7] into its seat. Remove the securing screws (Item 1) from the steering cylinder (item 2) [Figure 20-60-5] ure 20-60-8 Figure 20-60-6 Tighten the bolts (Item 1) [Figure 20-80-8] to 90 - 100 Nem (66 - 74 ft Ib) torque. Extract the cylinder (Item 1) [Figure 20-60-6] using a Plastic hammer. 146 01 910, 20-602 "72556, 12566 Service Manual Dealer Copy — Not for Resale‘STEERING CYLINDER (FRONT) (CONT'D) Installation (Cont'd) Figure 20-60-9 ‘Connect the left and right tie rods (Item 1) by screwing them onto the piston (Item 2) [Figure 20-60-9] using a torque wrench setting of 240-270 Nem (177 - 200 f-lb) Figure 20-60-10 Insert the tapered pins of the tie rod (Item 1) in the steering case (Item 2) and tighten the tie rod nut (Item 3) [Figure 20-60-10] to 270 - 300 N-m (200 - 222 ft-lb) torque. 147 910, 20-60-3 Figure 20-60-11, Install the centring sensor (Item 1) [Figure 20-80-11] for checking piston centring. Tighten the bolts (Item 2) [Figure 20-60-11] to 5 - 6 Nem (44.25 - 53 in-Ib) torque Dealer Copy ~ Not for Resale "72556, 72566 Service ManualSTEERING CYLINDER (FRONT) (CONT'D) Disassembly Figure 20-60-12 NOTE: Before disassembling the unit, drain the oil the cylinder chambers completely. Remove the snap ring (Item 1) from the cylinder head (Item 2) [Figure 20-60-12} Figure 20-60-13, S57 With the help of a plastic hammer, push the head (Item 1) inside the eylinder (Item 2) {Figure 20-60-13). NOTE: The head should line up with the edge of the cylinder. 14a of 910, 20-60-4 Figure 20-60-14 With the help of a drift, apply pressure to the stop ring (Item 1) that is placed inside the cylinder (Item 2) [Figure 20-60-14] and extract the ring using a screwdriver. Figure 20-60-15, Hammer the piston (Item 1) on the rear of the head (Item 2) [Figure 20-60-15] using a plastic hammer. Continue hammering until the head (Item 2) is ejected from the cylinder (Item 3) [Figure 20-60-15]. "72556, 12566 Service Manual Dealer Copy -- Not for Resale‘STEERING CYLINDER (FRONT) (CONT'D) Disassembly (Cont'd) Figure 20-60-16 Ey Disassemble the oylinder unit (Item 1) by extracting first the head (Item 2) then the piston (Item 3) [Figure 20-60- 16). NOTE: Down the assembly side of the piston (Item 3). The bevelled part “A” of the piston is oriented towards the head (Item 2) [Figure 20-60-16]. Figure 20-60-17 Eo Remove all seals, anti-extrusion rings and scraper rings from head, cylinder and piston [Figure 20-60-17]. NOTE: 1) All seals must be replaced every ti unit is disassembled. e the 2) Particular attention must be paid not to damage the seats of both seals and piston slide. 149 01 910, 20-60-5 Assembly Figure 20-60-18 oa ‘After applying grease, install the sealing ring (Item 1) on the shaft, the antiextrusion ring (Item 2) and the seraper ring (Item 3) [Figure 20-60-18] inside the cylinder. NOTE: Thoroughly check that positioning of the ant extrusion ring (Item 2) (Figure 20-60-18] is correct. Figure 20-6049 sey After applying grease, install the sealing ring (Item 1) on the shaft, the anticextrusion ring (Item 2) and the scraper ring (Item 3) [Figure 20-60-19] in the head. NOTE: Thoroughly check that positioning of the ant extrusion ring (Item 2) [Figure 20-60-19] correct. "72556, 72566 Service Manual Dealer Copy — Not for ResalSTEERING CYLINDER (FRONT) (CONT'D) Assembly (Cont'd) Figure 20-60-20 Install the seal (Item 1) onto the outside of the head (item 2) [Figure 20-80-20] NOTE: For easier assembly, apply grease to the outer surface of the piston. Do not roll the seal (item 1) [Figure 20-60-20]. Fiqure 20-60-21 Prepare the piston (Item 1) by instaling the guide ring (item 2), the magnetic ring (Item 3), the O-ring (Item 4) and the seal (Item 5) [Figure 20-60-24]. NOTE: For easier assembly, apply grease. 15001 910, 20-606 Figure 20-60-22 Centre the shaft on the cylinder (Item 1) so that it fits into the piston (Item 2) [Figure 20-60-22} NOTE: Apply a little grease to seals and cylinder. jure 20-60-23, Push the piston (Item 1) into the cylinder (Item 2) [Figure 20-60-23] for 100 mm (3.9 in) using a plastic hammer. "72556, 12566 Service Manual Dealer Copy -- Not for Resale‘STEERING CYLINDER (FRONT) (CONT'D) Assembly (Cont'd) Figure 20-60-24 Apply grease to head seals (Item 1), install the head onto the piston and push in into the cylinder (Item 2) [Figure 20-60-24] using a plastic hammer. Figure 20-60-25 Insert the stop ring (Item 1) ensuring that it fits into the seat of the cylinder (Item 2) [Figure 20-60-25]. Figure 20-60-26 Apply pressure to the head using two screwdrivers or levers until the head is fastened onto the stop ring (item 1) [Figure 20-60-26}, Figure 20-60-27 Dealer Copy -- Not for Resale Install the snap ring (Item 1) on the head (item 2) [Figure 20-80-27) NOTE: Make sure that the snap ring (Item 1) [Figure 20-80-27] is securely fastened in its seat. If necessary, force it into its seat using a drift and a hammer. 151 910, 20-60-7 "72556, 72566 Service Manual152 of 910 = ae Bobcat. 20-608 "72556, 12566 Service Manual Dealer Copy ~ Not for Resale‘STEERING CYLINDER (REAR) Removal Figure 20-61-1 Remove the centering sensor (Item 1) [Figure 20-61-1] of the steering piston. Figure 20-61-2 Remove the nuts (item 1) that lock the pivot pins (item 2) [Figure 20-61-2). 15301910, Figure 20-61-3 Disconnect the tapered pins of the tie rod (Item 1) from the steering case (Item 2) [Figure 2061-3] by means of a puller. Figure 20-61-4 20-61-1 Dealer Copy —- Not for Resale Disconnect the left and right steering bars (Item 1) from the piston (Item 2) [Figure 20-614] "72556, 72566 Service ManualSTEERING CYLINDER (REAR) (CONT'D) Installation Removal (Cont'd) Figure 20-61-7 Figure 20-61-5 Check that the O-rings of the axle unit are in good | . condition: lubricate the seats of the seals and install the Remove the securing screws (Item 1) from the steering steering cylinder (Item 1) [Figure 20-647] into its seat. cylinder (item 2) [Figure 20-61-5] Figure 20-61-8, Figure 20-61-6 Lock the cylinder by cross-tightening the screws Extract the cylinder (Item 1) [Figure 20-61-6] using a (Item 1) [Figure 20-61-8], apply a torque of 90 - 100 plastic hammer. Nem (68 - 74 feb), NOTE: For cylinder disassembly, (See “Disassembly” on Page 20-61-4.) 454.01 910, 20-612 "72556, 12566 Service Manual Dealer Copy — Not for ResaleSTEERING CYLINDER (REAR) (CONTD) Figure 20-61-14 Installation (Cont'd) Figure 20-61-9 Install the proximity sensor (Item 1) [Figure 20-61-11] for checking piston centring, Tighten the bots (Item 2) [Figure 20-61-14] to 5 -6 Nem Apply Loctite 242 tothe thread and connect the steering [lve ts pons em» bars by screwing the terminals onto the piston stem [Figure 20-61-9] Tighten the bolts to 240 - 270 Nem (177 - 200 ft-b) torque NOTE: Itis required that the rim of the articulation is, riveted onto the surfaces of the piston stem. Figure 20-64-40 Dealer Copy ~ Not for Resale Insert the pins (Item 1) in the steering case (item 2) [Figure 20-61-10] and lock into position using a torque wrench setting of 270 - 300 Nem (200 - 224 ft-lb). 455.01 910, 20-61-3 "72556, 72566 Service ManualSTEERING CYLINDER (REAR) (CONT'D) Disassembly Figure 20-61-12 Before disassembling the unit, drain the oil in the cylinder chambers completely. Remove the snap ring (Item 1) from the cylinder head (Item 2) [Figure 20-64-12} Figure 20-61-13, S57 With the help of a plastic hammer, push the head (Item 1) inside the cylinder (Item 2) [Figure 20-61-13]. NOTE: The head should line up with the edge of the cylinder. 156.01 910, 20-614 Figure 20-61-14 With the help of a drift, apply pressure to the stop ring (Item 1) that is placed inside the cylinder (Item 2) [Figure 20-61-14] and extract the ring using a screwdriver. Figure 20-61-15, Hammer the piston (Item 1) on the rear of the head (Item 2) [Figure 20-61-15] using a plastic hammer. Continue hammering until the head (Item 2) is ejected from the cylinder (Item 3) [Figure 20-61-15]. "72556, 12566 Service Manual Dealer Copy -- Not for ResaleSTEERING CYLINDER (REAR) (CONTD) Disassembly (Cont'd) Figure 20-61-16 Disassemble the cylinder unit (Item 1) by extracting first the head (Item 2) then the piston (Item 3) [Figure 20-61- 16). Nort :: Down the assembly side of the piston (Item 3). The bevelled part “A” of the piston is oriented towards the head (Item 2) [Figure 20-61-16]. Figure 20-61-17 Remove all seals, anti-extrusion rings and scraper rings from head, cylinder and piston [Figure 20-61-17]. NOTE: 1) All seals must be replaced every time the unit is disassembled. 2) Particular attention must be paid not to damage the seats of both seals and piston slide. 157 910, 20-615 "72556, 72566 Service Manual Dealer Copy ~ Not for ResaleSTEERING CYLINDER (REAR) (CONT'D) Assembly Figure 20-61-18 ‘After applying grease, install the sealing ring (Item 1) on the shaft, the anti-extrusion ring (Item 2) and the scraper ring (Item 3) [Figure 20-61-18] inside the cylinder. NOTE: Check the positioning of the anti-extrusion ring (Item 2) [Figure 20-61-18] to make sure it is securely in the groove. Figure 20-61-19 cy | After applying grease, install the sealing ring (Item 1) on the shaft, the antiextrusion ring (item 2) and the scraper ring (Item 3) [Figure 20-61-19] in the head. NOTE: Check the positioning of the anti-extrusion ring (Item 2) [Figure 20-61-19] to make sure it is securely in the groove. 458.01 910, 20-616 Figure 20-61-20 Install the seal (Item 1) [Figure 20-61-20] onto the outside of the head. Apply grease to the outer surface of the piston. Do not roll the seal (tem 1) [Figure 20-61-20] "72556, 12566 Service Manual Dealer Copy -- Not for ResaleSTEERING CYLINDER (REAR) (CONTD) Assembly (Cont'd) Figure 20-61-24 Prepare the piston (Item 1) by installing the guide ring (item 2), the magnetic ring (Item3), the O-ring (item 4)’ and the seal (Item 5) [Figure 20-61-21] Figure 20-61-22 Centre the shaft on the cylinder (Item 1) so that it fits into the piston (Item 2) [Figure 20-61-22]. NOTE: Apply a little grease to seals and cylinder. 15901 910, 20-61-7 Figure 20-61-23, Push the piston (Item 1) into the eylinder (Item 2) [Figure 20-61-23] for 100 mm (3.9 in) using a plastic hammer. Figure 20-61-24 Y Bcd Dealer Copy — Not for Resale Apply grease to head seals (Item 1), install the head onto ‘the piston and push in into the cylinder (Item 2) [Figure 20-81-24] using a plastic hammer. "72556, 72566 Service ManualSTEERING CYLINDER (REAR) (CONT'D) Figure 20-61-27 ‘Assembly (Cont'd) Figure 20-61-25, Install the snap ring (Item 1) on the head (Item 2) [Figure 20-61-27] | oo Make sure that the snap ring (Item 1) [Figure 20-61-27] Insert the stop ring (Item 1) ensuring that it fits into the is securely fastened in its seat. If necessary, force it seat of the cylinder (Item 2) [Figure 20-61-25] into its seat using a drift and a hammer. Figure 20-61-26 kt Apply pressure to the head using two screwdrivers or levers until the head is fastened onto the stop ring (Item 1) [Figure 20-61-26] 46001 910, 20-618 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleDRIVE BOX Parts Identification Figure 20-70-4 1. Gear 2. Snap ring 3. Ball bearing 4, Snap ring 5. Vent 6. Nut 7. Bearing 8. Shim 9. Plug 10. Seal 11, Ball bearing 12. Gear ‘Snap ring Ball bearing Seal Plug Lock washer Bott Magnet plug Dowel Plug Flange Oring 24. Bolt 25. Cover 26. Shim 27. Bearing 32500 161 of 910 20-704 "72556, T2566 Service Manual Dealer Copy — Not for ResaleDRIVE BOX (CONT'D) Disassembly Remove the front axle. (See Removal on Page 40-30-1.) Remove the drive motor. (See Removal And Installation on Page 30-30-1.) Figure 20-70-2 ‘S61 Loosen the securing bolts (Item 1) [Figure 20-70-2] only so that later when you pry the drive side flange cover loose. it does not fal Figure 20-70-3, Loosen the drive side flange cover (Item 1) [Figure 20- 70-3] using a plastic hammer. 16201910, 20-702 Figure 20-70-4 Take off the drive side flange cover (Item 1) [Figure 20- 70-4] by alternatively forcing a screwdriver into the appropriate slots, NOTE: Look out not to damage the surfaces. Figure 20-70-5, Remove the securing bolts and lift off the cover (Item 1) [Figure 20-70-5}, "72556, 12566 Service Manual Dealer Copy — Not for ResaleDRIVE BOX (CONT'D) Figure 20-70-8 Disassembly (Contd) Figure 20-70-6 Using two levers, remove the flange sealing ring (Item 1) [Figure 20-70-8] Figure 20-70-9 To remove the drive side shaft (Item 1), hook off the snap ring (Item 2) [Figure 20-70-6], Figure 20-70-7 Dealer Copy — Not for Resale Remove the snap ring (Item 1) [Figure 20-70-9] Using two levers, remove the drive side shaft (Item 1) [Figure 20-70-7), 463.1910, 20-70-3 "72556, 72566 Service ManualDRIVE BOX (CONT'D) Disassembly (Cont'd) Figure 20-70-10 With a puller, remove the bearing (Item 1) from the input shaft (item 2) [Figure 20-70-10}. Figure 20-70-11 Figure 20-70-12 With a puller, remove the bearing (Item 1) from the flange shaft (Item 2) [Figure 20-70-12]. Figure 20-70-13, Remove the secondary gear wheel (Item 1) [Figure 20- 70-13] using two levers. Remove the bearing (Item 1) and the snap ring (Item 2) [Figure 20-70-14}. 464 910, 20-704 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleDRIVE BOX (CONT'D) Figure 20-70-16 Disassembly (Cont'd) Figure 20-70-14 Remove the internal bearing (Item 1) [Figure 20-70-16] Figure 20-70-17 Remove the snap ring (Item 1) [Figure 20-70-14]. Figure 20-70-15 Dealer Copy -- Not for Resale Pull out the cup of the sealing ring (Item 1) by using drift {item 2) [Figure 20-70-47] [ssi Remove the flange (Item 1) [Figure 20-70-15] by means of a plastic hammer. 46501910, 20-70-5 "72556, 72566 Service ManualDRIVE BOX (CONT'D) Assembly Figure 20-70-18 Insert the sealing ring using tool T12 [Figure 20-70-18]. NOTE: Bring the sealing ring just to the end stop, apply grease to the sealing lips. Figure 20-70-19 Insert the sealing ring (Item 1) [Figure 20-70-19] with a standard tool. NOTE: Bring the sealing ring just to the end stop, apply grease to the sealing lips. 466.01 910, 20-706 Figure 20-70-20 [ise] Install the flange (Item 1) [Figure 20-70-20] and fasten it. For installing the flange (Item 1) [Figure 20-70-20], use a plastic hammer if necessary. Figure 20-70-24 Insert the bearing (Item 1) [Figure 20-70-21]. "72556, 12566 Service Manual Dealer Copy — Not for ResaleDRIVE BOX (CONT'D) Assembly (Cont'd) Figure 20-70-22 Using a standard tool insert the bearing (Item 1) and snap ring (Item 2) [Figure 20-70-22} Figure 20-70-23 = COT a Install the secondary gear wheel (Item 1) [Figure 20-70- 23] with a plastic hammer. 467 of 910, Using a standard tool insert the bearing (Item 1) [Figure 20-70-24}, Figure 20-70-25 i 20-70-7 [sons87s2aa0 | Insert the snap ring (Item 1) and using a standard tool insert the bearing (Item 2) [Figure 20-70-25} "72556, 72566 Service Manual Dealer Copy — Not for ResaleDRIVE BOX (CONT'D) ‘Assembly (Cont'd) Figure 20-70-26 Fix the bearing with the snap ring (Item 1) [Figure 20-70- 26). Figure 20-70-27 Hold the drive side saft (Item 1) [Figure 20-70-27] using a plier and install the drive side shaft with a plastic hammer. 468.1 910, 20-708 Figure 20-70-28 Install drive side flange cover, apply LOCTITE® 510 to the alignment bolts [Figure 20-70-26]. Figure 20-70-29 Tighten the alignment bolts with a torque wrench setting of 80 - 90 Nem (59 - 66 fib) [Figure 20-70-29} "72556, 12566 Service Manual Dealer Copy — Not for ResaleDRIVE BOX (CONT'D) Special Tools TOOL IMAGE DESCRIPTION BOBCAT PN Tz eS 603 dropbox seal ex 4218 6912179 46901910, Dealer Copy — Not for Resale "72556, 72566 Service Manual170 0f 910 A «- Bobcat. 20-70-10 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleMAIN RELIEF VALVE Testing And Adjustment The following tool will be needed to do the following procedure: MEL10003-Hydraulic Tester Figure 20-80-1 Connect the inlet hose (Item 1) from the tester (Item 5) to the front coupler (Item 2) [Figure 20-80-1] Connect the outlet hose (Item 3) from the tester (Item 5) to the rear coupler (Item 4) [Figure 20-80-1] IMPORTANT The hydraulic tester must be in the fully open in before you start the engine. 1-2024.0284 Figure 20-80-2 ‘SIN ABFR13000 & ABOVE, S/N A8G313000 & ABOVE 171 of 910 20-80-4 Figure 20-80-3 ‘SIN ABFR12999 & BELOW, SIN ASG312909 & BELOW --Not for Resale Start the engine, lower the restraint bar (if equipped) and run at low idle rpm. Push the detent rocker switch (Item >, 4) and front auxiliary rocker switch (Item 2) [Figure 20- & 80-2] and [Figure 20-80-3]. Make sure the tester is O 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 2200 & pm, Warm the fluid to 60°C (140°F) by turning the restrictor control (item 5) [Figure 20-80-1] on the tester to about 6,9 MPa (69 bar) (1000 psi). DO NOT exceed system relief pressure. Open the restrictor control knob and record the free flow (U.S. gpm) at 2200 rpm. There should be 55 L/min (13 U.S. gpm) free flow. Turn the restrictor control (Item 5) [Figure 20-80-1] on the tester until the main relief opens. The correct pressure should be 26,5 MPa (265 bar) (3844 psi). adjustment is needed, (See [Figure 20-80-4].) 72556, 12566 ServicMAIN RELIEF VALVE (CONT'D) Testing And Adjustment (Cont'd) Remove the rear cover. Figure 20-80-4 Locate the main relief valve (Item 1) on the front right side of the control valve [Figure 20-B0-4] Figure 20-80-5 Loosen the lock nut (tem 1) and turn the adjustment ‘screw (Item 2) [Figure 20-80-5] clockwise to increase the pressure or counterclockwise to decrease the pressure, NOTE: A 90° turn = 4 MPa (10 bar) (150 psi). Retest the main relief valve after adjustment. s7201 910, 20-802 Removal And Installation IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 1-2003.0888 Remove the rear cover. Locate the main relief vaive (Item 1) [Figure 20-80-6] on the front right side of the control valve. Clean the area around the control valve. Remove the main relief valve (Item 1) [Figure 20-80-6]. Installation: Tighten the main relief valve to 45 Nem (33 felb) torque. "72556, 12566 Service Manual Dealer Copy — Not for ResaleQUICK-TACH CYLINDER Removal And Installation Figure 20-90-1 Rotate the quick-tach forward and place on wood blocks [Figure 20-90-1], Figure 20-90-2 Remove the two hoses (item 1) [Figure 20-90-2} from the oyiinder. No} :: Mark the hoses for correct assembly. Figure 20-90-3, Remove the bolt (Item 1) [Figure 20-90-3] from each side of the cylinder. Figure 20-90-4 Dealer Copy — Not for Resale Remove the end bushing (Item 1) [Figure 20-90-4] 17301910, 20-90-1 "72556, 72566 Service ManualQUICK-TACH CYLINDER (CONT'D) Figure 20-90-7 Removal And Installation (Cont'd) Figure 20-90-5, Remove the roll pin (Item 1) and remove the extension rod (Item 2) [Figure 20-90-7] from the cylinder rod. Remove the roll pin (Item 1) [Figure 20-90-5]. re 2090-8 Figure 20-90-6 5 CU ‘oO Remove the cylinder (Item 1) [Figure 20-90-8]. Remove the washer (Item 1) and spring (Item 2) [Figure 20-90-6] from the cylinder rod extension. 17401910, 20.902 "72556, 12566 Service Manual Dealer Copy — Not for ResaleQUICK-TACH CYLINDER (CONT'D) Parts Identification ©@NOHeons Housing Extension Wiper Seal O-ring Head Gland Rod Piston Wear Ring 17501910, 20.90-3 "72556, 72566 Service Manual Dealer Copy — Not for ResaleQUICK-TACH CYLINDER (CONT'D) Disassembly Use the following tools to disassemble the cylinder: MEL1074-O-ring Seal Hook MEL1076-Cylinder Wrench Clean the outside of the quick-tach cylinder before disassembly. Figure 20-90-9 Place the cylinder in a vise [Figure 20-90-8). Figure 20-90-10 Remove the two fittings (Item 1) [Figure 20-90-10] Figure 20-90-11 Loosen the head gland [Figure 20-90-11] Figure 20-90-12 f O Remove the rod assembly (Item 1) [Figure 20-90-12] from the housing. ‘176 0f 910 20-904 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleQUICK-TACH CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-90-13 i// Pane Loosen the second head gland (Item 1) [Figure 20-90- 13] on the opposite side. Figure 20-90-14 P Remove the rod assembly (Item 1) [Figure 20-90-14] from the housing. art 910 Figure 20-90-15, os ——F: Remove the head (Item 1) [Figure 20-90-15] from each rod. Pane Figure 20-90-16 Remove the O-rings (Item 1) [Figure 20-90-16] from each head gland. "72556, 72566 Service Manual Dealer Copy —- Not for ResaleQUICK-TACH CYLINDER (CONT'D) Disassembly (Cont'd) Figure 20-90-17 ‘ -” Pai? N , ‘ Remove the seal (Item 1) and wiper (Item 2) [Figure 20- 90-17] from each head gland. QP Figure 20-90-18 =| Remove the wear ring (Item 1) and seal (Item 2) [Figure 20-90-18] from each piston. 1701910, 20.906 Figure 20-90-19 Sy hd b Remove the expander O-ring (Item 1) [Figure 20-90-19] from each piston. PRI "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleQUICK-TACH CYLINDER (CONT'D) Assembly Use the following tool to assemble the cylinder: MEL1076-Cylinder Wrench Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn ‘or damaged parts. Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation. Figure 20-90-20 y aid b Install a new expander O-ring (Item 1) [Figure 20-90-20] (on each piston. Figure 20-90-24 Install a new seal (Item 1) and wear ring (Item 2) [Figure 20-90-24] on each piston, 179 0f 910 Figure 20-90-22 Install the wiper (Item 1) and seal (Item 2) [Figure 20-90- 22} in each head gland. NOTE: The groove in the seal must point away from the wiper seal (Item 4) [Figure 20-90-22). Figure 20-90-23, 20.90-7 Install the two O-rings (item 1) [Figure 20-80-23] on each head gland "72556, 72566 Service Manual Dealer Copy — Not for ResaleQUICK-TACH CYLINDER (CONT'D) ‘Assembly (Cont'd) Figure 20-90-24 ot Figure 20-90-26 PaaTeD Tighten both head glands [Figure 20-90-26} PARTS Install each head gland (Item 1) [Figure 20-90-24] onto the rod. Figure 20-90-25, > Figure 20-90-27 Install the two fittings (Item 1) [Figure 20-90-27), Install each rod assembly (Item 1) [Figure 20-90-25] into the housing. 19001 910, 20.908 "72556, 12566 Service Manual Dealer Copy — Not for ResalePORT RELIEF VALVES Adjustment Procedure IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12000-0888 ‘A portable hydraulic hand pump will be used to test the ‘work port relief valves. The hand pump must have clean hydraulic fluid that is compatible with the Bobcat hydraulic fui, NOTE: The valve is shown removed from the machine for photo clarity. jure 20-100-1 Install the hand pump, hose and a pressure gauge minimum of 34,5 MPa (345 bar) (5000 psi) into the valve section work port in which the port relief valve is located [Figure 20-100-1]. Pressurize this section with the hand pump until the port relief valve opens and record the pressure reading. If the port relief pressure setting needs to be adjusted, release the hand pump pressure valve. 191 of 910, 20-1004 Figure 20-100-2 Remove the protective end cap (Item 1) [Figure 20-100- 2. Figure 20-100-3 2 3 3 g a Ss 3 2 1 > 2 3s S 5 3 3 a Loosen the lock nut (Item 1) (Figure 20-100-3} Tum the adjusting serew (Item 2) [Figure 20-100-3] clockwise to inerease the pressure and counterclockwise to reduce the pressure. NOTE: A 90° turn is approximately 2,75 MPa (27,5 bar) (400 psi). When the correct pressure setting is obtained, tighten the locknut while holding the adjustment screw from turning. Adjust the port relief vaive until the correct setting is obtained. Install the end cap. "72556, 72566 Service Manual182 of 910 = ae Bobcat. 20-1002 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleSTEERING MODE VALVE BLOCK Removal And Installation WMI 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 doctor familiar with this injury is not received immediately. W2145-€N-0210 Figure 20-110-1 Remove the tie-straps (Item 1) [Figure 20-110-1] 499.1910, 20-1104 Figure 20-110-2 Relieve hydraulic pressure, Remove the retainer screw from the two wire connectors {Item 4) [Figure 20-1402}. Remove the wire connectors from the two solenoids. NOTE: Mark the location of the wire connectors for correct installation. Figure 20-110-3, pr | Dealer Copy -- Not for Resale Seed en Remove the four mounting bolts (Item 1) [Figure 20-110- 31 NOTE: Mark the location of the valve on the block. Remove the valve (Item 2) [Figure 20-110-3] from the block. "72556, 72566 Service ManualSTEERING MODE VALVE BLOCK (CONT'D) Removal And Installation (Cont'd) eA When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 1.200.088 Figure 20-110-4 Remove the four hoses (Item 1) (Figure 20-110-4] NOTE: Mark the location of the hoses, Figure 20-110-5 Remove the four mounting bolts (Item 1) [Figure 20-110- 5] and remove the block 184 of 910 20-1102 172556, 72566 Service Manual Dealer Copy -- Not for ResaleSTEERING MODE VALVE BLOCK (CONT'D) Parts Identification PeNPMReNs * Supplied with fitting. Dealer Copy — Not for Resale < 105 01 910, 20-1103, "72556, 72566 Service ManualSTEERING MODE VALVE BLOCK (CONT'D) Disassembly Clean the outside of the valve block before disassembly. Mark the outside of the valve block for ease of assembly. Figure 20-110-6 Remove the four O-rings (Item 1) [Figure 20-110-6] from the housing. Figure 20-140-7 P2202 Remove the nut (Item 1) [Figure 20-110-7] from each solenoid, NOTE: Mark the location of the solenoids. 196 of 910 20-1104 IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12003-0888 Figure 20-110-8 Remove the solenoids (Item 1) [Figure 20-110-8] from the solenoid shafts. igure 20-110-9 Remove the O-ring (Item 1) [Figure 20-110-9] from both shafts. 172556, 72566 Service Manual Dealer Copy — Not for Resale‘STEERING MODE VALVE BLOCK (CONT'D) Disassembly (Cont'd) Figure 20-110-10 pe] Loosen the shafts (Item 1) [Figure 20-110-10] ; Figure 20-110-11 ° P >. fo Pas Remove the shaft (Item 1), pin (Item 2), spring (Item 3) and spring retainer (Item 4) from the housing (Item 5) [Figure 20-110-11]. (Both Sides) 197 of 910, Figure 20-110-12 P 742290 Remove the O-ting (Item 1) [Figure 20-110-12] from each shaft, jure 20-140-13, 20-1105, Carefully remove the spool (Item 1) [Figure 20-110-13] from the housing. "72556, 72566 Service Manual Dealer Copy — Not for ResaleSTEERING MODE VALVE BLOCK (CONT'D) Solenoid Testing Figure 20-110-14 Use a circuit tester, touch one probe to the prong and the other probe to the other prong [Figure 20-110-14], there ‘must be continuity. If there is no continuity, replace the solenoid, Assembly Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn ‘or damaged parts, Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation Figure 20-10-15 | P2300 Carefully install the spool (Item 1) [Fiqure 20-10-15], Figure 20-110-10 Po Install a new O-ring (Item 1) [Figure 20-110-16] on each shaft. 498. 910, 20-1106 "72556, 12566 Service Manual Dealer Copy -- Not for Resale‘STEERING MODE VALVE BLOCK (CONT'D) Assembly (Cont'd) Figure 20-110-17 Install the spring retainer (Item 1), spring (Item 2), pin (item 3) and shaft (Item 4) in the housing (Item 5) [Figure 20-110-17]. (Both Sides) Figure 20-110-18 Tighten each shaft (Item 1) 19901 910, 20-110-7, Figure 20-110-19 [ran] Install an O-ring (Item 1) [Figure 20-10-19] on each shaft jure 20-140-20 Install the O-ring (Item 1) [Figure 20-110-20] on the two solenoids. "72556, 72566 Service Manual Dealer Copy — Not for ResaleSTEERING MODE VALVE BLOCK (CONT'D) ‘Assembly (Cont'd) Figure 20-10-21 Install the solenoids (Item 1) on the shafts (Item 2) [Figure 20-110-21] Figure 20-110-22 P2252 Install the nuts (Item 1) [Figure 20-10-22] on each shaft and hand tighten. NOTE: Do not overtighten the nuts. 19001 910, 20-1108 Figure 20-10-23, Install the four O-rings (Item 1) [Figure 20-10-23] on the housing 172556, 72566 Service Manual Dealer Copy -- Not for ResaleBRAKE VALVE Figure 20-120-3, Removal And Installation i SIN ABFR12999 & Below, S/N A8G312999 & Below: Remove the dashboard / steering column cover. (See Removal And Installation on Page 50-130-1.) SIN ABFR13000 & Above, S/N A8G313000 & Above: Remove the dashboard / steering column cover. (See Removal And Installation on Page 50-131-1.) Remove the accelerator cable (tem 1) from the pedal and mounting bracket (Item 2) [Figure 20-120-3]. Disconnect the connector (Item 1) [Figure 20-120-1] ‘rom the brake light switch. Figure 20-120-2 Remove the three hoses (Item 1) [Figure 20-120-4] from the brake valve, NOTE: Mark hoses for correct installation. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, Disconnect the connector (Item 1) [Figure 20-120-2] __tubelines and ports to keep dirt out. Dirt can quickly damage the system. from the inching switch. 12003-0888 191 of 910 20-1204 72556, 72566 Service Manual 2 3 3 g a Ss 3 2 > 2 3s S 5 3 13 aBRAKE VALVE (CONT'D) Figure 20-120-7 Removal And Installation (Cont'd) Figure 20-120-5 Remove the roll pin (Item 1) and pedal (Item 2) [Figure 20-120-7], Figure 20-120-8 Remove the mounting bolts (Item 1) [Figure 20-120-5]. Remove the pedal assembly. Disassembly And Assembly Figure 20-120-6 aa ign the hole (Item 1) in the pedal with the hole (Item 2) [Figure 20-120-8] in the shaft. P2068 Remove the bolt (Item 1) and spring (Item 2) [Figure 20- 120-6), 19201910 20-1202 172556, 72566 Service Manual Dealer Copy — Not for ResaleBRAKE VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-120-9 Loosen the two set screws (Item 1) [Figure 20-120-9] on the two bearings. Figure 20-20-10 Remove the three bolts (Item 1) [Figure 20-120-10] from both bearing fianges. 199.1910, 20-1203, Figure 20-120-14 | Remove the shaft and bearing assembly [Figure 20-120- 11, jure 20-20-12 1 e. Remove the flanges (Item 1) and bearings (Item 2) [Figure 20-120-12]. Dealer Copy —- Not for Resale "72556, 72566 Service ManualBRAKE VALVE (CONT'D) Figure 20-120-15 Disassembly And Assembly (Cont'd) Figure 20-120-13 Remove the brake valve (Item 1) [Figure 20-20-15] Remove the three fittings (Item 1) [Figure 20-120-13] from the brake valve. Figure 20-120-14 Remove the four bolts (Item 1), spacers (Item 2) [Figure 20-20-14] and nuts from the brake valve. 404 910, 20-120-4 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleGEAR PUMP Removal And Installation er When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12000-0888 Figure 20-130-1 Drain the hydraulic reservoir. Disconnect the electrical connectors (Item 1) [Figure 20- 130-1] in the battery box. NOTE: Mark all electrical connectors, hoses and tubelines for correct assembly. 195 01 910, 20-1304 Figure 20-130-2 Remove the two bolts (Item 1) [Figure 20-130-2] and separate the main harness, Figure 20-130-3 Dealer Copy — Not for Resale Remove the hose (Item 1) [Figure 20-130-3] from the pump. "72556, 72566 Service ManualGEAR PUMP (CONT'D) Removal And Installation (Cont'd) Figure 20-130-4 Remove the hose (Item 1) [Figure 20-130-4] from the ‘gear pump. Figure 20-130-5 Remove the hose (Item 1) [Figure 20-130-5] from the brake valve. 196 of 910 20-1302 Figure 20-130-6 Remove the two hoses (Item 4) [Figure 20-130-6] from the gear pump. Remove the two gear pump mounting bolts (Item 1) [Figure 20-130-7]. Remove the gear pump. Installation: Tighten the mounting bolts to 70,8 - 80 Nem (62-59 flb) torque. 172556, 72566 Service Manual Dealer Copy — Not for ResaleGEAR PUMP (CONT'D) Parts Identification Fitting O-ring Spring ‘Spring Seat Spool ‘Screen, Orifice Spool Bolt Housing Plug Seal Ring Main Housing Backup Ring Seal Ring Holder Gear Drive Shaft BESSSASARAN SS omromaonn wae 197 910, 20-1303, "72556, 72566 Service Manual Dealer Copy — Not for ResaleGEAR PUMP (CONT'D) Disassembly And Assembly Clean the outside of the gear pump before disassembly. Mark the outside of the gear pump for ease of assembly. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12008-0888 Figure 20-130-8 P08 Remove the fittings (Item 1) [Figure 20-130-8]. Figure 20-130-9 P00 Remove the four bolts (Item 1) [Figure 20-130-9] Assembly: Tighten the bolts to 33 Nem (25 ftb) torque. Figure 20-130-10 Remove the flow divider from the housing [Figure 20- 130-10}. Figure 20-130-11 Remove the plug (Item 1), O-ring (Item 2), spring (Item 3), spring seat (Item 4) and spool (Item 5) from the housing (iter 6) (Figure 20-130-14] NOTE: Always use new O-rings. 198 of 910 20-1304 172556, 72566 Service Manual Dealer Copy — Not for ResaleGEAR PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-130-12 Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- 130-12] from the housing. Figure 20-130-13 oN ot rs aS 4 + : f ian Pk sim 20 ~ | 38mm (1.500" NS 109.0 910, 20-1305, Figure 20-130-14 To remove the orifice assembly (Item 1) [Figure 20-130- 414] from the spool, make a holding fixture from a 19 mm thick x 38 mm wide x 50 mm long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of hardwood. Drill a 14 mm (0.550 in) hole in the centre of the hardwood block. Cut the block lengthwise [Figure 20-130-13}. Place both halves of the hardwood block around the ‘spool. Clamp the blocks in a vise [Figure 20-130-14]. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged. Remove the orifice assembly, Figure 20-130-15 Dealer Copy -- Not for Resale ‘bes Remove the screen (Item 1) from the orifice (Item 2) [Figure 20-130-15] and clean. "72556, 72566 Service ManualGEAR PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-130-16 Remove the four mounting bolts (Item 1) [Figure 20-130- 16) Figure 20-130-17 Remove the cover (Item 1) [Figure 20-130-17]. Figure 20-130-18 Remove the housing / gear assembly (Item 1) [Figure 20-130-18] from the main housing Figure 20-130-49 Remove the housing (Item 1) from the gear assembly (Item 2) [Figure 20-130-19], Assembly: The position of the small opening (Item 3) on the gear holders will point towards the large port (item 4) [Figure 20-130-19] on the housing, 20001 910, 20-1306 172556, 72566 Service Manual Dealer Copy — Not for ResaleGEAR PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-130-20 = Remove both O-rings (Item 1) [Figure 20-130-20] from the housing, Figure 20-30-24 PSO Remove the back-up ring (Item 1) and seal ring (Item 2) [Figure 20-130.21] from the gear holder. Assembly: The seal ring (item 2) [Figure 20-130-21] is installed onto the gear holder first followed by the back- up ring. 201 of 910, Figure 20-130-22 P5080 Remove and discard the two O-rings (Item 1) [Figure 20- 130-22] from the flange. jure 20-130-23, 20-130-7, Remove the four bolts (Item 1) and drive shaft (Item 2) [Figure 20-130-23]. Assembly: Tighten the bolts to 33 Nem (25 ftb) torque. "72556, 72566 Service Manual Dealer Copy — Not for ResaleGEAR PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-130-24 gies Turn the housing over and remove the mount plate [Figure 20-130-24). Figure 20-130-25 Remove the snap ring (Item 1) [Figure 20-130-25]. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn or damaged parts. Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fuid before installation. Figure 20-130-26 Remove the shaft seal (item 1) [Figure 20-30-26}. Figure 20-130-27 Remove the O-ring (Item 1) and gear assembly (Item 2) [Figure 20-130-27] from the housing Assembly: The position of the V portion (Item 3) on the thrust plate must point towards the larger port (Item 4) [Figure 20-130-27] on the housing. 202 of 910 20-1308, "72556, 12566 Service Manual Dealer Copy -- Not for ResaleGEAR PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-130-28 Pasa Remove the two thrust plates (Item 1), seal ring (Item 2) and back-up ring (Item 3) [Figure 20-130-28] from the gears. Assembly: The seal ring (Item 2) will be installed on the thrust plate (Item 1) first followed by the back-up ring (item 3) [Figure 20-130-28]. 209. 910, 20-1309 Dealer Copy — Not for Resale "72556, 72566 Service Manual204. 910, = ae Bobcat. 20-30-10 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleFAN MOTOR Removal And Installation er When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12000-0888 Drain the radiator. (See Removing And Replacing The Coolant on Page 10-70-1.) Figure 20-140-1 Loosen the two hose clamps (Item 1) and remove the radiator hose (Item 2) [Figure 20-140-1) Figure 20-140-2 Remove the mounting bolt (item 1) and nut (Item 2). Remove the radiator support (Item 3) [Figure 20-140-2] Loosen the two hose clamps (Item 4) and remove the intercooler hose (Item 5) [Figure 20-140-2] Figure 20-140-3 Mark the location of the hood lateh (Item 1). Remove the ‘two mounting bolts (Item 2) [Figure 20-140-3]. Remove the hood latch. 205 of 910, 20-1404 "72556, 72566 Service Manual Dealer Copy - Not for ResaleFAN MOTOR (CONT'D) Figure 20-140-6 Removal And Installation (Cont'd) Figure 20-140-4 Loosen the screw (Item 1) and disconnect the connector (Item 2) [Figure 20-140-6] Figure 20-140-7 Remove the top hose (Item 1) [Figure 20-140-4] from the fan motor. Figure 20-140-5, Remove the two bolts (Item 1) [Figure 20-140-7] (both sides) from the fan guard. Tilt the cooler forward and carefully remove the fan Remove the three hoses (Item 1) [Figure 20-140-5] from assembly. the bottom of the fan motor. 206 of 910, 20-1402 172556, 72566 Service Manual Dealer Copy — Not for ResaleFAN MOTOR (CONT'D) Removal And Installation (Cont'd) Figure 20-140-8 Remove the four bolts (Item 1) and remove the blade assembly (Item 2) [Figure 20-140-8] from the fan motor. NOTE: Mark the direction of the fan for correct assembly. Figure 20-140-9 Mark the location of the fan motor to the fan guard for correct assembly (Item 1) [Figure 20-140-9], 207 of 910 20-1403, Figure 20-140-10 Remove the four fan guard mount bolts (Item 1) and remove the fan guard (Item 2) [Figure 20-140-10]. Figure 20-140-14 Remove the nut and lock washer (Item 1) [Figure 20- 140-14] "72556, 72566 Service Manual Dealer Copy — Not for ResaleFAN MOTOR (CONT'D) Removal And Installation (Cont'd) Figure 20-140-12 Remove the fan blade mounting flange (Item 1) [Figure 20-140-12] from the fan motor. 208 f 910, 20-140-4 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleFAN MOTOR (CONT'D) Parts Identification 1, Seal 2. Valve 3. Housing 4, Gear assembly 209 0f 910, 20-1405 "72556, 72566 Service Manual Dealer Copy — Not for ResaleFAN MOTOR (CONT'D) Disassembly And Assembly IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12003-0808 Figure 20-140-13 Pare Remove the nut (Item 1) and solenoid (Item 2) [Figure 20-40-13] Mark the housing for correct assembly. Figure 20-140-14 PTS Remove the solenoid stem (Item 1) and three fittings (Item 2) [Figure 20-40-14], 21001 910, 20-1408 Figure 20-140-15, Remove the plug (Item 1), spring (item 2) and check valve (Item 3) from the housing (Item 4) [Figure 20-140- 15]. Figure 20-140-16 oO Pa Remove the O-ring Item 1) [Figure 20-140-16] from the plug. Replace as needed. 172556, 72566 Service Manual Dealer Copy — Not for ResaleFAN MOTOR (CONT'D) Figure 20-140-19 Disassembly And Assembly (Cont'd) Figure 20-40-17 Remove the quad ring (Item 1) [Figure 20-40-19] from PST the housing, yure 20-140-20 Remove the four bolts (Item 1) [Figure 20-140-17] from the end. Assembly: Tighten bolts to 43 - 47 Nem (32 - 36 ft-lb) torque. Figure 20-40-18 Dealer Copy — Not for Resale Remove the gear assembly (Item 1) from the housing {ltem 2) [Figure 20-140-20}, PasTe Remove the end cover (Item 1) from the main housing (tem 2) [Figure 20-140-18). 211 of 910, 20-140-7, "72556, 72566 Service ManualFAN MOTOR (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-140-21 Remove the back-up ring / seal (Item 1) [Figure 20-140- 24] from the gear holder. Figure 20-140-22 PRS Remove the snap ring (Item 1) and remove the seal (Item 2) [Figure 20-140-22). Assembly: The open part of the seal goes into the housing first. 21261910, 20-1408, Figure 20-140-23 Inspect the gears (Item 1) [Figure 20-140-23] for damage or wear. "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC FLUID RESERVOIR Removal And Installation Remove the engine / hydrostat assembly. (See Removal And Installation on Page 70-90-1.) Figure 20-150-1 Remove the two bolts (Item 1) [Figure 20-150-1] Figure 20-150-2 Remove the bolt (Item 1) and shield (Item 2) [Figure 20- 150-2]. Figure 20-150-3, Remove the hose (Item 1) [Figure 20-150-3] from the tubeline, Remove the mounting bolt Item 2) [Figure 20-150-3) Figure 20-150-4 Dealer Copy — Not for Resale Loosen the nut (Item 1) [Figure 20-150-4] on the tubeline, Remove the tubeline. Remove the two hoses (Item 2) [Figure 20-150-4] from the filter. 21301 910, 20-1504 "72556, 72566 Service ManualHYDRAULIC FLUID RESERVOIR (CONT'D) Figure 20-150-6 Removal And Installation (Cont'd) Figure 20-150-5 Figure 20-150-7 Remove the hose (Item 1) [Figure 20-150-5] from the tank. Remove the two tank mounting bolts (Item 1) [Figure 20- 150-6] and [Figure 20-150-7]. Remove the hydraulic reservoir. 21401 910, 20-1502 172556, 72566 Service Manual Dealer Copy -- Not for Resale‘STEERING VALVE Removal And Installation ‘SIN ABFR12999 & Below, S/N A8G312999 & Below. Remove the dashboard / steering column cover. (See Removal And Installation on Page 50-130-1.) SIN ABFR13000 & Above, S/N A8G313000 & Above: Remove the dashboard / steering column cover. (See Removal And Installation on Page 50-131-1.) Remove the five hoses (Item 1) [Figure 20-160-1] from the steering valve. Nor Mark hoses for correct installation. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12008-0888 215.01 910, 20-1604 Figure 20-160-2 Remove the four bolts (Item 1) [Figure 20-160-2] and remove the steering valve. "72556, 72566 Service Manual Dealer Copy ~ Not for Resale‘STEERING VALVE (CONT'D) Parts Identification Bolt End Cap ‘Spacer Gear O-ring Geroler Assembly Drive Shaft Valve Plate ‘Spool Sleeve Springs Drive Pin Pin Check Ball Housing Thrust Washer Thrust Bearing Quad Ring Seal Housing Seal Retainer Ring Ball Seat Poppet ‘Spring Plug RBBRBSSABHRESB2S emNomeona 21801 910, 20-1602 172556, 72566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Disassembly er When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12000-0888 Figure 20-160-3 Pane Remove the fitings (Item 1) from the steering valve [Figure 20-160-3} Figure 20-160-4 Remove the seven end cap bolts (Item 1) [Figure 20- 160-4]. 247 of 910, Figure 20-160-5 Pare Remove the end cap (Item 1) [Figure 20-160-5]. Figure 20-160-6 20-1603, PTH Remove and discard the O-ring (Item 1) [Figure 20-160- 6) "72556, 72566 Service Manual Dealer Copy — Not for ResaleSTEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-160-7 Le] Remove the spacer gear (item 1) [Figure 20-160-7]. Figure 20-160-8, Pars Remove the geroler assembly (Item 1) [Figure 20-160- 8, 21801 910, 20-160-4 Figure 20-160-9 Remove the O-ring (Item 1) [Figure 20-160-9] from the valve plate. Figure 20-160-10 Remove the drive shaft (Item 1) [Figure 20-160-10] 172556, 72566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-160-11 Remove the valve plate (Item 1) [Figure 20-160-11]. jure 20-160-12 Pane Remove the O-ring (Item 1) [Figure 20-160-12] from the housing. 21901 910, 20-1605, Figure 20-160-13 ‘Mark the location of the three ports (item 1) [Figure 20- 160-13] for correct assembly. Figure 20-160-14 Dealer Copy — Not for Resale Remove the three pins (Item 1) [Figure 20-160-14] from each port. NOTE: Record the location of each pin for correct assembly. "72556, 72566 Service ManualSTEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-160-15 Par70 Remove the three check balls (Item 1) [Figure 20-160- 15] from each port. NOTE: Record the location of each check ball for correct assembly. Figure 20-160-16 Remove the seal retainer ring (Item 1) [Figure 20-160- 16} Figure 20-160-17 PTT Remove the seal housing (Iter 1) [Figure 20-160-17] by prying upward. Figure 20-60-18, Remove and discard the seal (Item 1) [Figure 20-160- 18] 22001 910, 20-1608 172556, 72566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-60-19 Pana Remove and discard the quad ring seal (Item 1) [Figure 20-160-19], Figure 20-160-20 Remove and discard the O-ring (Item 1) [Figure 20-160- 20] from the housing, 221 of 910, 20-160-7, Pane Remove the two thrust washers (Item 1) and thrust bearing (Item 2) [Figure 20-160-24] from the spool. Figure 20-160-22 Dealer Copy — Not for Resale Remove the control spool / sleeve assembly (Item 1) from the metering end of the housing (Item 2) [Figure 20-160- 2a. NOTE: When removing the spool, keep the drive pin (Item 3) [Figure 20-160-22] horizontal. if the pin becomes vertical, it can drop from the spool and get caught in an oil passage inside the housing. "72556, 72566 Service ManualSTEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-160-23 ParTe Remove the drive pin (Item 1) [Figure 20-160-23]. Figure 20-160-24 Figure 20-160-25, | Remove the springs (Item 1) [Figure 20-160-25] from the spool. NOTE: There are six springs positioned three per side and back to back. Figure 20-160-26 Paris Remove the spool (Item 1) from the sleeve (tem 2) [Figure 20-160-24). NOTE: If the spool and sleeve will not slide or rotate within each other freely or in the housing, they must be replaced. 22201 910, 20-1608, Remove the two check valve plugs (Item 1), springs (Item 2), ball seat (Item 3) and check ball (Item 4) [Figure 20- 160-26] from the housing. NOTE: Record the location of each check ball assembly for correct assembly. 172556, 72566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Disassembly (Cont'd) Figure 20-160-27 Parise Remove the check valve plug (Item 1), spring (Item 2) and poppet (Item 3) [Figure 20-160-27] from the housing. NOTE: Record the location of the port for correct assembly. 2291 910, 20-1609 Inspection Figure 20-160-28 Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20- 160-28] for any damage or wear. Replace as needed. ° Figure 20-160-29 Dealer Copy — Not for Resal =o Inspect the drive shaft (Item 1) [Figure 20-160-29} for damage or wear. "72556, 72566 Service Manual‘STEERING VALVE (CONT'D) Assembly eA When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 1.200.088 Prior to assembly, clean and lightly oil all parts. Figure 20-160-30 PaTis0 Install a new O-ring (Item 1) [Figure 20-160-30] on the three check valve plugs. 22401 910, 20-60-10 Figure 20-160-31 $< ae a-© Install the poppet (Item 1), spring (Item 2) and plug (Item 3) [Figure 20-160-31] into the correct port marked earlier. Figure 20-160-32 Install the check ball (Item 1), ball seat (item 2), spring (Item 3) and plug (Item 4) [Figure 20-160-32} into the correct port marked earlier. ‘Turn each of the port plugs (Item 3) [Figure 20-160-34] and (Item 4) [Figure 20-60-32] in the housing unt they are tight, then back each of them out 1.5 turns. "72556, 12566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Assembly (Cont'd) Figure 20-160-33 Install the springs (Item 1) [Figure 20-160-33] into the spool. NOTE: There are six springs and should be positioned three per side and back to back. Figure 20-160-34 Install the spool (Item 1) into the sleeve (Item 2) [Figure 20-160-34] NOTE: The spool should turn freely inside the sleeve. 225.01 910, 20-160-11, Figure 20-160-35 [er] Install the drive pin (Item 1) [Figure 20-160-35] Figure 20-160-36 Install the control spool / sleeve assembly (Item 1) into the metering end of the housing (Item 2) [Figure 20-160- 36], NOTE: When installing the spool assembly keep the drive pin (Item 3) [Figure 20-60-36] horizontal. if the pin becomes vertical drop from the spool and get caught in an oil passage inside the housing, "72556, 72566 Service Manual Dealer Copy — Not for ResaleSTEERING VALVE (CONT'D) ‘Assembly (Cont'd) Figure 20-160-37 Pane Figure 20-160-39 Para Install a new quad ring seal (Item 1) [Figure 20-160-39] Figure 20-160-40 Install the two thrust washers (Item 1) and thrust bearing (Item 2) [Figure 20-160-37] on the spool. Figure 20-160-38 Install a new O-ring (Item 1) [Figure 20-160-38} into the housing, 226 01 910, 20-60-12 Install a new seal (Item 1) [Figure 20-60-40] "72556, 12566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Assembly (Cont'd) Figure 20-60-41 Install the seal retainer ring (Item 1) [Figure 20-60-42], 227 of 910, 20-160-13 Figure 20-160-43 Install the three check balls (Item 1) [Figure 20-60-43] in their proper port (marked earlier). Figure 20-160-44 Install the three pins (Item 1) [Figure 20-160-44] in their proper port (marked earlier) Paro Dealer Copy — Not for Resale "72556, 72566 Service ManualSTEERING VALVE (CONT'D) ‘Assembly (Cont'd) Figure 20-160-45 Pane? Install a new O-ring (Item 1) [Figure 20-160-45] into the housing groove. Figure 20-160-46 Align and install the 14 hole vaive plate (Item 1) [Figure 20-60-46] on the housing 228 01 910, 20-160-14 Figure 20-160-47 ‘Align the groove (Item 4) in the drive shaft with the drive pin (Item 2) [Figure 20-160-47] and install the drive shaft. Be sure the drive shaft is engaged with the pin. NOTE: The pin (Item 2) must be parallel with the port face of the housing (Item 3) [Figure 20-160- an. Figure 20-160-48 To assure proper geroler alignment, mark the top of the drive shaft (Item 1) (as shown) parallel to the port face (Item 2) [Figure 20-160-48]. Install a new O-ring (Item 3) [Figure 20-160-48] into the valve plate groove. "72556, 12566 Service Manual Dealer Copy — Not for Resale‘STEERING VALVE (CONT'D) Assembly (Cont'd) Figure 20-160-49 Install the geroler star (Item 1) [Figure 20-160-49] onto the valve plate and drive shaft. No} : Align the two valleys (Item 2) of the star with the mark on the drive gear (Item 3) [Figure 20- 160-49). re 20-160-50 Install the outer gear (Item 1) onto the star (Item 2) [Figure 20-160-50] and align the bolt holes without disengaging the drive shaft. 22901 910, Figure 20-160-54 Pane Install the spacer gear (Item 1) and a new O-ring (Item 2) [Figure 20-160-51] into the geroler plate groove. Figure 20-160-52 20-160-15 Dealer Copy — Not for Resale P2768 Install the end cap using the seven bolts (Item 1) [Figure 20-160-52]. Tighten to 11 - 18 Nem (8 - 13 fib) torque in a criss cross pattern. "72556, 72566 Service ManualSTEERING VALVE (CONT'D) ‘Assembly (Cont'd) Figure 20-160-53 Pare Install the fittings (Item 1) [Figure 20-160-53] as shown. 22001 910, 20-160-16 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE ‘Troubleshooting Chart (Controllers) ‘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 Persons WUT Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. w-2004-1208 PROBLEM ‘CAUSE CORRECTION None of the controllers work Insufficient power supply Check battery voltage Tnsufficient pilot pressure Check pilot pressure Plugged controller fiter Clean fitter ‘Only one controller works No actuation signal Check signal voltage Unsuitable actuation signal Check signal voltage Insufficient actuation power supply Check signal voltage All controllers not working orjerky_| Plugged controller fiter Clean fitter ‘One controler not working or jerky | Faulty actuation sgnal Check signal Friction or jamming of the plunger Replace controller ‘One controler not working orjerky | Contamination of the proportional Replace controller in one direction valve in the controller Controller creeps Neutral position incorrect ‘Adjust neutral adjustment Oilleakage between control valve | Faully seals Replace seal and controller Oil leakage between contiullers Faully controller euplers Replace corolla: couplers 221 of 910, 20-1704 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-2 Telescoping Valve Section Troubleshooting Record the serial number of the machine, control valve and control module. The following procedure must be done with the control valve in the machine. The control valve is removed for photo clarity With the engine OFF, the key switch in the run position, move the joystick handle to relieve any hydraulic pressure, Remove the rear cover from machine. Figure 20-170-1 ‘SIN ABFR13000 & ABOVE, SIN ABG313000 & ABOVE ‘The hydraulic control function switch (Item 1) [Figure 20- 470-4] and (Figure 201702] must be ON (igh on for 1 2201 910 20-1702 all testing procedures. Locate the telescoping valve section (Item 1) [Figure 20-170-3] on the contro! valve. 172556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Troubleshooting (Cont'd) Figure 20-170-4 2. With the engine OFF, the key in the run position, check that the battery voltage on the controller connector (Item 1) [Figure 20-170-4] (pin 1, biue wire) is atleast 12 volt or higher 3. With the engine OFF, the key in the run position, check the regulated voltage on the controller connector (tem 1) [Figure 20-170-4] (pin 4, black wire) ic 6 volt. If 6 volt iz not seen, replace the controller. 229.1 910, 20-1703, Figure 20-170-5, 4. With the telescopic function switch (Item 1) [Figure a 20-170-5] in the minimum (back) position check that the voltage on the controller connector (Item 1) [Figure 20-170-4] (pin 3, brown wire) is 0.9 volt. If the voltage drops below 0.9 volt the controller will 5 interpret ths as a failure. 5. With the telescopic function switch (Item 1) [Figure 20-470-5] in the neutral (middle) position check that the voltage on the controller connector (Item 1) [Figure 20-170-4] (pin 3, brown wire) is 2.5 volt. ler Copy —- Not f 6. With the telescopic function switch (Item 1) [Figure 20-170-5] in the maximum (forward) position check that the voltage on the controller connector (Item 1) [Figure 20-170-4] (pin 3, brown wire) is 4.1 volt. IF one of the three voltage readings in Steps 4, 5 and 6 is not correct, replace the joystick handle. (See Removal ‘And installation on Page 20-180-1.) If all voltage readings in Steps 4, 5 and 6 are correct go to step 7. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Checking Drain Pressure Telescoping Valve Section Troubleshooting (Cont'd) Figure 20-1708 Checking Pilot Pressure Raise the boom and install the boom stop. (See Installing ‘The Approved Boom Stop on Page 10-150-1.) Figure 20-170-6 Figure 20-170-9 Pane 7. Locate the test fitting (Item 1) [Figure 20-170-6] and remove the cap. Figure 20 1707 P2018 bar) (22 psi) maximum 8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test fitting [Figure 20-170-7]. 14, Remove the gauge. 9. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Record the pressure. The pressure at the gauge should be 3,5 MPa (35, bar) (508 psi) maximum. 10. Remove the gauge. 224 01 910, 20-170-4 11, Remove the hose (Item 1) [Figure 20-170-8] from the control valve, and install a tee fitting 12. Install a 3,5 MPa (35 bar) (500 psi) gauge on the tee fitting [Figure 20-170-9], 13, Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Record the pressure. ‘The pressure at the gauge should be 0,15 MPa (1,5 172556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Troubleshooting (Cont'd) Figure 20-70-10 415. With adequate room in front of the machine, start the engine, lover the restraint bar (if equipped) and run the engine at 2200 rpm. Move the telescopic control sswiteh (tem 1) [Figure 20-170-10] forward and back to see if this function works. Stop the engine. Figure 20-70-11 16. If the telescopic function does not work, with the engine running disconnect the controller connector (tem 1) [Figure 20-170-11] and reconnect it back in. Figure 20-170-12 17. Ifthe telescopic function does not work, remove the ‘two serews (Item 1) and remove the cover (Item 2) [Figure 20-170-12} 18. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Figure 20-170-13 Dealer Copy — Not for Resale 19. Manually push and pull the spool (Item 1) [Figure 20- 170-13] to test the movement of the telescopic function in both directions. NOTE: If by manually operating the spool, and the telescopic function is working the controller must be replaced. 225 01 910, 20-1705 "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Troubleshooting Record the serial number of the machine, control valve and control module. The following procedure must be done with the control valve in the machine. The control valve is removed for photo clarity With the engine OFF, the key switch in the run position, move the joystick handle to relieve any hydraulic pressure, Figure 20-170-14 SIN ABFR12999 & BELOW, SIN A8G312999 & BELOW 226 1 910, 20-1706 Figure 20-170-15 ‘SIN ABFR13000 & ABOVE, SIN AGG313000 & ABOVE so ‘The hydraulic control function switch (Item 1) must be ON (light is on) and the front auxiliary hydraulics ON/OFF switch (Item 2) [Figure 20-170-14] and [Figure 20-170- 15] must be ON (top position). jure 20-170-46 1. Locate the auxiliary valve section (Item 1) [Figure 20- 170-16] on the control valve, 172556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Troubleshooting (Cont'd) Figure 20-70-17 2. With the engine OFF, the key in the run position, check that the battery voltage on the controller connector (Item 1) [Figure 20-70-17] (pin 1, blue wire) is atleast 12 volt or higher 3. With the engine OFF, they key switch in the run position, check the regulated voltage on the controller connector (Item 1) [Figure 20-170-17] (pin 4, black wire) i 6 volt. If 6 volt iz not seen, replace the controller. 227 of 910, 20-170-7, Figure 20-170-18 4. With the auxiliary function switch (Item 1) [Figure 20- ., 170-18] in the minimum (back) position check that the “= voltage on the controller connector (Item 1) [Figure $ 20-170-47] (pin 3, brown wire) is 0.9 volt. If the a voltage drops below 0.9 volt the controller will 5 interpret this as a failure. —Not fc ‘5. With the auxiliary function switch (Item 1) [Figure 20- 170-43] in the neutral (middle) position check that the >, voltage on the controller connector (item 1) [Figure & 20-170-17] (pin 3, brown wire) is 2.5 volt. 6. With the auxiliary function switch (Item 1) [Figure 20- 170-18] in the maximum (forward) position check that the voltage on the controller connector (Item 1) [Figure 20-170-17] (pin 3, brown wire) is 4.1 volt. jealer Cr IF one of the three voltage readings in Steps 4, 5 and 6 is not correct, replace the joystick handle. (See Removal ‘And Installation on Page 20-180-1.) If all voltage readings in Steps 4, 5 and 6 are correct go to step 7. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Checking Drain Pressure Auxiliary Valve Section Troubleshooting (Cont'd) Figure 20-170-21 Checking Pilot Pressure Raise the boom and install the boom stop. (See Installing ‘The Approved Boom Stop on Page 10-150-1.) Figure 20-170-19 Figure 20-170-22 Pane 7. Locate the test fitting (Item 1) [Figure 20-170-19] and remove the cap. Figure 20 170 20 P2018 bar) (22 psi) maximum 8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test fitting [Figure 20-170-20}. 14, Remove the gauge. 9. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Record the pressure. The pressure at the gauge should be 3,5 MPa (35, bar) (508 psi) maximum. 10. Remove the gauge. 228 1 910, 20-1708 11. Remove the hose (Item 1) [Figure 20-170-21] from the control valve, and install a tee fitting. 12. Install a 3,5 MPa (35 bar) (500 psi) gauge on the tee fitting [Figure 20-70-22]. 13, Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Record the pressure. ‘The pressure at the gauge should be 0,15 MPa (1,5 172556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Troubleshooting (Cont'd) Figure 20-170-23 415. With adequate room in front of the machine, start the engine, lover the restraint bar (f equipped) and run the engine at 2200 rpm. Move the auxiliary control sswiteh (Item 1) [Figure 20-170-23] forward and back to see if this function works. Stop the engine. Figure 20-170-24 16. Ifthe auxiliary function does not work, with the engine running disconnect the controller connector (Item 1) [Figure 20-170-24] and reconnect it back in. Figure 20-170-25 17. Ifthe auxiliary function does not work, remove the two screws (Item 1) and remove the cover (Item 2) [Figure 20-170-25}. 18. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 rpm. Figure 20-170-26 Dealer Copy — Not for Resale 19. Manually push and pull the spool (Item 1) [Figure 20- 170-26] to test the movement of the auxiliary function in both directions. NOTE: If by manually operating the spool, and the auxiliary function is working the controller must be replaced. 229.01 910, 20-1709 "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Troubleshooting Chart (Control Valve) 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. 7 Ie ‘Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. 2004-1285 PROBLEM CAUSE ‘CORRECTION Tack of strength at all actuators | Load sense relief cartridge defective _ | Replace relief cartridge Load sense relief cartridge out of Make necessary adjustments adjustment Lack of force on one actuator only ‘Secondary relief valve out of adjust- ment Reset to original pressure ‘Secondary relief valve blocked open Replace relief valve Tack of load hold Load check valve failure Replace load check valve Excessive clearance belween hous ing and spool Replace housing and spool ‘Simultaneous movement of con- trols Blockage of individual compensator orifice Remove and clean orifice Individual pressure compensator blocked Replace housing and compensator Toad sense line leakage Replace load sense regulator Engine remains under load after | Flow regulator blocked Replace flow regulator ‘spooks are returned to neutral Flow regulator filer vlogged Replace filler Datent malfunction Controller defective Replace controller ‘Spool return difficult Tie rod bolts too fight Re-forque tie rod bolts ‘Spool leaking oil Defective spool seal Replace spool seal Dilleakage between valve section | Defective seals. Replace seals 240.01 910, 20.170-10 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Removal And Installation Relieve hydraulic pressure. Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-100-2.) 7 Na te 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 IMPORTANT ‘When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, Tubellnes and ports to keep dirt out. Dirt can quickly damage the system. 12008-0888 Remove the fuel tank. (See Removal And Installation on Page 50-80-1.) ‘igure 20-170-27 Remove the tubeline (Item 1) [Figure 20-170-27]. 241 of 910, a70-41 NOTE: Mark all hoses and tubelines for correct installation. Figure 20-170-28 Remove the tubeline (Item 1) [Figure 20-170-28). Figure 20-170-29 Remove the two hoses (Item 1) [Figure 20-170-29] "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-170-30 Remove the five hoses (Item 1) [Figure 20-170-30] from the control vaive Figure 20-170-31 Remove the five hoses (Item 1) [Figure 20-170-34] from the control valve. 24201 910, 20.170-12 Figure 20-170-32 Remove the two tubelines (Item 1) and two hoses (Item 2) [Figure 20-170-32} Figure 20-170-33 Remove any tie-straps (Item 1) from the electrical harness. Remove the tubeline (Item 2) [Figure 20-170- 33]. "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-170-34 Disconnect the two wire connectors (Item 1) [Figure 20- 170-34] from the main wire harness. NOTE: Mark the location of the connectors for correct installation. Figure 20-170-35 Figure 20-170-36 Remove the mounting bolt (Item 1) [Figure 20-70-36] from the lower front right hand side of the control valve, Figure 20-170-37 we c Remove the two mounting bolts (Item 1) [Figure 20-170- 37] from the control valve. Installation: Tighten the mounting bolts to 24 - 26 Nem (18-19 ft-lb) torque, Remove the tubeline (tem 1) [Figure 20-170-35] from the front right hand side of the control valve. 243 01 910, 20-17043 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-170-38 Install a hoist and lift strap (Item 1) [Figure 20-70-38] ‘on the control valve. Use care not to damage the tubelines or fittings. Raise the hoist and remove the control valve. 244 of 910 20-170-14 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Parts Identification End Housing Lifting Valve Section Tilting Valve Section Telescoping Valve Section Auxiliary Valve Section Inlet-Outlet Valve Section oonens Dealer Copy — Not for Resale par] 245 of 910 20.47045 "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Disassembly And Assembly Clean the outside of the control valve before disassembly. Mark the outside of the control valve for ease of assembly. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12003-0888 Figure 20-170-39 Remove the tubeline (|tem 1) [Figure 20-170-39], 246 01 910, 20-170-16 Figure 20-170-40 Remove all hydraulic fittings [Figure 20-170-40]. Figure 20-170-41 Remove the three nuts (Item 1) [Figure 20-170-41] from the tie rod bolts, Assembl ghten the nuts to 35 Nem (26 ftlb) torque. "72556, 12566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-44 End Housing Disassembly And Assembly Figure 20-70-42 P2086 Remove the O-ring (item 1) [Figure 20-170-44] from the plug. Remove the end housing (Item 1) [Figure 20-170-42] Figure 20-170-43 Remove the dust cap (Item 1) and plug (Item 2) [Figure 20-170-43] from the end housing. 247 of 910 20-1707 "72556, 72566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And Assembly Figure 20-170-45 Remove the telescoping valve section (Item 1) [Figure 20-170-45]. Figure 20-170-46 Punts Remove the four O-rings (Item 1) [Figure 20-170-46] from the valve section. 248 of 910 20.170-18 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And Assembly (Cont'd) Figure 20-70-47 Remove the two screws (Item 1) [Figure 20-170-47] from the controller assembly. Assembly: Ib) torque. fighten the screws to 14-16 Nem (10- 12 ft re 20-170-48 Pos Remove the controller assembly (Item 1) [Figure 20-170- 48] from the valve section. 249.01 910, 20-170-19 Figure 20-170-49 =| Remove the O-ring (Item 1) [Figure 20-170-49] from the controller assembly. jure 20-170-50 Remove the two couplers (Item 1) [Figure 20-70-50] from the controller assembly. "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-53 Telescoping Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-51 Remove the four screws (Item 1) and cover (Item 2) [Figure 20-170-53] from the controller assembly. Remove the two O-rings (Item 1) [Figure 20-170-51] from the couplers. Figure 20-170-52 Loosen the four screws (Item 1) the controller assembly. Assembly: Tighten the screws to 3 - in-Ib) torque. 250.1 910, Figure 20-170-54 Remove the seal (Item 1) [Figure 20-170-54] from the cover. P01 ‘igure 20-170-52] on 3,5 Nem (26.6 - 31 20-70-20 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-55 *D cover. Figure 20-170-56 Remove the plug (Item 1) [Figure 20-170-55] from the a Remove the O-ring (Item 1) [Figure 20-70-56] from the plug. 251 of 910, Figure 20-170-57 % OL Remove the port block (Item 1) from the controller (Item. 2) [Figure 20-70-57] 0170-21 "72556, 72566 Service Manual Dealer Copy ~ Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-60 Telescoping Valve Section Disassembly And ‘Assembly (Cont'd) Figure 20-170-58 Figure 20-170-64 Remove the two valve cartridges (Item 1) and plunger (Item 2) [Figure 20-70-58] from the controller, NOTE: The upper valve cartridge (Item 3) is for extending the boom and the lower valve cartridge (Item 4) [Figure 20-170-58] is for retracting the boom. Figure 20-170-59 ty Remove the spool (Item 1) and spring (Item 2) [Figure 20-170-60] from the port valve. from the spool. Remove the cover (Item 1), poppet (Item 2), spool (Item 3) and spacer (Item 4) from the valve (Item 8) [Figure 20- 170-59} 25201 910, 20-70-22 Remove the three O-rings (Item 1) [Figure 20-170-61] "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-62 Remove the four O-rings (Item 1) [Figure 20-170-62] from the valve, Figure 20-170-63, Q [ee] igure 20-170-63] from Remove the relief valve (Item 1) the valve section, Assembly: Tighten the valve to 45 Nem (33 fib) torque. 253 1 910, 20-170-23 Figure 20-170-64 7 we 7-08 Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-64] from the relief valve. jure 20-170-65 OQ Dealer Copy — Not for Resale Loosen the serew (Item 1) [Figure 20-170-65] on the piston. Assembly: Tighten the screw to 10 Nem (88.5 inlb) torque. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And ‘Assembly (Cont'd) Figure 20-170-66 Figure 20-170-68 valve section, Figure 20-170-69 Remove the screw (item 1) and piston (Item 2) [Figure 20-70-66] from the adapter. Figure 20-170-67 P4008 Remove the plug (tem 1) [Figure 20-170-68] from the P 4.) Remove the two O-rings (Item 1) [Figure 20-170-67] from the piston. 254 f 910, 20-170-24 Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-69] from the plug. "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-70 Loosen the two screws (item 1) [Figure 20-170-70] on the cover. Assembly: Tighten the screws to 10 Nem (88.5 torque. Ib) re 20-170-71 Remove the two screws (Item 1) and cover (Item 2) [Figure 20-170-71] from the valve section 255 of 910, 20-170-25 Figure 20-170-72 Install a hex wrench in the screw (Item 1) [Figure 20- 170-72] on the end of the spoo! yure 20-170-73 As ae Loosen the adapter (Item 1) [Figure 20-170-73] Assembly: Tighten the adapter to 9 - 11 Nem (79.7 -97.4 indo) torque. "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Telescoping Valve Section Disassembly And ‘Assembly (Cont'd) Figure 20-170-74 Remove the adapter (Item 1) [Figure 20-170-74] from the spool. Figure 20-170-75 Oo PDT Remove the O-ring (Item 1) [Figure 20-170-75] from the adapter. 256 01 910, 20-170-28 Figure 20-170-76 Remove the washer (Item 1) [Figure 20-170-76] from the valve section. Figure 20-170-77 © Remove the controller (Item 1) from the port block (Item 2) [Figure 20-170-103], P02 263 1 910, Figure 20-170-104 Remove the two valve cartridges (Item 1) and plunger {Item 2) [Figure 20-170-104] from the controller jure 20-170-105 Dealer Copy — Not for Resale 20.170-33 Remove the cover (Item 1), poppet (Item 2), spool (Item 3) and spacer (Item 4) from the valves (Item 5) [Figure 220-170-105) "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-108 Auxiliary Valve Section Disassembly And Assembly (Cont) Figure 20-170-106 Remove the four O-rings (Item 1) [Figure 20-170-108] from the valves. Figure 20-170-09 Remove the spool (Item 1) and spring (item 2) [Figure 20-170-106] from the port valve. Figure 20-170-107 = Remove the plug (Item 1) [Figure 20-170-109]. (Both sides) P4065 Remove the three O-rings (Item 1) [Figure 20-170-107] from the spools, 264 of 910, 20-170-34 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-110 P Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-110] from the plugs. Figure 20-170-111 [aa] Loosen the serew (Item 1) [Figure 20-170-111] on the piston Assembly: Tighten the screw to 10 Nem (88.5 in-Ib) torque. 265 of 910, 20.170-35 Figure 20-170-112 | Remove the screw (item 1) and piston (Item 2) [Figure 20-170-112] from the adapter. jure 20-170-113 Remove the two O-rings (Item 1) [Figure 20-170-113] from the piston, "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont) Figure 20-170-114 Loosen the two screws (Item 1) [Figure 20-170-114] on the cover. Assembly: Tighten the screws to 10 Nem (88.5 inlb) torque. Figure 20-170-115 P-a7O18 Remove the two screws (Item 1) and cover (Item 2) [Figure 20-170-115] from the valve section. Figure 20-170-116 Remove the O-ring (Item 1) [Figure 20-170-146] from the cover. Figure 20-170-447 Install a hex wrench in the serew (Item 1) [Figure 20- 170-147). 266 of 910, 20-170-36 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-118 a Loosen the adapter (Item 1) [Figure 20-170-118}, Assembly: Tighten the adapter to 9- 11 Nem (79.7 - 97.4 indb) torque. Figure 20-170-119 &.. PATEZI Remove the adapter (Item 1) and washer (Item 2) [Figure 20-170-119} from the valve section. 267 of 910, Figure 20-170-120 Pao Assembly: Install the countersunk side of the washer (tem 1) [Figure 20-170-120] into the valve section jure 20-170-124 2017037 Remove the O-ring (item 1) [Figure 20-170-121] from the adapter. "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont) Figure 20-170-122 Remove the spool (Item 1) [Figure 20-170-122] from the valve section. NOTE: When the spool is removed, use care not to. soratch the spool surface and do not interchange spools and valve blocks. Figure 20 170 423 P4051 Remove the O-ring (Item 1), seal (Item 2) and retainer (item 3) [Figure 20-170.123] from the spool. 268 of 910, 20.170-38 Figure 20-170-124 Assembly: The lip on the seal (item 1) [Figure 20-170- 124) fits inside the retainer. re 20-170-425, To remove the spring assembly from the spool, make a holding fixture from a 19 mm thick x 38 mm wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of hardwood. Drill a 18 mm (0.710 in) hole in the centre of the hardwood block. Cut the block lengthwise [Figure 20- 170-125} "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-126 Using the wood blocks clamp the spool (Item 1) [Figure 20-170-126] in a vise. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged, Loosen the sorew (Item 2) [Figure 20 470 426}. Assembly: Tighten the screw to 10 Nem (88.5 in-Ib) torque. Figure 20-170-127 Remove the screw (Item 1), spring retainer (item 2), spring (Item 3) and spring retainer (Item 4) [Figure 20- 170-127] from the spool. 260.01 910, 20-170-39 Figure 20-170-128 [osm Remove the two load check valve plugs (item 1) [Figure 20-170-128} from the valve section. Assembly: Tighten the plugs to 27 - 33 Nem (20 - 24 ft- 'b) torque. yure 20-170-129 Remove the spring (Item 1) and poppet (Item 2) [Figure 220-170-129) from the plugs. "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-130 es Remove the O-ring (Item 1) [Figure 20-170-130] from the plugs. Figure 20-170-131 Pane Loosen the plug (Item 1) [Figure 20-170-131]. Assembly: Tighten the plug to 54 - 66 Nem (40 - 49 ft-lb) torque. 27001 910, 20.170-40 Figure 20-170-132 > wo Remove the individual pressure compensator plug (Item 1), poppet (Item 2) and guide (Item 3) [Figure 20-170- 132] from the valve section, Figure 20-170-133, Pan60 Remove the O-ring (Item 1) [Figure 20-170-133] from the plug. "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Lifting Valve Section Disassembly And Assembly Figure 20-170-134 [er] Remove the lifting valve seetion (Item 1) [Figure 20-170- 134] Figure 20-170-135 Remove the four O-rings (Item 1) [Figure 20-170-135] from the valve section, 271 910, 2170-41 Figure 20-170-136 =| Remove the plug (Item 1) [Figure 20-170-136] from the valve section. yure 20-170-137 Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-137] from the plug. "72556, 72566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-140 Lifting Valve Section Disassembly And Assembly (Conta) Figure 20-170-138 Remove the O-ring (Item 1) [Figure 20-170-140] from the cover. Figure 20-170-144 Loosen the four serevs (item 1) [Figure 20-170-138} Assembly: Tighten the screws to 10 Nem (88.5 in-lb) torque. Figure 20-170-139 4 A ingenieceb tebe Se [Figure 20-170-144] from the spool. P0952 Remove the four screws (Item 1) and cover (Item 2) [Figure 20-170-139}. 27261910 20.170-42 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Lifting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-142 On Remove the relief valve (Item 1) [Figure 20-170-142] from the valve section. Assembly: Tighten the relief valve to 45 Nem (33 ft-lb) torque. ire 20-170-143, fan =O) Remove the two O-rings (Item 1) and back-up ring (item 2) [Figure 20-170-143] from the relief valve. 27301910, Figure 20-170-144 [ean] Loosen the four serews (Item 1) [Figure 20-70-14) Assembly: Tighten the screws to 10 Nem (88.5 inh) torque. Figure 20-170-145 Dealer Copy — Not for Resale 20-170-43 Remove the four screws (Item 1) and cover (tem 2) [Figure 20-170-145] from the valve section, "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Lifting Valve Section Disassembly And Assembly (Conta) Figure 20-170-146 or” Remove the O-ring (item 1) [Figure 20-170-146] from the cover. Figure 20-170-147 P2008 Remove the spring (Item 1) and spring retainer (Item 2) [Figure 20-170-147] from the spool 27401 910, 20-170-44 Figure 20-170-148, Remove the spool (Item 1) [Figure 20-170-t 48] from the valve section. re 20-170-449 Remove the two plugs (Item 1) [Figure 20-170-149] from the valve section. Assemb! Ib) torque. ighten the plugs to 27 - 33 Nem (20 - 24 f- "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Lifting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-150 Remove the spring (Item 1) and poppet (Item 2) [Figure 20-170-150] from the plugs. Figure 20-170-151 70) ware Remove the O-ring (Item 1) [Figure 20-170-154] from the plugs. 275.01 910, 20.170-45 Figure 20-170-152 | Loosen the plug (Item 4) [Figure 20-170-152]. Assembly: Tighten the plug to 54 - 66 Nem (40 - 49 fb) torque. Figure 20-170-153 @. Remove the individual pressure compensator plug (item 4) poppet (Item 2) and guide (item 3) [Figure 20-170- 153] from the valve section. "72556, 72566 Service Manual Dealer Copy —- Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Lifting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-154 2D Tilting Valve Section Disassembly And Assembly jure 20-170-455 ou? Patra Remove the titing valve section (Item 1) [Figure 20-170- 155) Remove the O-ring (Item 1) [Figure 20-170-154] from Figure 20-170-156 the plug. 27601 910, Remove the four O-rings (item 1) [Figure 20-170-156] from the valve section, 20-17-48 "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Tilting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-157 On Remove the relief valve (Item 1) [Figure 20-170-157] from the valve section, Assembly: Tighten the relief valve to 45 Nem (33 ft-lb) torque. ire 20-170-158 Remove the two O-rings (Item 1) and back-up ring (item 2) [Figure 20-170-158] from the relief valve. 277 910, Figure 20-170-159 Paa00e Loosen the four screws (Item 1) [Figure 20-170-159] on the cover. Assembly: Tighten the screws to 10 Nem (88.5 inlb) torque. yure 20-170-160 6 Dealer Copy -- Not for Resale 20.170-47 Remove the four screws (Item 1) and cover (Item 2) [Figure 20-170-160) from the valve section. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Tilting Valve Section Disassembly And Assembly (Conta) Figure 20-170-161 Remove the O-ring (Item 1) [Figure 20-170-161] from the cover. Figure 20-170-162 es 44006 Remove the spring (Item 1) and spring retainer (Item 2) [Figure 20-170-162] from the spool 27001 910, 20.170-48 Figure 20-170-163, Q Remove the relief vaive (Item 1) [Figure 20-170-163] from the valve section, Assembly: Tighten the relief valve to 45 Nem (33 ft-lb) torque. Figure 20-170-164 iar Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-164] from the relief valve. "72556, 12566 Service Manual Dealer Copy —Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Tilting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-165 Loosen the four screws (Item 1) [Figure 20-170-165] on the cover. Assembly: Tighten the screws to 10 Nem (88.5 in-Ib) torque. wre 20-170-166 woo Pods Remove the four screws (Item 1) and cover (Item 2) [Figure 20-170-166] from the valve section 27901 910, 20-170-49 Figure 20-170-167 Za Remove the O-ring (Item 1) [Figure 20-170-167) from the cover. yure 20-170-168 Dealer Copy — Not for Resale Remove the spring (Item 1) and spring retainer (Iter 2) [Figure 20-170-168] from the spool. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Tilting Valve Section Disassembly And Assembly (Conta) Figure 20-170-169 sF : o Remove the spool Item 1) [Figure 20-170-169] from the valve section. Figure 20-170-170 Pants Remove the two plugs (Item 1) [Figure 20-170-170] from the valve section. Assembly: Tighten the plugs to 27 - 33 Nem (20 - 24 ft- 1b) torque. 200 of 910, 20-70-50 Figure 20-170-174 Remove the spring (Item 1) and poppet (item 2) [Figure 120-170-471] from the plugs. ire 20-170-472 Remove the O-ring (Item 1) [Figure 20-170-172] from the plugs. "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Figure 20-170-175 Tilting Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-173 the plug. Loosen the plug (Item 1) [Figure 20-170-173] Assembly: Tighten the plug to 54 - 66 Nem (40 - 49 f-Ib) torque. Figure 20-170-174 Pare Remove the individual pressure compensator plug (Item 4), poppet (Item 2) and guide (Iter 3) [Figure 20-170- 4174] from the valve section. 201 of 910, 20-170-51 Panam Remove the O-ring (Item 1) [Figure 20-170-175] from Dealer Copy -- Not for Resale "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Inlet-Outlet Valve Section Disassembly And Assembly Figure 20-170-176 Remove the four O-rings (Item 1) [Figure 20-170-176] from the valve section. Figure 20-170-177 Ow Paste Remove the flushing valve plug (Item 1) [Figure 20-170- 1771 from the valve section. Assembly: Tighten the plug to 100 Nem (74 ft1b) torque. 202.01 910, 20-70-52 Figure 20-170-178 Yo Remove the O-ring (Item 1) [Figure 20-170-178] from the plug Figure 20-170-479 Remove the spring, shims and piston (Item 1) [Figure 220-170-179] from the valve section. "72556, 12566 Service Manual Dealer Copy — Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Inlet-Outlet Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-180 Remove the plug (Item 1) [Figure 20-170-180] from the valve section. Assembly: Tighten the plug to 20 Nem (15 ft-lb) torque. Figure 20-170-181 1) Paanee Remove the O-ring (Item 1) [Figure 20-170-184] from the plug. 209 f 910, Figure 20-170-182 Oo, aan Remove the load sense relief cartridge (Item 1) [Figure 20-170-182] from the valve section. Assembly: Tighten the relief valve to 45 Nem (33 fib) torque. yure 20-170-183 Oa d Dealer Copy — Not for Resale 20-170-53 Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-183] from the relief cartridge. "72556, 72566 Service ManualHYDRAULIC CONTROL VALVE (CONT'D) Inlet-Outlet Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-184 Remove the flow regulator valve (Item 1) [Figure 20-170- 184] from the valve section. Assembly: Tighten the flow regulator valve to 20 Nem (15 ft-lb) torque. Figure 20-170-185 Remove the plug (Item 1), shim (Item 2), spring (Item 3) and spool Item 4) [Figure 20-170-185] from the valve. 204 f 910, 20-170-54 Figure 20-170-186 Remove the O-ring (Item 1) [Figure 20-170-186] from the plug jure 20-170-487 Remove the screen (Item 1) [Figure 20-170-187] from the valve. "72556, 12566 Service Manual Dealer Copy —Not for ResaleHYDRAULIC CONTROL VALVE (CONT'D) Inlet-Outlet Valve Section Disassembly And Assembly (Cont'd) Figure 20-170-188 Q bb Remove the two O-rings (Item 1) and back-up ring (Item 2) [Figure 20-170-188] from the flow regulator valve. Figure 20-170-189 ad Paar Remove the test fiting (Item 1) [Figure 20-170-189] from the valve section, 205 of 910, Figure 20-170-190 2 [ee Remove the O-ring (Item 1) [Figure 20-170-190] from the test fiting, Figure 20-170-194 Dealer Copy — Not for Resale 20-170-55 Remove the cap (Item 1) [Figure 20-170-191] from the test iting. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn or damaged parts, Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation. "72556, 72566 Service Manualx Bobcat e- 206 of 910, 20-70-56 "72556, 12566 Service Manual Dealer Copy ~ Not for ResaleJOYSTICK Removal And Installation SIN ABFR12999 & Below, S/N ABG312999 & Below: Remove the dash cover / steering column cover. (See Removal And Installation on Page 50-130-1.) Remove the joystick panel Installation on Page 50-120-1.) (See Removal And Figure 20-180-4 Dicoonnest the electrical conneeter (Item 1) [Figure 20 180-1] ‘SIN A8FR13000 & Above, S/N A8G313000 & Above: Figure 20-180-2 Remove the fuse box cover (Item 1) [Figure 20-180-2] Remove the joystick panel. (See Removal And Installation on Page 50-121-1.) 207 of 910, 20-1804 Figure 20-180-3, Disconnect the electrical connector (Item 1) [J 180-3], For All Models: NOTE: The joystick is not serviceable and must be replaced as a complete unit. Figure 20-180-4 Dealer Copy -- Not for Resale Raise the dust boot (Item 1) [Figure 20-180-4]. 72556, 72566 Service ManualJOYSTICK (CONT'D) Removal And Installation (Cont'd) Figure 20-180-5 Remove the four mounting bolts and spacers (Item 1) [Figure 20-180-5}. Installation: The joystick harness (Item 2) [Figure 20- 180-5] must be positioned around the swivel joint as shown. 7 Na Ne) 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 IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean, Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12008-0888 208 of 910, 20-1802 Figure 20-180-6 Remove the six hoses (Item 1) the joystick Mark the hoses for correct assembly. Figure 20-180-7 Remove the joystick assembly (Item 1) [Figure 20-180- 7) 172556, 72566 Service Manual Dealer Copy — Not for ResalePARKING BRAKE Figure 20-190-3, Valve Removal And Installation Figure 20-190-1 Figure 20-190-4 Remove the pin retainer (Item 1) [Figure 20-190-1] Figure 20-190-2 aler Copy — Not for Resale ‘Support the brake valve (Item 1) [Figure 20-190-3] and remove the two screws (Item 1) [Figure 20-190-4]. De Remove the parking brake valve. Remove the pin (Item 1) [Figure 20-190-2] from the lever. 209 01 910, 20-1904 "72556, 72566 Service ManualPARKING BRAKE (CONT'D) Valve Disassembly And Assembly Clean the outside of the brake valve before disassembly. Mark the outside of the brake valve for ease of assembly. Figure 20-190-5 Remove the fittings (Item 1) [Figure 20-190-5]. Figure 20-190-6 Pas Loosen the collar (Item 1) [Figure 20-190-6] NOTE: Use care removing the collar. The collar is under spring pressure. 200 of 910, 20-1902 Figure 20-190-7 Remove the collar (Item 1), spring (Item 2) and shaft (Item 3) [Figure 20-190-7] from the housing jure 20-190-8 wo) 6 Remove the washer (Item 1) [Figure 20-190-8] from the housing 172556, 72566 Service Manual Dealer Copy — Not for ResalePARKING BRAKE (CONT'D) Valve Disassembly And Assembly (Cont'd) Figure 20-190-9 a Remove the electrical connector (Item 1) [Figure 20-190- 9] from the housing Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn or damaged parts. Aiwaye inetall new eeale and © rings. Lubrieate all eeale and O-rings with clean hydraulic fluid before installation. 201 of 910, 20-1903, "72556, 72566 Service Manual Dealer Copy -- Not for Resale2201 910, 20-190-4 172556, 72566 Service Manual Dealer Copy ~ Not for ResalePILOT PRESSURE LOCKOUT VALVE Testing Raise the boom and install the boom stop. (See Installing The Approved Boom Stop on Page 10-150-1.) Figure 20-200-1 ; . Remove the rear cover (Item 1) [Figure 20-200-t], Figure 20-200-2 Locate the test fitting (Item 1) [Figure 20-200-2] below the control valve and remove the cap. 209. 910, 20-2004 Install a 7 MPa (70 bar) (1000 psi) gauge on the test fiting [Figure 20-200-3], Start the engine and run engine at 2200 rpm. Record the pressure. The pressure at the gauge should be 2,7 MPa (27 bar) (382 psi) at minimum rpm to 3,42 MPa (34 bar) (493 psi) at maximum rpm, The pilot pressure lock out valve is not adjustable. If the pressure is incorrect, replace the pilot pressure lock out valve. (See Removal And Installation on Page 20-200-2.) Dealer Copy ~ Not for Resale "72556, 72566 Service ManualPILOT PRESSURE LOCKOUT VALVE (CONT'D) Removal And Installation Relieve hydraulic pressure. Drain the hydraulic reservoir. (See Removing And Replacing Hydraulic Fluid on Page 10-100-2.) Figure 20-200-4 ( - ie Remove the rear cover (Item 1) [Figure 20-200-4} Mark the hoses and electrical connectors for correct installation, Figure 20-200-5 Remove the screw (Item 1) and disconnect the electrical ‘connector (item 2) [Figure 20-200-5] NOTE: The fuel tank is removed for photo purposes. 204 0f 910, 20-2002 7 MEGS 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 inj. not received immediately. 2145-0290, IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 2003-0888 Figure 20-200-6 Remove the two tubelines (Item 1) [Figure 20-200-6}, 172556, 72566 Service Manual Dealer Copy — Not for ResalePILOT PRESSURE LOCKOUT VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-200-7 Remove the tubeline (Item 1) [Figure 20-200-7] Figure 20-200-8 Remove the two mounting bolts (Item 1) and remove the pilot pressure lock out valve (Item 2) [Figure 20-200-8]. Disassembly And Assembly Figure 20-200-9 Oo = Remove the nut (item 1) 200-8] from the spool Figure 20-200-10 and coil (Item 2) [Figure 20- Dealer Copy — Not for Resale Remove the spool (Item 1) 208 of 910, 20-2003, ) [Figure 20-20-10] "72556, 72566 Service ManualPILOT PRESSURE LOCKOUT VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-200-11 “AL S of Remove the three O-rings (Item 1) and four back-up rings (item 2) [Figure 20-20-14] from the spool. Figure 20-200-12 ony Remove the fittings (Item 1) [Figure 20-20-12]. Past Wash the valve in clean solvent and dry with compressed air. Check the components for wear or damage. Replace any worn or damaged components. Aiways use new O- rings and back-up rings. Apply clean hydraulic fluid to the components during assembly. 206 of 910, 20-200-4 172556, 72566 Service Manual Dealer Copy -- Not for ResaleACCUMULATOR Removal And Installation Raise the boom and install the boom stop. (See Installing The Approved Boom Stop on Page 10-150-1.) The accumulator is located below the hydraulic control valve. 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 ee When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 2003-0888 Figure 20-210-4 ‘SIN ABFR12000 & ABOVE, SIN A8G313000 & ABOVE 297 of 910, 20-2104 Figure 20-210-2 ‘SIN ASFR12099 & BELOW, SIN A8G312900 & BELOW With the engine off, relieve the hydraulic pressure by pressing the bottom of the button (Item 1) (Figure 20- 240-1] and [Figure 20-210-2], Figure 20-210-3 Remove the accumulator (Item 1) from the manifold (Item 2) [Figure 20-210-3], "72556, 72566 Service Manual Dealer Copy -- Not for Resale208 of 910, = ae Bobcat. 20-2102 172556, 72566 Service Manual Dealer Copy ~ Not for ResaleTOW VALVE Removal And Installation Open the engine cover. (See Opening And Closing on Page 10-160-1.) Figure 20-220-1 Position the tow valve to towing position to relieve hydraulic pressure [Figure 20-220-1] WIIG) 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.214s.0790 IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. +2003 088 20.2204 209 0f 910, Figure 20-220-2 Mark the hoses for correct installation. Remove the two hoses (Item 1) [Figure 20-220-2] Figure 20-220-3 Remove the two bolts, nuts (Item 1) and strap (Item 2). Remove the tow vaive (item 3) [Figure 20-220-3]. 72556, 72566 Service Manual Dealer Copy - Not for ResaleTOW VALVE (CONT'D) Figure 20-220-6 Disassembly And Assembly Clean the outside of the tow valve before disassembly. Mark the outside of the tow valve for ease of assembly. Figure 20-220-4 Remove the screw (Item 1) and washer (Item 2) [Figure 20-220-4), Figure 20-220-5 Proper assembly. Figure 20-220-7 é Remove the retainer (Item 1) and stop plate (Item 2) [Figure 20-220-6], NOTE: Record the position of the stop plate for P68 Remove the handle (Item 1) [Figure 20-220-5}. 20.2202 200 1 910, Remove the two fittings (Item 1) [Figure 20-220-7] 72556, 72566 Service Manual Dealer Copy — Not for ResaleTOW VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-220-8 Figure 20-20-10 fittings. Figure 20-220-9 Remove the O-ring (Item 1) [Figure 20-220-8] from the Peres adapters, PaaTst Remove the two adapters (Item 1) [Figure 20-220-9]. 01 of 910, 20.2203, a Paar Remove the O-ring (item 1) [Figure 20-20-10] from the 72556, 72566 Service Manual Dealer Copy — Not for ResaleTOW VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-20-11 Figure 20-20-12 Remove the seal (Item 1) [Figure 20-20-11] from the valve (Both sides). Assembly: The concave side of the seal (Item 1) [Figure 20-20-14] fits over the ball (Item 2) [Figure 20-20-12]. Tur the shaft (Item 1) until the shaft and ball (Item 2) [Figure 20-220-12] are in the position shown. Remove the ball Assembly: Record the position of the shaft and ball for proper assembly. Figure 20-20-13 ‘igure 20-20-14 Assembly: Align the slot (Item 1) [Figure 20-20-13] with the noteh (Item 1) [Figure 20-220-14] in the shaft. 20.2204 72556, 72566 Service Manual 0201 910, Dealer Copy -- Not for ResaleTOW VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-20-15 Figure 20-20-17 pressing the shaft into the housing Figure 20-20-16 Remove the shaft (Item 1) [Figure 20-20-15] by or damaged parts. e PAGTOT Remove the O-ring (Item 1) [Figure 20-20-16] from the shaft. 209. 910, 20.2205 PBT Remove the seal (Item 1) [Figure 20-220-47] from the [esre_] housing Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn ‘Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic luid before installation. 72556, 72566 Service Manual Dealer Copy — Not for Resale04 of 910, = < Bobcat. 20.2206 72556, 72566 Service Manual Dealer Copy ~ Not for ResaleFRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE Removal And Installation Raise the boom and install the boom stop. (See Installing ‘The Approved Boom Stop on Page 10-150-1.) Stop the engine. Engage the parking brake. Exit the machine. A WARNING 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 fat injury is not received immediately. w2145.0700 igure 20-230-1 Turn the handle (Item 1) [Figure 20-230-1] to relieve hydraulic pressure. 20.2304 206 of 910, Figure 20-230-2 & P0018 Remove the two bolts (Item 2) [Figure 20-230-1], nuts {Item 1) and strap (item 2) [Figure 20-230-2] Figure 20-230-3 Dealer Copy — Not for Resale Relocate the valve (Item 1) and remove the two hoses {Item 2) [Figure 20-2303} Mark the hoses for correct installation. Remove the valve. IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean, Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 1.200.088 72556, 72566 Service ManualFRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE (CONT'D) Disassembly And Assembly Clean the outside of the pressure release valve before disassembly. Mark the outside of the pressure release valve for ease of assembly. Figure 20-230-4 PaGraT Remove the screw (item 1) and washer (Item 2) [Figure 70-230-8] Figure 20-230-5 Remove the handle (Item 1) [Figure 20-230-5}, 20.2302 206 of 910, Figure 20-230-6 Remove the retainer (Item 1) and stop plate (Item 2) [Figure 20-230-6], NOTE: Record the posi assembly. of the stop plate for proper Figure 20-230-7 é Remove the two fittings (Item 1) [Figure 20-230-7], 72556, 72566 Service Manual Dealer Copy — Not for ResaleFRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE (CONT'D) Disassembly And Assembly (Cont'd) igure 20-230-8 Pere Remove the O-ring (Item 4) [Figure 20-230-8] from the fittings. ire 20-230-9 Remove the two adapters (Item 1) [Figure 20-230-9]. Figure 20-230-10 a Paar Remove the O-ring (item 1) [Figure 20-230-10] from the adapters. Dealer Copy — Not for Resale 20.2303, 72556, 72566 Service Manual 207 of 910,FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-13, RELEASE VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-230-14 ye ‘igure 20-230-14 PATE Figure 20-230-12 fi Remove the seal (Item 1) [Figure 20-230-11] from the valve. (Both sides) Assembly: Align the slot (Item 1) [Figure 20-230-13] with the noteh (Item 1) [Figure 20-230-14] in the shaft. ‘Assembly: The concave side ofthe seal (tem 1) [Figure 20-230-14] fis over the ball (Item 2) [Figure 20-230-12] ‘Turn the shaft (Item 1) until the shaft and ball (Item 2) [Figure 20-230-12] are in the position shown, Assembly: Record the position of the shaft and ball for proper assembly. 20.230-4 72556, 72566 Service Manual 08 of 910, Dealer Copy -- Not for ResaleFRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE (CONT'D) Disassembly And Assembly (Cont'd) igure 20-230-15 PAGTED Remove the shaft (Item 1) [Figure 20-230-15] by pressing the shaft into the housin re 20-230-16 Remove the O-ring (Item 1) [Figure 20-230-16] from the shaft. 209 of 910, Figure 20-230-17 PBT Remove the seal (Item 1) [Figure 20-230-17] from the housing, Wash the components in clean solvent and dry with ‘compressed ait. Check the components for wear or damage. Replace any worn or damaged components. Always use new O-rings and seals. Apply clean hydraulic fluid to the O-rings and seals, during assembly. Dealer Copy ~ Not for Resale 72556, 72566 Service Manual31001910, x Bobcat Cae = é 20.2306 72556, 72566 Service Manual Dealer Copy ~ Not for ResaleFLOW CONTROL VALVE Figure 20-240-3, Removal And Installation Figure 20-240-1 Remove the flow control valve (Item 1) [Figure 20-240-3] from the front of the hydraulic control valve. Installation: Tighten the flov control valve to 20 Nem Remove the rear cover (Item 1) [Figure 20-240-1] (15 ftlb) torque Figure 20-240-2 Figure 20-240-4 2 3 Ja Ss 3 2 > 2 & -_O ff 5 3 3 ja The flow control valve is located on the front right side of Remove and clean the fiter (Item 1) [Figure 20-240-4] the hydraulic control valve [Figure 20-240-2]. NOTE: Check the filter for any damage. Replace the filter if required. 20.2404 72556, 12566 Service Manual att 910,1201910, = < Bobcat. 20.2402 72556, 72566 Service Manual Dealer Copy ~ Not for ResaleHYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION - 30-10-1 Troubleshooting Chart - 30-10-41 Replenishing Valve Function + 30-10-2 OIL COOLER . . » 30-10-1 Description... : a : coe 30-10-1 HYDROSTATIC DRIVE MOTOR vee 30-30-1 Removal And Installation... : : coe 30-30-1 Parts Identification a veces 30-30-2 Disassembly .. . : . . coe 30-30-5 Inspection .. a oe 30-30-16 Assembly . . oe . cece 30-30-18 HYDROSTATIC PUMP ..... . 30-40-1 Removal And Installation +. 30-401 Parts Identification : : = 30-40-2 Disassembly .. . : . . coe 30-40-7 Inspection : : : coos 30-40-19 Assembly . oe . cece 30-40-23 Charge Pressure Checking Procedure 30-40-38 Charge Pressure Adjusting Procedure ©... 000... ee eeeeeeeee eee 30-40-38 31301910, 30.01 "72556, 72566 Service Manual Dealer Copy -- Not for Resale31401 910, 30-02 "72556, 12566 Service Manual Dealer Copy -- Not for ResaleHYDROSTATIC SYSTEM INFORMATION ‘Troubleshooting Chart ‘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. ler does not move ler does not move aS lescopic TeScopie [The hydrostatic system is overheating GATE. WUT Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. w-2004-1208 ming Tight comes [t™—CS_____ KEY TOCORRECTIHECAUSEOOOCOC~—SSSSCSCSCSCSCSCSY T. The hydrostatic pump has Gamage. 2.The hydrostatic motor has damage. ‘The tires do not have the correct tire pressure. The tires are not the same size. 3. The hydrostatic Tuids not at the correct evel B.The oll cooler has a restriction. The temperature sending switch is not operating correctly. . The Telescopic handler 1s not belng operated at the correct (pM. The sender ie defection 10, Pump is defective or worn hydrostatios 7. Hydraulic fiteris plugged 215 0 910, s0-10-1 "72556, 72566 Service Manual Dealer Copy -- Not for ResaleHYDROSTATIC SYSTEM INFORMATION (CONT'D) Replenishing Valve Function Figure 30-10-1 — Ht Iii — Valve Moves For Charge Oil Replacement fi Valve Stays on Seat to Hold High Pressure Drive Function 1 Function 2 218 01 910, 30-402 IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all Parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. 12003-0888 The functions of the replenishing valves are 1. 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; Function 1 [Figure 30-10-1] 2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [Figure 30-10-1]. "72556, 12566 Service Manual Dealer Copy -- Not for Resale