s770 b3bv11101 SM Doosan

Service Manual
Compact Track Loader

S/N AT5A11001 & Above
S/N B3BV11001 & Above
7248296enUS (10-18) (D) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
T4-B S4-B
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1694 NA1693

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
NA1674 NA1695 NA1680

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1682 NA1683 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW39-0609
1-1 S770 Service Manual

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

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

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

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

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

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

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

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

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

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

the work lights.
FW SSL-0617 SM

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

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-0617 SM

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

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

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

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

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1016 SM

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

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

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

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1016SM

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

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

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
Check all electrical wiring and connections for damage. system, but the muffler and the exhaust gases are still
Keep the battery terminals clean and tight. Repair or hot.
replace any damaged part or wires that are loose or
frayed. Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
Battery gas can explode and cause serious injury. Use procedure in the Operation & Maintenance Manual for
the procedure in the Operation & Maintenance Manual cleaning the spark arrester muffler (if equipped).
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-1016 SM

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

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

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

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

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1016 SM

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

requesting service information or when ordering parts.
Earlier or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1 1
P121092A
1
The engine serial number (Item 1) [Figure 3] is located

on the side of the engine below the oil fill cap.
P100390E
The loader serial number plate (Item 1) [Figure 1] is

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

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

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

the order which the loader is produced.

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

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.
The delivery report must be reviewed and signed by the

owner or operator and the dealer.

LOADER IDENTIFICATION
2 20
1
11
3
19
4 12
5 18
13
10
14
6
9
7 8 15 17
16
NA5350
NA9412
ITEM DESCRIPTION ITEM DESCRIPTION

Operation & Maintenance Manual and Operator’s
1 11 Lift Cylinder (Both Sides)
Handbook
2 Front Lights 12 Rear Grille
3 Grab Handles 13 Back-up Alarm
4 Operator Seat with Seat Belt and Seat Bar 14 Rear Work Lights and Taillights
5 Tilt Cylinders 15 Rear Door
Rear Tie-down (Both Sides) Front Tie-down located
6 Bucket [A] 16
behind Bucket
7 Bucket Steps 17 Tires [C]
8 Step 18 Lift Arm Support Device
9 Alternate Front Tie-down (Both Sides) 19 Lift Arm
10 Front Auxiliary Quick Couplers 20 Operator Cab (ROPS and FOPS) [B]
[A] Bucket – Several different buckets and other attachments are available for the Bobcat loader.
[B] ROPS – Roll-Over Protective Structure per ISO 3471 and FOPS – Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
[C] Tires – Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

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

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

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

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

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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-5

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 10-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101-1
Filling The DEF / AdBlue® Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1


LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-85985
Lift the front of the loader and put jack stands under the
B-7023A axle tubes [Figure 10-10-2].
NOTE: Make sure the jack stands do not touch the

tires. Make sure tires clear floor or any
obstacles.
WARNING
Figure 10-10-3
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Always park the loader on a level surface.

P-90556
P-85425
WARNING Lift the rear of the loader and install jack stands [Figure
10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
10-10-1 S770 Service Manual

LIFT ARM SUPPORT DEVICE
Description
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
Figure 10-20-1
P109924
The lift arm support device (Item 1) [Figure 10-20-1] is

used to support the lift arms while working on a machine
with the lift arms up.
A decal (Item 2) [Figure 10-20-1] located on the right

side of the operator cab provides instructions for
installing and removing the lift arm support device.
The procedures are described in more detail on the

following pages. (See Installing on Page 10-20-2.) and
(See Removing on Page 10-20-3.)

LIFT ARM SUPPORT DEVICE (CONT’D) The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
Installing support device is installed.
Start the engine and raise the lift arms all the way up.
DANGER Figure 10-20-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised P-90567B
unless supported by an approved lift arm
support. Replace if damaged. Have a second person install the lift arm support device
D-1009-0409
over the rod of one of the lift cylinders [Figure 10-20-3].
Remove attachment from the loader. The lift arm support device must be tight against the
cylinder rod.
Figure 10-20-2
Figure 10-20-4
P100399
P107247A P100009
P100398
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-2]. Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
Remove the lift arm support device (Item 1) [Figure 10- of the lift arm support device must go past the end of the
20-2] from the storage position. cylinder (Inset) [Figure 10-20-4].

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5
Removing
DANGER
P-90567B
P-90328
AVOID DEATH Have a second person remove the lift arm support device
• Disconnecting or loosening any hydraulic [Figure 10-20-5] after the lift arms are all the way up.
can cause lift arms to drop. Lower the lift arms and stop the engine.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Figure 10-20-6
support. Replace if damaged.
D-1009-0409
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is removed and the lift arms are lowered
all the way.
NOTE: The lift arm support device should remain

resting on the cylinder barrel when the lift
arms are raised. Service or replace the lift arm
support device if the lift arm support raises
with the cylinder rod.
Start the engine and raise the lift arms all the way up. P109924
Return the lift arm support device to the storage position

and secure with the clamping knobs [Figure 10-20-6].
Remove the jackstands.

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

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

Never modify the cab. Replace the cab and hardware if
damaged.
ROPS - Roll-Over Protective Structure per ISO 3471 and

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

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

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

OPERATOR CAB (CONT'D)
Raising WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See Installing on Page • STOP ENGINE before raising or lowering cab.
10-20-2.) W-2758-0908
Figure 10-30-1 NOTE: On some machines, the operator cab frame

can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3
P107247
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
Hardware Installed Hardware Removed

P-90564E
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P100235A P100236A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

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

operator cab. WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
Hardware Removed Hardware Installed
P100953 P-90565A
Pull down on the bottom of the operator cab until stopped

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

when equipped with options and accessories,
such as: cab door, heater, and air
P100236A P100235A
conditioning. In these cases, the operator cab
may need to be raised slightly from the latch
to be able to release the latch. Install the washers and nuts (both sides) [Figure 10-30-
5].
Tighten the nuts to 54 – 61 N•m (40 – 45 ft-lb) torque.

WARNING Remove the jackstands.
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.

OPERATOR CAB (CONT’D)
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
P-68116B
The cab door has a sensor (Item 1) [Figure 10-30-6]

installed that deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
NA3275
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

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

7] is ON when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.
[DOOR] will appear in the data display (Item 2) [Figure

10-30-7] when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

OPERATOR CAB (CONT’D) Special Applications Kit Inspection And Maintenance
Special Applications Kit • Inspect for cracks or damage. Replace if required.

• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
AVOID INJURY OR DEATH • Do not clean with metal blades or scrapers.
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-8
NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.5 in) thick
polycarbonate front door and polycarbonate rear window
[Figure 10-30-8].
Polycarbonate top window (standard item) must be

installed for special applications to restrict material from
entering cab openings.

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-9 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-10
NA1819
Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the
loader. Kit includes 19,1 mm (0.75 in) thick laminated
1
polycarbonate front door, polycarbonate side windows
and polycarbonate rear window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Applications Kit to restrict
material from entering cab openings.
P100984
• Inspect both emergency exit levers (Item 1) [Figure

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

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

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can P107245A P107253A
break and cause personal injury.

W-2058-0807
Be sure the transport and towing vehicles are of

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

loading or unloading the loader on a trailer.
Figure 10-40-1
P100706
Alternate Rear Tie-Down Alternate Front Tie-Down
1 P107246A P-85599C
P100705 Use the following procedure to fasten the Bobcat loader

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

positions [Figure 10-40-2]. (Lift arms shown raised
for visual clarity.) (Some models have two front tie-
down locations on the transmission.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.

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

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

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

REMOTE START TOOL KIT - MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
The tools listed will be needed to do the following

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

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

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

REMOTE START TOOL - MEL1563 (CONT'D) Figure 10-60-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
2 2
1
1
P114629
Loaders equipped with an attachment harness (Item 1)

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

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

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

harness connector.

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

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

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

REMOTE START TOOL KIT - MEL1563 (CONT’D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
1
P114631
Figure 10-60-11
P-85729
Figure 10-60-9 2
P114632
Connect the Remote Start Tool to the engine harness

P114629
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the Remote Start Tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (if equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (if equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

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

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

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

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

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

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

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

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

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

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

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

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

the Remote Start Tool (Service Tool) on and activates the
loader electrical system. The button will illuminate to
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678 The traction lock button (Item 5) [Figure 10-61-2] is used

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

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

2
Figure 10-61-3
1 1
P114629
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The Loader Service Tool Harness (Item 1) is used to When the remote start procedure is completed, replace
connect the Remote Start Tool (Service Tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. reconnect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
Figure 10-61-6
2
3
P-85729
P114632
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and NOTE: The Remote Start Tool (Service Tool)
connect the Loader Service Tool Harness from the connection harness has two connectors (Item
Remote Start Tool (Service Tool). 1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Connect the Remote Start Tool (Service Tool) connector

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

the Remote Start Tool (Service Tool) will not
operate.
WARNING 2
P-76450

• Lift and block the machine.
• Check that wheels or tracks are clear. The Computer Service Tool Harness (Item 1) is required
• Cab ignition must be in the “STOP” position to to connect Remote Start Tool (Service Tool) to the
start the engine with the Service Tool (if Service PC (Item 2) [Figure 10-61-7].
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

REMOTE START TOOL (SERVICE TOOL) KIT - Raise the operator cab (if required by the procedure).
7217666 (CONT'D)
Remote Start Procedure
Figure 10-61-9
WARNING
1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
P-85729
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area. Loaders without an attachment control harness, remove
W-2457-1110 the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
The tool listed will be needed to do the following Remote Start Tool (Service Tool).
procedure:
NOTE: When using a Remote Start Tool (Service tool)
7217666: Remote Start Tool (Service Tool) Kit harness on loaders not equipped with an
attachment control device, the Remote Start
Figure 10-61-8 Tool (Service Tool) harness attachment
control device connector must be capped.
Figure 10-61-10
1
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure P114629

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

install an approved lift arm support device.

7217666 (CONT'D)
Remote Start Procedure (Cont'd) WARNING

When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-9] or AVOID INJURY OR DEATH
reconnect the attachment control harness to the loader • Lift and block the machine.
harness. • Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
Figure 10-61-11 start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
3 W-2792-0409
2
Figure 10-61-12
1 2
5 3
6 4
P114632
1
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-11] is always used for P-76439
connection to the loader harness.
The second connector (Item 3) [Figure 10-61- The Remote Start Tool (Service Tool) (Item 1) [Figure
11] is used for attachment ACD upgrades or 10-61-12] has five buttons.
attachment operational diagnostics only. This
connector has a cap attached to it to prevent The STOP button (Item 2) [Figure 10-61-12] is used to
damage or corrosion when not in use. stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
Connect the Remote Start Tool (Service Tool) connector
(Item 1) to the loader harness connector (Item 2) and the The RUN button (Item 3) [Figure 10-61-12] is used to
other Remote Start Tool (Service Tool) connector to the turn the Remote Start Tool (Service Tool) on and
ACD harness connector (Item 3) [Figure 10-61-11]. activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
NOTE: The key switch must be in the off position or
the Remote Start Tool (Service Tool) will not The START button (Item 4) [Figure 10-61-12] is used to
operate. start the loader engine.
The traction lock button (Item 5) [Figure 10-61-12] is

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

activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when testing pressures and flow rate.

7217666 (CONT'D)
Figure 10-61-13
1 2
P106657
Push the couplers on the front auxiliary block toward the

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

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

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

SERVICE SCHEDULE
Maintenance Intervals WARNING

Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early AVOID INJURY OR DEATH
failures. Instructions are necessary before operating or
servicing machine. Read and understand the
The service schedule is a guide for correct maintenance Operation & Maintenance Manual, Operator’s
of the Bobcat loader. Handbook and signs (decals) on machine. Follow
W-2003-0807
Every 10 Hours (Before Starting The Loader)
• Engine Oil – Check level and add as needed.

• Engine Air Filters and Air System – Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System – Clean debris from hydraulic fluid cooler and radiator assembly, fuel cooler, air conditioning
condenser (if equipped), rear grille, and screens on the rear door and engine cover. Check coolant level COLD and
add premixed coolant as needed.
• Fuel Filter – Check the display panel. Remove the trapped water when required.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges – Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks – Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) – Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm – Check for proper function.
• Tires – Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the
tire.
• Operator Cab – Check the fastening bolts, washers, and nuts. Check the condition of the cab.
• Indicators and Lights – Check for correct operation of all indicators and lights.
• Wheel Nuts – Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts
and tighten to correct torque.
• Safety Signs and Safety Treads – Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid – Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) – Clean or replace filters as needed.
SS SSL LF EXLF T4-B-0118

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 50 Hours
• Hydraulic Hoses and Tubelines – Check for damage and leaks. Repair or replace as needed.
• Final Drive Transmission (Chaincase) – Check fluid level and add as needed.
• Parking Brake, Foot Pedals, Hand Controls and Steering Levers, or Joysticks – Check for correct operation.
Repair or adjust as needed.
• Wheel Nuts – Check for loose wheel nuts and tighten to correct torque.
• Engine / Hydrostatic Drive Belt – Perform at first 50 hours, then as scheduled. Check for wear or damage. Adjust
or replace as needed.
• Engine Oil and Filter – Perform at first 50 hours, then as scheduled. Replace oil and filter.
Every 100 Hours
• Battery – Check cables and connections.

• Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours or Every 12 Months
• Engine / Hydrostatic Drive Belt – Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) – Check condition. Replace as needed.
• Bobcat Interlock Control System (BICS™) – Check the function of the lift arm bypass control.
• Fuel Filter – Replace filter element.

• Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap – Replace the charge filter and the reservoir breather
cap.
• Engine Oil and Filter – Replace oil and filter.
• Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.
• Hydraulic / Hydrostatic Filter – Replace the hydraulic / hydrostatic filter.

• Hydraulic Reservoir – Replace the fluid.
• Final Drive Transmission (Chaincase) – Replace the fluid.
• Engine Valves – Adjust the engine valve clearance.
• Coolant – Replace the coolant.
• Diesel Exhaust Fluid (DEF) / AdBlue® Filter – Replace the diesel exhaust fluid (DEF) / AdBlue® filter.
SS SSL LF EXLF T4-B-0118

ENGINE AIR CLEANER Figure 10-80-2
Replacing Filters
Figure 10-80-1
1
2
3
2
1
P121218A
NA3352
Open the latches (Item 2) and remove the cover (Item 1)

Replace the air filters only when necessary. The service [Figure 10-80-2].
indicator (Item 1) will FLASH. Press the Information
button (Item 3) until the display screen shows the service Figure 10-80-3
codes. Service code [AIRF] (Replace Engine Air Filter)
or [M0117] (Air Filter Plugged) will show in the display
screen (Item 2) [Figure 10-80-1] when air filter
replacement is necessary.
NOTE: Prolonged operation with an active [AIRF] or

[M0117] code can cause severe engine
component damage.
Prolonged operation with an active [AIRF] 1

code will cause the engine to derate (torque
and rpm reduction).
Replace the inner filter every second time the outer filter
is replaced or as indicated.
P121219
Outer Filter
Remove the outer filter (Item 1) [Figure 10-80-3] and
Stop the engine and remove the rear grille. (See discard.
Removing on Page 50-60-1.)
NOTE: Make sure the filter housing is free of dirt and
debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new outer filter. Push in until the filter contacts the
base of the housing.
Install the cover and secure the latches [Figure 10-80-2].
NOTE: The rubber boot attached to the air cleaner

cover is an important part of the engine
cooling system and must remain correctly
installed on the air cleaner cover.
Install the rear grille.

ENGINE AIR CLEANER (CONT’D) Figure 10-80-5
Replacing Filters (Cont’d)
Inner Filter
Replace the inner filter only under the following 1

conditions:
• Replace the inner filter every second time the outer

filter is replaced.
• After the outer filter has been replaced, start the 2

engine and operate at full rpm. If service code [AIRF]
(Replace Engine Air Filter) or [M0117] (Air Filter
Plugged) is still displayed in the data display, replace
P121218A
the inner filter.
Stop the engine and remove the rear grille. (See Install the cover (Item 1) and secure the latches (Item 2)
Removing on Page 50-60-1.) [Figure 10-80-5].
Remove the cover [Figure 10-80-2] and the outer filter NOTE: The rubber boot attached to the air cleaner
[Figure 10-80-3]. cover is an important part of the engine
cooling system and must remain correctly
Figure 10-80-4 installed on the air cleaner cover.
P121220
Remove the inner filter (Item 1) [Figure 10-80-4].
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new inner filter. Push in until the filter contacts the
base of the housing.
Install the outer filter [Figure 10-80-3].

ENGINE COOLING SYSTEM Cleaning
Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Maintenance Platform Stop the engine.
Figure 10-90-1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 10-90-2
P107266
1
A maintenance platform [Figure 10-90-1] is available to
facilitate access when cleaning the engine cooling
system.
3
P121169B
Use low air pressure or low water pressure to clean the

top of the rear grille (Item 1) [Figure 10-90-2].

engine cover screen (Item 2) [Figure 10-90-2].

rear door fan screens (Item 3) [Figure 10-90-2].
Remove the rear grille. (See Removing on Page 50-60-

1.)

ENGINE COOLING SYSTEM (CONT’D) Use low air pressure or low water pressure to clean the
top of the hydraulic fluid cooler and radiator assembly
Cleaning (Cont’d) (Item 3) [Figure 10-90-4].
Loaders With Air Conditioning Return the support bar to storage position and lower the
air conditioning condenser.
Figure 10-90-3
Figure 10-90-5
1
1
2 2
P121216B
P121162

top of the air conditioning condenser (Item 1) [Figure 10- Ensure the air conditioning condenser is installed into the
90-3]. two slotted brackets [Figure 10-90-5]. (Right side
shown.)
Unhook the two rubber straps (Item 2) [Figure 10-90-3].
Ensure the clips (Item 1) are properly installed over the
NOTE: The air conditioning condenser fits into two two slotted brackets (Item 2) [Figure 10-90-5]. (Right
slotted brackets mounted on the hydraulic side shown.)
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains Fasten the two rubber straps [Figure 10-90-3].
connected to the brackets when raising and
lowering. NOTE: The air conditioning condenser can be lifted
out of the two slotted brackets by removing
Figure 10-90-4 the clips. This allows greater access to clean
the hydraulic fluid cooler and radiator
assembly.
NOTE: Be careful when removing and installing the

1 air conditioning condenser so that the air
conditioning condenser does not fall on the
hydraulic fluid cooler and radiator assembly
2 and damage the fins.
3
Skip ahead to All Loaders. (See All Loaders on Page 10-
90-3.)
P121217D
Pivot the air conditioning condenser (Item 1) up and

rotate the support bar (Item 2) [Figure 10-90-4] into
position.

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Figure 10-90-7
Loaders Without Air Conditioning
Figure 10-90-6 2
3
1
1
P121216D

P121097A
top of the fuel cooler (Item 2) [Figure 10-90-7].
The area between the fuel cooler and the hydraulic fluid
Use low air pressure or low water pressure to clean the cooler and radiator assembly will require occasional
top of the hydraulic fluid cooler and radiator assembly cleaning. Remove the bolt (Item 3) and lift the fuel cooler
(Item 1) [Figure 10-90-6]. up while sliding out of the brackets (Item 1) [Figure 10-
90-7].
NOTE: Be careful when removing and installing the

fuel cooler so that the fuel cooler does not fall
on the hydraulic fluid cooler and radiator
assembly and damage the fins.
Install the fuel cooler into the brackets. Install and tighten
the bolt (Item 3) [Figure 10-90-7].
Check the cooling system for leaks.

ENGINE COOLING SYSTEM (CONT’D)
Checking And Adding Coolant

IMPORTANT
Check the engine coolant level every day before starting
the engine for the work shift. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Stop the engine and remove the rear grille. (See
Removing on Page 50-60-1.) Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-90-8 damage.
Too little antifreeze reduces the additives which

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

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
Add premixed coolant, 47% water and 53% propylene

glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-90-8].
P121221A Install the coolant fill cap [Figure 10-90-8].
NOTE: The coolant fill cap must be tightened until the

Coolant must be between the top and bottom level
cap clicks.
markers (Item 2) [Figure 10-90-8] when the engine is
cold.
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to test the condition of propylene

glycol in your cooling system.
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Remove the coolant fill cap (Item 1) [Figure 10-90-8] to

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

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

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-10
Removing And Replacing Coolant
See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine, open the rear door, and remove the rear
grille. (See Removing on Page 50-60-1.)
1
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P121163
is hot. You can be seriously burned.
W-2607-0804
Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
NOTE: This procedure requires the use of a spare 19 [Figure 10-90-10] or similar tool.
mm (0.75 in) coolant hose approximately 600
mm (24 in) long. Install the coolant fill cap (Item 1) [Figure 10-90-9].
Figure 10-90-9 Figure 10-90-11
1 3
2
P121221A P121164
Remove the coolant fill cap (Item 1) [Figure 10-90-9]. Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-11].
Quickly install the spare 19 mm (0.75 in) coolant hose

onto the engine oil cooler fitting.
Drain the coolant into a container.

ENGINE COOLING SYSTEM (CONT’D) The correct mixture of coolant to provide a -37°C (-34°F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
Removing And Replacing Coolant (Cont’d) of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Figure 10-90-12
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

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

protect the internal engine components; reduces the
P121221A
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

Remove the coolant fill cap (Item 1) [Figure 10-90-12] to concentrated coolant can cause serious premature
drain the coolant faster. engine damage.
I-2124-0497
Remove the spare 19 mm (0.75 in) coolant hose from the
engine oil cooler fitting when the coolant has drained.
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
Figure 10-90-13
the lower level marker on the tank (Item 2) [Figure 10-90-
12].
Install the coolant fill cap (Item 1) [Figure 10-90-12].
NOTE: The coolant fill cap must be tightened until the

cap clicks.
Install the rear grille and close the rear door.
2 Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
1
Check the coolant level when cool. Add coolant as
needed. (See Checking And Adding Coolant on Page 10-
P121165 90-4.)
Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-13].
Remove the tool used to pinch off the coolant hose.
Recycle or dispose of used coolant in an environmentally

safe manner.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-5.)

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.
The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0% five percent biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.
Apply the following guidelines if biodiesel blend fuel is

NOTE: Biodiesel blend fuel may also be used in this
used:
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed
• Ensure the fuel tank is as full as possible at all times
with ultra low sulfur petroleum based diesel.
to prevent moisture from collecting in the fuel tank.
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5
• Ensure that the fuel tank cap is securely tightened.
blended diesel fuel must meet ASTM
specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
E.U. Standard (EN590)
immediately.
Use only clean, high quality diesel fuel that meets the
• Drain all water from the fuel filter daily before
EN590 specifications listed below:
operating the machine.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10
• Do not exceed engine oil change interval. Extended
ppm) sulfur maximum
oil change intervals can cause engine damage.
• Diesel fuel with cetane number of 51.0 and above.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer, and
NOTE: Biodiesel blend fuel may also be used in this
operate the engine for at least 30 minutes.
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
NOTE: Biodiesel blend fuel does not have long term
with ultra low sulfur petroleum based diesel.
stability and should not be stored for more
This biodiesel blend fuel is commonly
than 3 months.
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Stop the engine and open the rear door.

NA1684
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
1 100-1].
NOTE: The fuel fill cap must be tightened until the

cap clicks.
Close the rear door.
P121465
WARNING
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Replacing Element
Fuel Filter See the SERVICE SCHEDULE for the correct service
Removing Water
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-100-4

3
Figure 10-100-3
1
1 2
P121903
Disconnect the electrical connector (Item 2) [Figure 10-

P121337
100-4].
Loosen the fuel filter head (Item 3) from the fuel filter
Loosen the drain (Item 1) [Figure 10-100-3] at the element (Item 1) [Figure 10-100-4]. Do NOT remove the
bottom of the filter to remove trapped water from the filter. hoses from the fuel filter head.
Securely tighten the drain. Loosen the clamps (Item 4) [Figure 10-100-4].
Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-100-4].
WARNING
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
Put clean oil on the two new fuel filter element O-rings,
install the element, and tighten to 13,5 N•m (10 ft-lb)
torque.
explosion or fire.
W-2103-0508
Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector (Item 2) [Figure 10-
Close the rear door. 100-4].
Remove air from the fuel system. (See Removing Air

From The Fuel System on Page 10-100-4.)

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter (Cont’d) After replacing the filter element or if the fuel tank has run
out of fuel, the air must be removed from the fuel system
Replacing Element (Cont’d) before starting the engine.
WARNING WARNING
Always clean up spilled fuel or oil. Keep heat, flames, AVOID INJURY OR DEATH
sparks or lighted tobacco away from fuel and oil. Diesel fuel or hydraulic fluid under pressure can
Failure to use care around combustibles can cause penetrate skin or eyes, causing serious injury or
explosion or fire. death. Fluid leaks under pressure may not be visible.
W-2103-0508 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
Start the engine and allow to operate for one minute.
Figure 10-100-5
WARNING
AVOID INJURY OR DEATH 1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do 2
from a doctor familiar with this injury.
W-2072-EN-0909 P121904
Stop the engine and check for leaks at the filter. Open the air vent plug (Item 1) [Figure 10-100-5] on the
fuel filter assembly three full turns.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

10-100-5] until fuel flows from the air vent plug with no air
bubbles.
Close the air vent plug (Item 1) [Figure 10-100-5].
WARNING
explosion or fire.
W-2103-0508

DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM Filling The DEF / AdBlue® Tank
Description Stop the engine.
The engine exhaust system is equipped with a selective NOTE: The engine must be stopped with the key
catalytic reduction (SCR) system. The SCR is an switch in the STOP position when filling the
emissions reduction system that removes nitrogen oxides DEF / AdBlue® tank.
from the exhaust gases.
Figure 10-101-1
The machine will periodically perform a process to clean
sulfur oxides from the SCR system. This process is
called DeSOX. (See DeSOX Process on Page 70-30-3.)
The SCR system requires Diesel Exhaust Fluid (DEF) /

AdBlue® to function correctly. 1
NOTE: Diesel exhaust fluid (DEF) and AdBlue® are

different names for the same fluid.
The SCR system will use one tankful of DEF / AdBlue®

for approximately two to four tankfuls of diesel fuel.
The DEF / AdBlue® level indicator is located on the left

panel. (See Left Panel on Page 60-50-1.)
P121091
The DEF / AdBlue® fill cap is located on the left side of

the machine. Remove the fill cap (Item 1) [Figure 10-
101-1].
Add only clean, unused DEF / AdBlue®. (See Capacities

on Page SPEC-10-5.)
Install and tighten the fill cap (Item 1) [Figure 10-101-1].
NOTE: The DEF / AdBlue® fill cap must be tightened

until the cap clicks.

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE CRANKCASE OIL
engine for the work shift. Recommended SAE Viscosity Number
Figure 10-110-1
Refer to temperature range anticipated before next

oil change
Must use API Category CJ-4 or better, or ACEA E9 or
1
better
2 Do not use API Category FA-4 engine oil
[1] SAE 10W-30
P121156 [2] SAE 15W-40
[3] Bobcat Synthetic Oil – SAE 5W-40
Park the loader on a level surface. Stop the engine. Open
Bobcat engine oils are recommended for use in this
the rear door and remove the dipstick (Item 2) [Figure
machine. If Bobcat engine oil is not available, use a good
10-110-1].
quality engine oil that meets API Service Classification of
CJ-4 or better, or ACEA E9 or better [Figure 10-110-2].
Keep the oil level between the marks on the dipstick. Do
not overfill.
Remove the oil fill cap (Item 1) [Figure 10-110-1] to add

engine oil.
IMPORTANT
AVOID ENGINE DAMAGE
WARNING Use of API Service Category FA-4 engine oil is not
approved and may cause irreversible damage to the
engine.
AVOID INJURY OR DEATH I-2384-0916
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-5
Removing And Replacing Oil And Filter

Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
Figure 10-110-3
P-90498A
P109762A
Remove the oil drain cap (Item 1) [Figure 10-110-5] from

the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
1 2
Install and tighten the oil drain cap [Figure 10-110-5].
P109086B
Return the oil drain hose to the storage location on top of
the fuel tank [Figure 10-110-4].
The oil drain hose is located behind a cover (Item 2) Install the cover and the cover mounting bolts [Figure 10-
under the right rear corner of the loader (Inset) [Figure 110-3]. Tighten both bolts.
10-110-3].
Remove the cover mounting bolts (Item 1) and remove

the cover (Item 2) [Figure 10-110-3].
Open the rear door.
Figure 10-110-4
P121158
The oil drain hose (Item 1) storage location is on top of

the fuel tank. Remove the hose from the storage location
and route through the opening (Item 2) [Figure 10-110-
4].

ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter (Cont’d) WARNING

Figure 10-110-6
explosion or fire.
W-2103-0508
1
2
3
P121156
Remove the oil filter (Item 3) [Figure 10-110-6] and clean

the filter base.
Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only.
Remove the oil fill cap (Item 1) [Figure 10-110-6].
Put oil into the engine and replace the oil fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Start the engine and allow to operate for several minutes.
WARNING
Use a piece of cardboard or wood to find leaks. Do
W-2072-0807
Stop the engine and check for leaks at the filter.
Remove the dipstick (Item 2) [Figure 10-110-6] and

check the oil level.
Add oil as needed if oil level is not at the top mark on the
dipstick. Install the dipstick and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3

HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG) AND
before starting the work shift. VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms and
place the attachment flat on the ground or tilt the Bob-
Tach® fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED DURING

MACHINE USE
[1] BOBCAT All-Season Fluid
[2] BOBCAT Synthetic Fluid
[3] BOBCAT Biodegradable Hydraulic / Hydrostatic
1 Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at
operating temperatures.)
[4] VG 100; Minimum VI 130
P100391 [5] VG 46; Minimum VI 150
Bobcat hydraulic fluids are recommended for use in this

Check the fluid level in the sight gauge (Item 1) [Figure
machine. If Bobcat hydraulic fluid is not available, use a
10-120-1]. Keep the fluid level within the operating range.
good quality hydraulic fluid meeting the viscosity grade
and viscosity index shown in the chart [Figure 10-120-
3].(See Hydraulic System on Page SPEC-10-4.)
1.)
Figure 10-120-2
WARNING
1 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
P121074A
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-120-1].
Install the fill cap [Figure 10-120-2] and install the rear
grille.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid

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

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.)
P100007
Stop the engine, and remove the rear grille. (See
Remove the right side access cover bolts (Item 1)
Figure 10-120-4 [Figure 10-120-5] and remove the access cover. (Lift
arms shown raised for visual clarity.)
Figure 10-120-6
1
1
2
P121074A
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4].

P115442
The drain hose is located behind the fan motor.
Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-120-6] near the fitting and disconnect hose
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.
Connect the hose to the fitting when the fluid stops

draining. Install the clamp [Figure 10-120-6].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Fluid (Cont’d)

WARNING
Recycle or dispose of used fluid in an environmentally
safe manner.
WARNING death. Fluid leaks under pressure may not be visible.

AVOID INJURY OR DEATH enters skin or eyes, get immediate medical attention
Always clean up spilled fuel or oil. Keep heat, flames, from a physician familiar with this injury.
sparks or lighted tobacco away from fuel and oil. W-2072-0807
explosion or fire. Stop the engine and check for leaks.
W-2103-0508
Check the fluid level in the reservoir and add as needed.
Install the side access cover and bolts [Figure 10-120-5]. (See Checking And Adding Fluid on Page 10-120-1.)
Figure 10-120-7
P121073A
Remove and clean the hydraulic fill screen (Item 1)

[Figure 10-120-7]. Use low air pressure to dry the
screen.
Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range
of the sight gauge. (See Capacities on Page SPEC-10-
5.) and (See Checking And Adding Fluid on Page 10-
120-1.)
Install the hydraulic fill cap [Figure 10-120-4].
Start the engine and operate the loader hydraulic

controls.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter element ensuring that element is fully
seated in the housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter Remove the filter cap O-rings (Item 3) [Figure 10-120-9]
and discard.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Install new filter cap O-rings and lubricate with clean oil.
Stop the engine and remove the rear grille. (See NOTE: The filter cap O-rings are not the same size.
Removing on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and bolts. Alternate tightening the
Figure 10-120-8 bolts to draw the cap down evenly. Tighten the bolts to 27
– 41 N•m (20 – 30 ft-lb) torque.
WARNING
1 AVOID INJURY OR DEATH
2 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P121214A Install the rear grille.

Remove the bolts (Item 1) and rotate the filter cap (Item controls.
2) [Figure 10-120-8] slightly.
Slowly pry the filter cap off the housing by hand.
Figure 10-120-9 WARNING

1
2 penetrate skin or eyes, causing serious injury or
W-2072-0807
3 Stop the engine and check for leaks at the filter.

P121072A P121580A
(See Checking And Adding Fluid on Page 10-120-1.)
Remove the filter element (Item 2) [Figure 10-120-9] and

discard.
Lubricate the O-ring (Item 1) [Figure 10-120-9] on new

filter element with clean oil.

Removing And Replacing Hydraulic Charge Filter WARNING

interval. (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Stop the engine. sparks or lighted tobacco away from fuel and oil.
Figure 10-120-10 explosion or fire.
W-2103-0508
1 Install the right side access cover and bolts [Figure 10-
120-10].

controls.
WARNING
P100007 Diesel fuel or hydraulic fluid under pressure can
Remove the right side access cover bolts (Item 1)
[Figure 10-120-10] and remove the access cover. (Lift
arms shown raised for visual clarity.)
Figure 10-120-11
W-2072-0807
Stop the engine and check for leaks at the filter.

(See Checking And Adding Fluid on Page 10-120-1.)
P121104
Put a suitable container below the filter, remove the filter

(Item 1) [Figure 10-120-11], and clean the filter base.
Put clean oil on the new filter gasket, install the new filter,
and tighten the filter to 37 – 45 N•m (27 – 33 ft-lb) torque.

safe manner.

Replacing Reservoir Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Stop the engine and remove the rear grille. (See

Figure 10-120-12
P121074A
Remove the breather cap (Item 1) [Figure 10-120-12]

and discard.
Install new breather cap.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Fluid
Checking And Adding Fluid See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Park the loader on a level surface and stop the engine.
The chaincase contains the final drive sprockets and Remove the check plug (Item 1) [Figure 10-130-1] from
chains and uses the same type fluid as the hydraulic / the front of the chaincase housing.
hydrostatic system. (See Hydraulic / Hydrostatic Fluid
Chart on Page 10-120-1.) Figure 10-130-2
Park the loader on a level surface and stop the engine.
Figure 10-130-1
P107281
Pump the fluid out of the chaincase [Figure 10-130-2].

P107956
(Lift arms shown raised for visual clarity.)

Remove the check plug (Item 1) [Figure 10-130-1] from safe manner.
the front of the chaincase housing. (Lift arms shown
raised for visual clarity.) Add fluid through the check plug hole until the fluid flows
from the hole. (See Capacities on Page SPEC-10-5.)
If fluid can be reached with the tip of your finger through
the hole, the fluid level is correct. Install and tighten the plug.
If the level is low, add fluid through the check plug hole
until the fluid flows from the hole.
Install and tighten the plug [Figure 10-130-1]. WARNING

WARNING Always clean up spilled fuel or oil. Keep heat, flames,

AVOID INJURY OR DEATH explosion or fire.
Always clean up spilled fuel or oil. Keep heat, flames, W-2103-0508
explosion or fire.
W-2103-0508

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

1
Figure 10-140-1
Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
The wedges (Item 1) [Figure 10-140-2] must extend

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

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-140-1]. frame (Item 2) [Figure 10-140-2].
The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-140-3

The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

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

BOB-TACH (POWER) Figure 10-141-2
This machine may be equipped with a Power Bob-Tach.

1
Figure 10-141-1 2
1 Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
2 The wedges (Item 1) [Figure 10-141-2] must extend

through the holes in the attachment mounting frame.
NA3234 The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-141-2].
Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure [Figure 10-141-2], the attachment will be loose and can
10-141-1] until the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely. Figure 10-141-3
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

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

LUBRICATING THE LOADER Lubricate the following:
Lubrication Locations Figure 10-150-2

Record the operating hours each time you lubricate the

Bobcat loader. 1
Always use a good quality lithium based multipurpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader.
Stop the engine.

P-90543B
Figure 10-150-1
1 1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-2].

2
4 Figure 10-150-3
8
9 10
11
2
3 5
6
7
P107399
The grease fitting locations [Figure 10-150-1] are shown

in more detail in the following figures.
P-90542A
2. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-3].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-6
Lubrication Locations (Cont’d)
Figure 10-150-4 5
3
P109928
5. Rear Control Link (Both Sides) (2) [Figure 10-150-6].

P107285
Figure 10-150-7
3. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

150-4].
Figure 10-150-5
P107292
6. Front Control Link (Both Sides) (2) [Figure 10-150-7].
P100908
4. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

150-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-10
Figure 10-150-8
7
P107960
9. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-31308A
150-10].
Figure 10-150-11
7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8].
Figure 10-150-9
10
8
P107961
P109929
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-
11].
8. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-9].

LUBRICATING THE LOADER (CONT’D)
Figure 10-150-12
11
P107959
11. Power Bob-Tach Hydraulic Cylinder (if equipped) (2)

[Figure 10-150-12].

TIRE MAINTENANCE Rotating
Wheel Nuts Inspect the tires regularly for wear, damage and
pressure.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-160-2
Figure 10-160-1
NA1023A
P-85479A
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
Follow the torques specified below for the wheel nuts to the front [Figure 10-160-2].
[Figure 10-160-1]:
The same size tires must be used on each side of the
When installing wheel nuts, tighten to 278 N•m (205 loader. If different sizes are used, each tire will turn at a
ft-lb) torque. different rate and cause excessive wear. The tread bars
of all the tires must face the same direction.
When checking wheel nut torque, set the torque
wrench to 251 N•m (185 ft-lb) to prevent over- Recommended tire pressure must be maintained to avoid
tightening. excessive tire wear and loss of stability and handling
capability. Test for correct pressure before operating the
loader.

TIRE MAINTENANCE (CONT’D)
Mounting
Tires are to be repaired only by an authorized person

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

before mounting. Inspect 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, test the tire pressure frequently

to avoid over inflation.
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010

PIVOT PINS
Figure 10-170-1
P107293A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-170-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 -

40 ft-lb) torque.

LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, perform the
procedures below to return the loader to service:
You may decide to store your Bobcat loader for an
extended period of time. Perform the procedures below • Check the engine oil and hydraulic fluid levels; check
for storage: coolant level.
• Thoroughly clean the loader including the engine • Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in position.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check tire inflation and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the
tires. • Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods. • Start the engine and operate for a few minutes while
observing the instrument panels and systems for
• Put fuel stabilizer in the fuel tank and operate the correct operation.
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors. • Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer, and operate the engine for at
least 30 minutes.
• Drain and flush the cooling system. Refill with

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

hydrostatic).
• Replace air cleaner, heater, and air conditioning

filters.
• Put all controls in NEUTRAL position.
• Remove the battery. Be sure the electrolyte level is

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

storage condition.

STOPPING THE ENGINE AND LEAVING THE LOADER Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Procedure
Unbuckle the seat belt.
Stop the loader on level ground.
(Standard Key Panel) Remove the key from the switch
Fully lower the lift arms and put the attachment flat on the to prevent operation of the loader by unauthorized
ground. personnel.
Figure 10-190-1 NOTE: Activating the Password Lockout Feature on

machines with the Keyless Start Panel or the
Deluxe Instrumentation Panel allows
operation of the loader without using a
password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-190-3
P107184
Set the engine speed control to the low idle position

[Figure 10-190-1].
P-85737A P-85735A
Engage the parking brake.
Figure 10-190-2 Exit the loader using grab handles, safety tread, and
steps (maintaining a three-point contact) [Figure 10-190-
3].
1 1
WARNING
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
P-90688A P-90214C
the ground.
• Stop the engine.
• Engage the parking brake.
Turn the key switch to the STOP position (Item 1) [Figure • Raise the seat bar.
10-190-2]. • Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
NOTE: If the loader lights are ON, they will remain ON drive functions are deactivated.
for approximately 90 seconds after turning
the loader OFF. The seat bar system must deactivate these functions
when the seat bar is up. See your Bobcat dealer for
NOTE: The cooling fans in the rear door may service if controls do not deactivate.
continue to operate for several minutes. W-2463-1110

EMERGENCY EXIT
The front opening on the operator cab and rear window provide exits.
Rear Window Identification There are two different procedures for removing the rear
window from your machine:
Figure 10-200-1
1. This window is equipped with latches [Figure 10-200-
Latches Rubber Cord 1].
2. This window is equipped with a rubber cord and tag

[Figure 10-200-1].
2
NOTE: Use these procedures to remove the rear
1 window only under emergency conditions.
Damage to machine may occur.
P-85309B P-64994G
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-200-2 Figure 10-200-4
P-85309A P-64994F
Turn both latches (Item 1) [Figure 10-200-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-200-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-200-3 Figure 10-200-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 10-200- Exit through the rear of the operator cab [Figure 10-200-
3]. 5].

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 10-200-6
Figure 10-200-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 10-200-8] up and out
[Figure 10-200-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove. Front Door
OR This machine may be equipped with a front door.
Figure 10-200-7 NOTE: Use this procedure to remove the front door
only under emergency conditions. Damage to
machine may occur.
1
Figure 10-200-9
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools. P-90725
Turn both knobs (Item 1) [Figure 10-200-7]

Turn both latches (Item 1) [Figure 10-200-9] down until
counterclockwise until the latches disengage from the
they disengage from the door frame.
window frame. Pull the top of the window away from the
cab and lift up to remove.
Push the door out of the operator cab door frame and exit
through the opening.

EMERGENCY EXIT (CONT’D) Figure 10-200-12
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-200-10
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-200-12] on the door. (Bottom
hinge shown.)
2
Figure 10-200-13
P-85781A 1
NOTE: Later models route the washer fluid hose

differently and will not require this step. 2
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) (if equipped) [Figure 10-200-10].
Figure 10-200-11
P-90686A
2
3
Install cast washers (Item 2) on door hinges taking care
to match rectangular surfaces. Hold cast washer firmly
against door and rotate latch (Item 1) [Figure 10-200-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity).
1
Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
the clip into the hole in the gas spring socket. Rotate the
P-85588A P-85589A
clip to lock into position [Figure 10-200-11].
Rotate and pull the clip (Item 1) out of the gas spring Connect electrical connector and washer fluid hose (if
socket. Pull the gas spring socket (Item 3) straight off the equipped) [Figure 10-200-10].
ball stud fitting (Item 2) [Figure 10-200-11].
Remove the door hinges from the loader.

SEAT BELT Figure 10-210-1

1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware, or any other obvious
problem should be replaced immediately. 5
NA3113
The items below are referenced in [Figure 10-210-1].
1. Check the webbing. If the system is equipped with a

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

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

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

rays from the sun, or extreme dust or dirt. If the
original color of the webbing in these areas is
extremely faded and / or the webbing is packed with
dirt, the webbing strength may have deteriorated.
5. Check the hardware on both sides of the seat.

Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.
See your Bobcat dealer for seat belt system replacement

parts for your machine.

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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-9
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-11
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Lift Spool And Detent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Lift Spool And Detent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-22
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24
Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

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

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

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

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

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly (FFI/FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2
Disassembly And Assembly (FFH/FH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
AUTOMATIC RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Checking The Pressure In The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-5
Adding Nitrogen To The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-7

Printable Version Click Here
(PRINTED JUNE 2015)

V-1603legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE
(SCREEN) 33 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal)
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 17 CHECK VALVE With 100 kPa 1,0 bar 34 NOT USED FOR THIS MODEL
(14.5 psi) Spring
2 SIGHT GUAGE 35 NOT USED FOR THIS MODEL
18 RESTRICTION . . . . . . 2,0 mm (0.079 in)
3 DIFFERENTIAL PRESSURE SWITCH: 36 CHARGE PUMP -
103 kPa (1,03 bar) (15 psi) 19 PULL BUTTON ACTIVATED
51,1 L/min (13.5 U.S. gpm) at High Engine Idle
Normally Closed DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
4 FILTER - HYDRAULIC (CANISTER) 37 HYDRAULIC PUMP . . . . . . . Gear Type
20 LIFT CYLINDER SPOOL - MADE TO 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
5 SPRING LOADED FILTER BY-PASS RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 38 VARIABLE CAPACITY DISPLACEMENT
VALVE: 172 kPa (1,7 bar) (25 psi) BIDIRECTIONAL HYDROSTATIC PUMP
21 ANTICAVITATION VALVE
6 DIAGNOSTIC COUPLER
39 RELIEF/REPLENISHING VALVE - HIGH
22 PROPORTIONAL RELIEF VALVE –
PRESSURE: 36500 kPa (365 bar) (5294 psi)
7 RELIEF VALVE - MAIN: (Fan Speed Regulator): 10797-12300 kPa
23787 - 24476 kPa (238 - 245 bar) (108 - 123 bar) (1566 - 1784 psi)
40 RELIEF VALVE - CHARGE INLET:
(3450 - 3550 psi) at Front Quick Couplers 23 SPRING LOADED FILTER BY-PASS VALVE: 3447 kPa (34,5 bar) (500 psi) at High
8 RELIEF/ANTICAVITATION VALVE - 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) Engine Idle With 60 ° C (140 ° F) Fluid
PORT: 27579 kPa (276 bar) (4000 psi) 24 FIXED CAPACITY DISPLACEMENT
9 HYDRAULIC MOTOR 41 CHECK VALVE – COLD WEATHER BY-PASS
RELIEF/ANTICAVITATION VALVE -
25 FILTER - HYDRAULIC (CANISTER) With 345 kPa (3,45 bar) (50 psi) Spring
PORT (OPTIONAL):
27579 kPa (276 bar) (4000 psi)
26 SENSOR – CHARGE PRESSURE – 42 FILL PORT – Factory Hydraulic Fill
10 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter
CONTROL VALVE - AUXILIARY
27 FRONT AUXILIARY MANUAL PRESSURE
11 LOAD CHECK VALVE BLEED-OFF VALVE
12 ANTICAVITATION VALVE 28 SENSOR – HYD. TEMPERATURE
29 RESTRICTION - 1,5 mm (0.06 in)

13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 30 CHECK VALVE - With 1379 kPa (13,8 bar)
14 PILOTED ACTIVATED DIRECTIONAL (200 psi) Spring
CONTROL VALVE - LIFT CONTROL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - BICS CONTROL 32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1603legend (5-27-15)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
27
Male
DRIVE MOTOR
27
30 Female
L
31
29
HYDRAULIC CONTROL VALVE
32
10
A 33 B 10
Auxiliary Spool
42
HYDROSTATIC PUMP
11
8
38 BOBCAT INTERLOCK CONTROL SYSTEM
(BICS)
M4
M3
Tilt Spool
D C
13
12 TILT CYLINDERS
39 11
39
14
8
40
Lift Spool
B A
LIFT CYLINDERS
M2 M1
20
11 16
15 18
39 39 IN
7 6
16 17
38 41
2
T
17
1
19
OIL COOLER
37 3 HYDRAULIC
HYDRAULIC 4 RESERVOIR
FILTER (VENTED)
36 VARIABLE SPEED HYDRAULIC

5 1
FAN MOTOR W/ INTEGRATED FILTER
25 23
26
WORKING CIRCUIT
B A CHARGE
PRESSURE
24 21 DRAIN / RETURN
22
P DR
32
DRAIN / RETURN MANIFOLD

28 HYDRAULIC/HYDROSTATIC SCHEMATIC
31
MANUAL WITH NO OPTIONS
29 S770 (S/N AT5A11001 & ABOVE)
30
L S770 (S/N B3BV11001 & ABOVE)
DRIVE MOTOR (PRINTED JUNE 2015)
7194312 (F)
Printed In U.S.A.
(PRINTED JUNE 2015)

V-1604legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 36 CHARGE PUMP - 57 RESTRICTOR - 0,8 mm (0.031 in)
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (SCREEN) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 58 LOAD SHUTTLE VALVE - BLEED OFF
17 CHECK VALVE - With 100 kPa (1,0 bar) HYDRAULIC PUMP . . . . . . . Gear Type
37
2 SIGHT GUAGE (14.5 psi) Spring 87,1 L/min (23.0 U.S. gpm) at High Engine Idle SOLENOID ACTIVATED DIRECTIONAL
59
VARIABLE CAPACITY DISPLACEMENT CONTROL VALVE - Female
3 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 38
DIFFERENTIAL PRESSURE SWITCH: BIDIRECTIONAL HYDROSTATIC PUMP SOLENOID ACTIVATED DIRECTIONAL
103 kPa (1,03 bar) (15 psi) 60
19 PULL BUTTON ACTIVATED CONTROL VALVE - Male
Normally Closed 39 RELIEF/REPLENISHING VALVE - HIGH
DIRECTIONAL CONTROL VALVE - LIFT PRESSURE: 36500 kPa (365 bar) (5294 psi)
4 61 SOLENOID ACTIVATED DIRECTIONAL
FILTER - HYDRAULIC (CANISTER) ARM BY-PASS
CONTROL VALVE - BUCKET POSITION
20 LIFT CYLINDER SPOOL - MADE TO 40 RELIEF VALVE - CHARGE INLET:
5 SPRING LOADED FILTER BY-PASS VALVE (ON/OFF)
RESTRICT FLOW DURING BOOM 3447 kPa (34,5 bar) (500 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) at High Engine Idle 62 FLOW DIVIDER ADJUSTMENT VALVE
DOWN BUT NOT DURING BOOM UP
6 DIAGNOSTIC COUPLER With 60 ° C (140 ° F) Fluid PILOTED ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 63 CONTROL VALVE - FLOW CONTROL
7 RELIEF VALVE - MAIN: 41 CHECK VALVE – COLD WEATHER BY-PASS
22 PROPORTIONAL RELIEF VALVE – SPOOL
23787 - 24476 kPa (238 - 245 bar) With 345 kPa (3,45 bar) (50 psi) Spring
(Fan Speed Regulator): 10797 – 12300 kPa 64 CHECK VALVE - BUCKET POSITION
(3450 - 3550 psi) at Front Quick Couplers 42 FILL PORT – Factory hydraulic Oil
(108 - 123 bar) (1566 - 1784 psi) VALVE
RELIEF VALVE – MAIN (OPTIONAL): 23 SPRING LOADED FILTER BY-PASS VALVE: PILOT ACTIVATED DIRECTIONAL CONTROL
43
VALVE – HYDRAULIC POWERED BOB-TACH 65 PILOTED ACTIVATED DIRECTIONAL
25855 – 26545 kPa (259 - 265 bar) 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) CONTROL VALVE - UNLOADING
(3750 - 3850 psi) at Diagnostic Coupler 6 24 FIXED CAPACITY DISPLACEMENT With Build-up Valve 275 kPa (2,75 bar) (40 psi) SPOOL
HYDRAULIC MOTOR 44 FILTER - BOB-TACH VALVE HIGH FLOW HYDRAULIC PUMP Gear Type
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 66
25 FILTER - HYDRAULIC (CANISTER) 51,1 L/min (13.5 U.S. gal) at High Engine Idle
23787 – 24476 kPa (238 - 245 bar) 45 RESTRICTION - 1,17 mm (0.46 in)
(3450 - 3550 psi) at Diagnostic Coupler 6 67 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
26 SENSOR – CHARGE PRESSURE – SOLENOID ACTIVATED DIRECTIONAL
46 CONTROL VALVE (TWO COIL)
8 Fan Filter 68 DUMP VALVE – ON / OFF
RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 27 FRONT AUXILIARY MANUAL PRESSURE 47 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
69 CHECK VALVE - With 34,5 kPa (0,34 bar)
BLEED-OFF VALVE (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 CHECK VALVE
28 SENSOR – HYD. TEMPERATURE
PORT (OPTIONAL): 27579 kPa 70 RIDE CONTROL VALVE
(276 bar) (4000 psi) 49 RESTRICTION - 0,25 mm (0.10 in)
71 HIGH PRESSURE CHAMBER
10 SOLENOID ACTIVATED DIRECTIONAL 50 NOT USED ON THIS MODEL
CONTROL VALVE - AUXILIARY 30 CHECK VALVE - With 1379 kPa 13,8 bar LOW PRESSURE CHAMBER
72
(200 psi) Spring 51 SOLENOID ACTIVATED DIRECECTIONAL
11 LOAD CHECK VALVE CONTROL VALVE – BRAKE
12 ANTICAVITATION VALVE 52 FILTER – BRAKE VALVE
13 PILOTED ACTIVATED DIRECTIONAL 32 FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC MOTOR 53
CONTROL VALVE - TILT CONTROL CONTROL VALVE – 2 Speed Shift
14 PILOTED ACTIVATED DIRECTIONAL 33 HYDRAULIC BRAKE – SPRING APPLIED – PILOT ACTIVATED DIRECTIONAL
PRESSURE RELEASE (SAPR) 54
CONTROL VALVE - LIFT CONTROL CONTROL VALVE - REAR AUXILIARY
15 SOLENOID ACTIVATED DIRECTIONAL 34 PILOT ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
55 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - BICS CONTROL CONTROL VALVE – 2 Speed springs have NO significant
FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL pressure value.
35 56
BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE - TWO COIL
2-SPEED DRIVE MOTOR
Male
30 27
L
31 Male
29
27
69
Female
RIDE CONTROL
(OPTIONAL)
HYDRAULIC CONTROL VALVE

X
LIFT CYLINDERS
REAR AUXILIARY VALVE 72 71

34 (OPTIONAL) 9
FEMALE MALE
35 REAR QUICK COUPLERS 70

32
9
58
Z
10
A 33 B 10
59 60 Auxiliary Spool
56 42
HYDROSTATIC PUMP
BUCKET POSITIONING
57 VALVE (OPTIONAL)
7A E1 E2 A1 A2
11 E3
8
38 BOBCAT INTERLOCK CONTROL SYSTEM
(BICS) 61
55 B
62
8
63
M4
M3
54
Tilt Spool 64
P in P out T
D C D2
2-SPEED & SAPR
BRAKE VALVE 13
12
B A
51 39 11 64
39
T
POWER BOBTACH CYLINDER
(OPTIONAL) 14
65 C2
POWER BOBTACH 8
VALVE (OPTIONAL) C1 D1
P 40
48 47 Lift Spool
B1 A1
B A
52 52 53
M2 M1
46
20
49 16
11
15 18
39 39 IN TILT CYLINDERS
D
7 6
45 16 17
38 41
2
44
T
1
43 19
OIL COOLER
37 3 HYDRAULIC
HYDRAULIC 4 RESERVOIR
FILTER (VENTED)
36 VARIABLE SPEED HYDRAULIC

5
1
FAN MOTOR W/ INTEGRATED FILTER
67 68
2
66 25 23 WORKING CIRCUIT
CHARGE
26 PRESSURE
B 33 A DRAIN / RETURN
24 21
35 32
22
P DR
34
X

DRAIN / RETURN MANIFOLD
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
31
29
S770 (S/N AT5A11001 & ABOVE)
30
L
S770 (S/N B3BV11001 & ABOVE)
2-SPEED DRIVE MOTOR (PRINTED MAY 2015)
Printed 7194312 (F)

Printed In
In U.S.A.
U.S.A.
(PRINTED JUNE 2015)

V-1605legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE
33 VARIABLE CAPACITY DISPLACEMENT
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (SCREEN) BIDIRECTIONAL HYDROSTATIC PUMP
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 17 CHECK VALVE With 100 kPa 1,0 bar
(14.5 psi) Spring 34 RELIEF/REPLENISHING VALVE - HIGH
2 SIGHT GUAGE
18 RESTRICTION . . . . . . 2,0 mm (0.079 in) PRESSURE: 36500 kPa (365 bar) (5294 psi)
3 DIFFERENTIAL PRESSURE SWITCH: 35 RELIEF VALVE - CHARGE INLET:
103 kPa (1,03 bar) (15 psi) 19 PULL BUTTON ACTIVATED
3413 kPa (34,1 bar) (495 ps) at High
Normally Closed DIRECTIONAL CONTROL VALVE - LIFT
Engine Idle With 60 ° C (140 ° F) Fluid
ARM BY-PASS
4 FILTER - HYDRAULIC (CANISTER)
20 LIFT CYLINDER SPOOL - MADE TO 36 SERVO PISTON – Swash Plate
5 SPRING LOADED FILTER BY-PASS RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 37 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 172 kPa (1,7 bar) (25 psi) CONTROL VALVE – FORWARD/REVERSE
21 ANTICAVITATION VALVE
6 DIAGNOSTIC COUPLER 38 FILTER
22 PROPORTIONAL RELIEF VALVE –
7 RELIEF VALVE - MAIN: (Fan Speed Regulator): 10797-12300 kPa
39 CHECK VALVE – COLD WEATHER BY-PASS
23787 - 24476 kPa (238 - 245 bar) (108 - 123 bar) (1566 - 1784 psi)
With 345 kPa (3,45 bar) (50 psi) Spring
(3450 - 3550 psi) at Front Quick Couplers 23 SPRING LOADED FILTER BY-PASS VALVE:
8 RELIEF/ANTICAVITATION VALVE - 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 40 HYDRAULIC PUMP . . . . . . . Gear Type
PORT: 27579 kPa (276 bar) (4000 psi) 24 FIXED CAPACITY DISPLACEMENT 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
9 RELIEF/ANTICAVITATION VALVE - HYDRAULIC MOTOR 41 CHARGE PUMP -

PORT (OPTIONAL): 25 FILTER - HYDRAULIC (CANISTER) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
27579 kPa (276 bar) (4000 psi)
26 SENSOR – CHARGE PRESSURE – 42 FILL PORT – Factory Hydraulic Fill
Fan Filter
CONTROL VALVE - AUXILIARY
27 FRONT AUXILIARY MANUAL PRESSURE
11 LOAD CHECK VALVE BLEED-OFF VALVE
12 ANTICAVITATION VALVE 28 SENSOR – HYD. TEMPERATURE

CONTROL VALVE - TILT CONTROL 30 CHECK VALVE - With 1379 kPa (13,8 bar)
14 PILOTED ACTIVATED DIRECTIONAL (200 psi) Spring
CONTROL VALVE - LIFT CONTROL
CONTROL VALVE - BICS CONTROL 32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC NOTE: Unless otherwise specified
MOTOR springs have NO significant
pressure value.

Male
27
Male
DRIVE MOTOR
29
27
30
L Female
31
OUT
HYDRAULIC CONTROL VALVE (SPOOL VALVE)
32
9
10
A B
10
Auxiliary Spool
42
33 R
HYDROSTATIC PUMP T 11
37 8
X1 38 BOBCAT INTERLOCK CONTROL SYSTEM
(BICS)
36
X2 8
34
38
Tilt Spool
13
MA TILT CYLINDERS
MB 12
BALL SCREW ACTUATOR WITH
PROPORTIONAL FEEDBACK
A B 11
MG
35 34
8 14
G
A B
MB
Lift Spool
MA
16
LIFT CYLINDERS
34 38 20
34
X2 11
15
18
36 IN
7
X1
6
16
38 2
37
17
T
33
1
R
19
39 OIL COOLER
40 HYDRAULIC FILTER
HYDRAULIC RESERVOIR
4 (VENTED)
2
VARIABLE SPEED HYDRAULIC
41 FAN MOTOR W/ INTEGRATED FILTER 1
5
3
25
23
26
WORKING CIRCUIT
CHARGE
21
24 PRESSURE
B A
DRAIN / RETURN
P DR 22
32 Printable Version Click Here

DRAIN/RETURN MANIFOLD
28
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
31
S770 (S/N AT5A11001 & ABOVE)
29
30
S770 (S/N B3BV11001 & ABOVE)
L
DRIVE MOTOR
(PRINTED JUNE 2015)
7194313 (F)
Printed In U.S.A.
(PRINTED JUNE 2015)

V-1606legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 38 VARIABLE CAPACITY DISPLACEMENT 62 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE - Female
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 39 SOLENOID ACTIVATED DIRECTIONAL
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) RELIEF/REPLENISHING VALVE - HIGH 63
2 SIGHT GUAGE PRESSURE: 36500 kPa (365 bar) (5294 psi) CONTROL VALVE - Male
19 PULL BUTTON ACTIVATED 64 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BUCKET POSITION
103 kPa (1,03 bar) (15 psi) ARM BY-PASS 3413 kPa (34,1 bar) (495 psi) at High
VALVE (ON/OFF)
Normally Closed Engine Idle With 60 ° C (140 ° F) Fluid
20 LIFT CYLINDER SPOOL - MADE TO 65 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM 41 SERVO PISTON – Swash Plate
PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP SOLENOID ACTIVATED DIRECTIONAL 66
5 SPRING LOADED FILTER BY-PASS 42 CONTROL VALVE - FLOW CONTROL
21 ANTICAVITATION VALVE CONTROL VALVE – FORWARD/REVERSE SPOOL
VALVE: 172 kPa (1,7 bar) (25 psi)
43 FILTER
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa 44 CHECK VALVE – COLD WEATHER BY-PASS VALVE
7 RELIEF VALVE - MAIN: (108 - 123 bar) (1566 - 1784 psi) With 345 kPa (3,45 bar) (50 psi) Spring 68 PILOTED ACTIVATED DIRECTIONAL
23787 - 24476 kPa (238 - 245 bar) 23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
45 FILL PORT – Factory Hydraulic Oil
(3450 - 3550 psi) at Front Quick Couplers 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) SPOOL
24 FIXED CAPACITY DISPLACEMENT 46 PILOT ACTIVATED DIRECTIONAL CONTROL HIGH FLOW HYDRAULIC PUMP Gear Type
RELIEF VALVE – MAIN (OPTIONAL): 69
VALVE – HYDRAULIC POWERED BOB-TACH 51,1 L/min (13.5 U.S. gal) at High Engine Idle
25855 – 26545 kPa (259 - 265 bar) HYDRAULIC MOTOR
6 With Build-up Valve 275 kPa (2,75 bar) (40 psi)
(3750 - 3850 psi) at Diagnostic Coupler 25 FILTER - HYDRAULIC (CANISTER) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
47 FILTER - BOB-TACH VALVE
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 26 SENSOR – CHARGE PRESSURE – 71 DUMP VALVE – ON / OFF
23787 – 24476 kPa (238 - 245 bar) Fan Filter
72 CHECK VALVE - With 34,5 kPa (0,34 bar)
(3450 - 3550 psi) at Diagnostic Coupler 6 27 FRONT AUXILIARY MANUAL PRESSURE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
BLEED-OFF VALVE CONTROL VALVE (TWO COIL)
8 RELIEF/ANTICAVITATION VALVE - 73 RIDE CONTROL VALVE
28 SENSOR – HYD. TEMPERATURE 50 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
PORT: 27579 kPa (276 bar) (4000 psi)
29 RESTRICTION - 1,5 mm (0.06 in) 51 CHECK VALVE 74 HIGH PRESSURE CHAMBER
9 RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL): 27579 kPa 30 CHECK VALVE - With 1379 kPa 13,8 bar 52 RESTRICTION - 0,25 mm (0.10 in) 75 LOW PRESSURE CHAMBER
(276 bar) (4000 psi) (200 psi) Spring 53 SOLENOID ACTIVATED DIRECECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE – BRAKE
CONTROL VALVE - AUXILIARY 54 FILTER – BRAKE VALVE
11 32 FIXED CAPACITY DISPLACEMENT
LOAD CHECK VALVE 55 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC MOTOR
CONTROL VALVE – 2 Speed Shift
12 ANTICAVITATION VALVE 33 HYDRAULIC BRAKE – SPRING APPLIED –
56 NOT USED ON THIS MODEL
PRESSURE RELEASE (SAPR)
PILOT ACTIVATED DIRECTIONAL 57 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 34
CONTROL VALVE – 2 Speed CONTROL VALVE - REAR AUXILIARY
14 PILOTED ACTIVATED DIRECTIONAL 58 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - LIFT CONTROL 35 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 59 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CHARGE PUMP - CONTROL VALVE - TWO COIL springs have NO significant
CONTROL VALVE - BICS CONTROL 36
51,1 L/min (13.5 U.S. gpm) at High Engine Idle 60 RESTRICTOR - 0,8 mm (0.031 in) pressure value.
16 FILTER - BICS CONTROL VALVE
(SCREEN) HYDRAULIC PUMP . . . . . . . Gear Type 61 LOAD SHUTTLE VALVE - BLEED OFF
37
Printed in U.S.A. 87,1 L/min (23.0 U.S. gpm) at High Engine Idle V-1606legend (6-1-15)
2-SPEED DRIVE MOTOR
Male
29
27
30
L
Male
31
72
27
Female
RIDE CONTROL
OUT (OPTIONAL)
HYDRAULIC CONTROL VALVE (SPOOL VALVE)

X
LIFT CYLINDERS
REAR AUXILIARY VALVE

75 74
(FIELD INSTALLED OPTION) 9
34 FEMALE MALE
73
35 32 REAR QUICK COUPLERS
9
BASE ROD
10
Z 61
A 33 B
63 10
62 Auxiliary Spool
45
59
38 R
BUCKET POSITIONING
60 VALVE (OPTIONAL)
HYDROSTATIC PUMP T
7A E1 E2 A1 A2
11
E3
42 8
X1 43 BOBCAT INTERLOCK CONTROL SYSTEM
(BICS) 64
41 B
65
58
X2 8 66
39
43 67
57 Tilt Spool
P in P out T
2-SPEED & SAPR D2
BRAKE VALVE 13
(OPTIONAL) MA
B A
MB 12
A B 11 67
54 MG
T POWER BOBTACH CYLINDER

39 (OPTIONAL)
40
C2
POWER BOBTACH 8 14 68
G VALVE (OPTIONAL)
C1 D1
A B
P
MB 51 50
Lift Spool
MA
16
B1 A1
53 55
54
43 49
39 20
52
39
X2 11
15
18
41 D IN
TILT CYLINDERS
7
X1
48 6 17 16
43 2
42 47
T
38
R
46 1
19
44 OIL COOLER
37 HYDRAULIC FILTER
HYDRAULIC RESERVOIR
4 (VENTED)
2
VARIABLE SPEED HYDRAULIC
36 FAN MOTOR W/ INTEGRATED FILTER 1
70 5
71 3
69 25 WORKING CIRCUIT
23
CHARGE
26 PRESSURE
B 33 A DRAIN / RETURN
21
32 24
35
P DR 22
X
34
DRAIN/RETURN MANIFOLD
28
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
31
S770 (S/N AT5A11001 & ABOVE)
29
30
S770 (S/N B3BV11001 & ABOVE)
L
2-SPEED DRIVE MOTOR

(PRINTED JUNE 2015)
7194313 (F)
Printed In U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS
WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

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

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

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

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

noise.

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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


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

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in NEUTRAL 4
position
The lift arms come down with the pedal in NEUTRAL position 4, 9, 10, 11
Lift Arm Bypass Control valve stuck 12
Lift Arm Bypass Control valve stem bent or broken 13
KEY TO CORRECT CAUSE
1. The fluid level is not correct.

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

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

(Item 2) [Figure 20-20-2], remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Test only one cylinder at a time. Disconnect the hose

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

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

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

container to collect the hydraulic fluid as the lift arms are
raised.

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

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

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

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

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

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

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

W-2059-0598
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder

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

Open the rear door.

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

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

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

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

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

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

lb) torque.

Parts Identification
1. Plug
2. O-ring
3. Tubeline
4. Tube
5. Clamp
6. Nut
7. O-ring
8. Seal
9. Piston
10. Spacer 1
2
11. Wear Ring
12. Seal
13. O-ring
14. Head
15. Seal 4
16. Wiper 1
17. Rod 2
18. Grease Fitting 5
3
6
7
8
9
10
11
12
13
14
15
16
17
18
NA6139S

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

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

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

on the piston, becomes damaged, the
complete piston must be replaced.
Figure 20-20-16
1
2
P-48033
Use a Spanner Wrench to loosen the head (Item 1)

[Figure 20-20-13] from the cylinder case.
Figure 20-20-14
4
3
2
P101716
1
Remove the O-ring (Item 1). Remove the Seal (Item 2)
[Figure 20-20-16] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].

CYLINDER (LIFT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-20-17 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
3 Piston Ring Compressor
Spanner Wrench
4 2 1 Figure 20-20-19
P-81036
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-17].
P7424
Remove the wear ring (Item 4) [Figure 20-20-17].
Figure 20-20-18 Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

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

installation.
Install the new seal on the tool and slowly stretch it until it
2
fits the piston [Figure 20-20-19].
1 Allow the seal to stretch for 30 seconds before installing it

on the piston.
P-81039
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20-

20-18].

Assembly (Cont’d)
Figure 20-20-20
1
2
P7425
Install the rod seal in the head [Figure 20-20-22].

P-48038
Figure 20-20-23
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

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

(Item 1) [Figure 20-20-21] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-21].

Assembly (Cont'd)
Figure 20-20-24 1
2 3
1 4
P-48036
Install the head (Item 1), spacer (Item 2) piston (Item 3),
P-81027 and nut (Item 4) [Figure 20-20-26].
NOTE: Clean and dry the rod threads. Install a NEW

Install the wear ring (Item 1) [Figure 20-20-24]. NUT with preapplied Loctite® included in the
seal kit or if a new nut is not available use
Figure 20-20-25 Loctite® #242 on threads.
Tighten the nut (Item 4) [Figure 20-20-26] to 1491 N•m

1
2 (1100 ft-lb) torque.
Figure 20-20-27
P101716
Install the O-ring (Item 1) and the seal (Item 2) [Figure

20-20-25] on the cylinder head.
P-48035
Put the base end of the hydraulic cylinder in a vise.
Using a Spanner Wrench tighten the head (Item 1)

[Figure 20-20-27] to 373 N•m (275 ft-lb) torque.

Assembly (Cont'd)
Figure 20-20-28
P-81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

20-28].
Tighten the plug to 50 N•m (37 ft-lb) torque.

CYLINDER (TILT) Figure 20-21-2
Testing
Figure 20-21-1 1
P85552
Install a plug (Item 1) [Figure 20-21-2] in the hydraulic

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

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

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

goes to the base end of the cylinder.

CYLINDER (TILT) (CONT'D) Figure 20-21-5
Figure 20-21-3
P-85648
Remove the retainer nut and washer (Item 1) [Figure 20-

P-85554 21-5] from the base end pivot pin.
Installation: Tighten the retainer nut to 257,6 N•m (190

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

3] from the rod end pivot pin.
Installation: Tighten the retainer nut to 48 - 54 N•m (35 - 3

40 ft-lb) torque.
Figure 20-21-4
2
1
1
P-85562
Disconnect the two hydraulic hoses (Items 1 and 2)

[Figure 20-21-6] from the tilt cylinder.
Cap and plug the hoses and the fittings on the cylinder.
Remove the base end pivot bolt and washer (Item 3)

P-85649 [Figure 20-21-6].
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

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

Base End Pivot Pin Removal And Installation
Figure 20-21-8
P-85567
1
Inspect pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a 22,2 mm (7/8 in) shaft (Item 1) [Figure 20-21-9]

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

1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston 5
10. Collar 6
11. Head
12. Wiper
13. Rod
14. Bushing 4 2
3
7
8
1
9
4
3 10
8
4
11
12
13
14
NA8189S

Disassembly
2
4
MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
rod in and out slowly to remove the fluid from the cylinder. 1
3
Figure 20-21-11
P109554
Remove the nut (Item 1), piston (Item 2), collar (Item 3)
and head (Item 4) [Figure 20-21-13].
1
Figure 20-21-14
P-85651B
Remove the bushing (Item 1) [Figure 20-21-11] with a

driver tool and hammer.
Figure 20-21-12
P109555
1 Remove the seal (Item 1) [Figure 20-21-14] and from the

piston.
P106021
Use an Adjustable Gland Nut Wrench to loosen the head

(Item 1) [Figure 20-21-12] from the cylinder case.

Disassembly (Cont'd)
Figure 20-21-15
1
1
P-48042
Remove the rod seal (Item 1) [Figure 20-21-17] from the

P109556 cylinder head.
Remove the O-ring (Item 1) and the seal (Item 2) [Figure

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

the cylinder head.

Assembly
Use the following tools to assemble the cylinder:

1
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
Wash the cylinder parts in solvent and air dry them.

P109555
Lubricate all O-rings and seals with hydraulic fluid during Install the seal (Item 1) [Figure 20-21-19] and on the
installation. cylinder piston.
Figure 20-21-18 Figure 20-21-20
P7424 N-22358
Install the new seal on the tool and slowly stretch it until it Use a ring compressor to compress the seal to the
fits the piston [Figure 20-21-18]. correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

Assembly (Cont'd)
Figure 20-21-21 2
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
23].
Install the rod seal on the rod seal tool [Figure 20-21-21]. Figure 20-21-24

(Item 1) [Figure 20-21-21] must be installed 1
2
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

21-21].
Figure 20-21-22
P109556
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-24] on the cylinder head.
P7425
Install the rod seal in the head [Figure 20-21-22].

Assembly (Cont'd) Put the base end of the hydraulic cylinder in a vise.
Figure 20-21-25 Figure 20-21-26
3
1 1
4
2
P109554 P106021
NOTE: Lube chamfer on shaft with oil or grease Using an Adjustable Gland Nut Wrench, lightly lubricate
before installing the collar. with grease and tighten the head (Item 1) [Figure 20-21-
26] to 373 N•m (275 ft-lb) torque.
Install the head (Item 1), collar (Item 2), piston (Item 3)
and nut (Item 4) [Figure 20-21-25]. Figure 20-21-27

NUT with preapplied Loctite® included in the
Loctite® #242 on threads.
1
Tighten the nut (Item 4) [Figure 20-21-25] to 1491 N•m
(1100 ft-lb) torque.
P-85651B
Install the bushing (Item 1) [Figure 20-21-27] using a

driver tool and hammer.

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

Power Bob-Tach cylinder base end port.

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

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

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

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

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

CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Installation: Tighten the bolts to 29,8 - 32,5 N•m (22 - 24

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

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

CYLINDER (BOB-TACH) (CONT’D)
1. Tube
2. Nut
3. Seal
4. O-ring
5. Piston
6. Spacer
7. Head
8. Back-up Ring
9. Rod
2
3
4
5
4
7
4
8 3
3
NA2603SA

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

P-85647 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9
MEL1074 - O-ring Seal Hook

Spanner Wrench 4
2
rod in and out slowly to remove the fluid from the cylinder.
1
Use a Spanner Wrench to loosen the head [Figure 20-

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

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

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

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

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.

Lubricate all O-rings and seals with hydraulic fluid during

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

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].

must be toward the inside of the cylinder.

Assembly (Cont’d)
1
Figure 20-22-13
P-48039
Install the O-ring (Item 1). Install the O-ring (Item 2) and
N-20613 back-up ring (Item 3) [Figure 20-22-15] onto the cylinder
head.
Rotate the handles to collapse the rod seal [Figure 20- Figure 20-22-16
22-13].
3
Figure 20-22-14 2 4
1
P16294
P7425 Install the head (Item 1) and spacer (Item 2) [Figure 20-
22-16].
Install the rod seal in the head [Figure 20-22-14]. Install the piston (Item 3) [Figure 20-22-16].
Install the wiper seal with the wiper toward the outside of Grease the piston where the nut contacts the piston. do
the head. not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].

NUT with preapplied Loctite® included in the
Loctite® #242 on threads.
Tighten the nut to 190 N•m (140 ft-lb) torque.

CYLINDER (BOB-TACH) (CONT'D)
Assembly (Cont'd)
Figure 20-22-17
P-85647
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a Spanner Wrench [Figure 20-

22-17] to 183 N•m (135 ft-lb) torque.

MAIN RELIEF VALVE
Description
The main relief valve and the optional auxiliary relief

valve (if equipped) limit the hydraulic system pressure by
opening at a certain pressure and allowing the hydraulic
fluid to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
Figure 20-30-1
P107749A
The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve (Item 1) is
located below the spool linkages, facing the front of the
machine. The optional auxiliary relief valve (Item 2) (if
equipped) [Figure 20-30-1] is located on the top of the
control valve facing the left side of the machine.

MAIN RELIEF VALVES (CONT’D)
Testing
WARNING
WARNING Hydraulic fluid escaping under pressure can have
When the engine is running during service, the and possible death if proper medical treatment by a
driving and steering controls must be in neutral and physician familiar with this injury is not received
the parking brake engaged. Failure to do so can immediately.
cause injury or death. W-2145-0290
W-2006-1209
Figure 20-30-3
procedure:
1
MEL1355-3 - Pressure gauge 34,5 MPa (345 bar) (5000
psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased
locally. Must be rated for pressures above 34,5 MPa (345
bar) (5000 psi). 3
3
Figure 20-30-2 2
P-43196D
1 3
Assemble the gauge (Item 1), hose (Item 2) and the
correct test coupler (Item 3) [Figure 20-30-3]. Tighten all
fittings.
Raise the operator cab. (See Raising on Page 10-30-2.)

2
4
Figure 20-30-4
P121789
Test ports have changed on the main valve. If your test 2

port looks like (Item 2) use test coupler (Item 1). If your
test port looks like (Item 4) Use test coupler (Item 3) 1
[Figure 20-30-2].
NOTE: This procedure is for loaders equipped with

SJC or SCPA controls. The main relief valve is
located in the same place on all of the loaders.
P107935
Connect the test coupler (Item 1) to the test port (Item 2)

[Figure 20-30-4].

MAIN RELIEF VALVES (CONT’D) Testing Auxiliary Relief Pressure
Testing (Cont’d) The auxiliary relief valve setting is 23787 - 24476 kPa
(238 - 245 bar) (3450 - 3550 psi).
Route the test gauge so it can be used in the operator
cab when lowered. Make sure the hose will not interfere Figure 20-30-5
with any moving parts.
Lower the operator cab. (See Raising on Page 10-30-2.)
NOTE: Do not have any attachment connected to the

loader auxiliary quick couplers while testing.
Enter the loader and engage the parking brake. Start the
2
engine.
1
Increase the engine speed to full rpm and make sure the
hydraulic fluid is at 60°C (140°F).
Testing Main Relief Pressure Without Auxiliary Relief

Valve NA3267
The main relief valve setting is 23,8 - 24,5 mPa (238 -

245 bar) (3450 - 3550 psi). Press the auxiliary hydraulics button (Item 1) [Figure 20-
30-5] to activate the auxiliary hydraulics.
Power loader lift arms down on the stops and monitor the
test gauge for the relief pressure setting. NOTE: The auxiliary indicator (Item 2) [Figure 20-30-
5] will illuminate when activated.
If the relief pressure is not correct, stop the engine and
adjust the relief valve. (See Main Relief Valve Adjustment Figure 20-30-6
on Page 20-30-4.)
Right
Steering
Testing Main Relief Pressure If Equipped With Auxiliary Lever
Relief Valve Control
If equipped with the optional auxiliary relief valve, the

main relief valve setting is 25,5 - 26,2 mPa (255 - 262
bar) (3700 - 3800 psi).
1
Power loader lift arms down on the stops and monitor the
test gauge for the relief pressure setting.

adjust the relief valve. (See Main Relief Valve Adjustment
on Page 20-30-4.) P107006B
Move the front auxiliary hydraulic switch (Item 1) [Figure

20-30-6] to the left or right and monitor the test gauge for
the relief pressure setting.

adjust the relief valve. (See Auxiliary Relief Valve
Adjustment on Page 20-30-5.).
Stop the machine and exit the loader.

MAIN RELIEF VALVES (CONT’D) Main Relief Valve Removal And Installation
Main Relief Valve Adjustment
Figure 20-30-7
IMPORTANT
damage the system.
I-2003-0888
2
Clean the area around the control valve.
1 NOTE: This procedure is for loaders equipped with

P107744 ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
Loosen the locknut (Item 1) [Figure 20-30-7].
Figure 20-30-8
Turn the adjustment screw (Item 2) [Figure 20-30-7] in or
out until the pressure is correct. Turning the screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve. 1
P107743
Remove the main relief valve (Item 1) [Figure 20-30-8].

MAIN RELIEF VALVES (CONT’D) Auxiliary Relief Valve Adjustment
Main Relief Valve Removal And Installation (Cont’d) NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve
Figure 20-30-9 is located in the same place on all of the
loaders.
Figure 20-30-10
1 2
P107745A 1
Remove the O-ring (Item 1) and back-up rings (Item 2)

P107747
[Figure 20-30-9] from the relief valve.
Clean the relief valve in clean solvent. Use air pressure to Loosen the locknut (Item 1) [Figure 20-30-10].
dry the valve.
Turn the adjustment screw (Item 2) [Figure 20-30-10] in
Install a new O-ring (Item 1) and back-up rings (Item 2) or out until the pressure is correct. Turning the screw in
[Figure 20-30-9]. Install the main relief valve and tighten. will increase pressure.
Installation: Tighten the relief valve to 51 - 62 N•m (38 - NOTE: If the correct pressure can not be reached,
45 ft-lb) torque. replace the auxiliary relief valve. Test the
pressure setting of the new auxiliary relief
Test the relief valve. (See Testing on Page 20-30-2.) valve.

MAIN RELIEF VALVES (CONT’D) Figure 20-30-12
Auxiliary Relief Valve Removal And Installation
IMPORTANT 2
damage the system.
I-2003-0888 1
P107627
Clean the area around the control valve. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-30-12] from the auxiliary relief valve.
NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve Clean the relief valve in clean solvent. Use air pressure to
is located in the same place on all of the dry the valve.
loaders.
Install new O-rings (Item 1) and back-up ring (Item 2)
Figure 20-30-11 [Figure 20-30-12]. Install the relief valve and tighten.
Installation: Tighten the relief valve to 51 - 62 N•m (38 -

45 ft-lb) torque.
Test the relief valve. (See Testing on Page 20-30-2.)
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic fluid to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
P107746
Remove the auxiliary relief valve (Item 1) [Figure 20-30-

11].

HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P107871
The hydraulic control valve is located inside the main

frame on the right hand side, below the operator’s cab.
The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
lift, tilt, and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.
The auxiliary function is operated by pilot pressure.

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

valve ports. The main relief valve is used on the 800, 700,
and 600 series loaders. The auxiliary relief valve is
standard on the 800 series and may be present on the
700 and 600 series.
The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve port is
adjacent to the spool linkages. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

HYDRAULIC CONTROL VALVE (STANDARD) Drain the hydraulic reservoir. (See Removing And
(CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-110-2.)
Remove the control linkage. (See Linkage Removal And

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

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

when tubelines or hoses are removed.
Clean area around control valve.

P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2
unless supported by an approved lift arm 3
D-1009-0409
WARNING 2

the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm P121154
W-2059-0598 Disconnect the harness (Item 1) [Figure 20-40-2] from
the bottom of the filter.
Remove the two bolts (Item 2) and reposition the fuel

filter assembly (Item 3) [Figure 20-40-2].
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm

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

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(CONT’D)
Figure 20-40-3
1
1
P122356
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
P122353 to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
Remove the two bolts (Item 1) [Figure 20-40-3] securing only be removed by first removing it from the fitting (Item
the fuel inlet assembly mount. 1) [Figure 20-40-5].
2
1
1 1
P122354 P-90269
Move the hose clamp (Item 1) to the middle of the hose Disconnect the wire harness connectors (Item 1) [Figure
(Item 2) [Figure 20-40-4] and place the fuel inlet 20-40-6] from the control valve.
assembly off to the side. Plug the fuel tank inlet.
Disconnect the hose (Item 2) [Figure 20-40-6] that
routes from the control valve to the drain manifold.

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

(CONT’D)
Figure 20-40-7
2 2
2
1
P-90272
Remove the tubeline clamp (Item 1) [Figure 20-40-9].
P-90270 Disconnect the two tubelines (Item 2) [Figure 20-40-9]

that route from the control valve to the front auxiliary
hydraulics.
routes from the control valve to the brake valve. Figure 20-40-10

routes from the control valve to the fan motor.
Figure 20-40-8
1
1
P122357
P-90271

routes from the top of the control valve to the hydraulic
filter.

(CONT’D)
Figure 20-40-11
1 1
1
P-90276
1 Disconnect the hose (Item 1) [Figure 20-40-13] that

routes from the bottom of the control valve to the outlet
P-90274 fitting of the hydraulic pump.
Figure 20-40-14
Disconnect the three tubelines (Item 1) [Figure 20-40-
11] that route from the control valve to the junction block
at the rear of the loader.
Figure 20-40-12
1
1
2
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-40-14].
P-90275
Remove the control valve from the loader.

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

[Figure 20-40-12] from the control valve.

(CONT’D)
Mount Bracket Removal And Installation
Figure 20-40-15
P-90280
Support the mount bracket [Figure 20-40-15] (Item 1).
Figure 20-40-16
P-90279
Remove the two control valve mount bolts (Item 1)

[Figure 20-40-16].
Remove the two frame bolts (Item 2) [Figure 20-40-16].
Installation: Torque the two frame bolts (Item 2) [Figure

20-40-16] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-17
AR
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2
D2
A1
H3 E1
B1
F3 MR
F1 H1 J1 J3
C1
NA5826

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulics Female Coupler E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Male Coupler F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(276 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – Without Auxiliary Relief
(276 bar) (4000 psi) Valve 24132 kPa (241 bar) (3500 psi)
Tilt (Rod End) MR Main Relief Valve - With Auxiliary Relief Valve
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) 25511-26200 kPa (255-262 bar) (3700-3800 psi)
27579 kPa (276 bar) (4000 psi) (Optional) AR Auxiliary Relief Valve - If Equipped 23787-
D6 Port Relief / Anti-Cavitation Valve (Auxiliary) 24476 kPa (238-245 bar) (3450-3550 psi)
27579 kPa (276 bar) (4000 psi) (Optional)

(CONT'D)
Lift Load Check Valve Removal And Installation
IMPORTANT 1
damage the system.
I-2003-0888
P107873
Figure 20-40-18
Remove the lift load check valve (Item 1) [Figure 20-40-
19] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
Figure 20-40-20
1
1
P107872
2
Remove the charge tubeline (Item 1) [Figure 20-40-18]
from the BICS™ valve fitting on the top of the lift load
check valve. 3
4
P107716
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-20].
Inspect the spring (Item 3) and the free movement in the

load check valve (Item 4) [Figure 20-40-20].
Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-40-20].

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

Auxiliary)
Figure 20-40-21 1
2
1 4
2
3
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-22].
P107874 Inspect the orifice (Item 3) [Figure 20-40-22] in the

poppet to make sure it is not plugged.
At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-40-
the tilt section load check valve (Item 1) [Figure 20-40- 22] and lubricate with oil before installing. Tighten the
21]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

the auxiliary section load check valve (Item 2) [Figure
20-40-21].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-25

Rod End)
Figure 20-40-23
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-40-25].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-23]. Figure 20-40-26
Figure 20-40-24
1
2
2
1
4
P107952
3
P107624
Remove the O-ring (Item 1) [Figure 20-40-26] from the
port relief / anti-cavitation relief valve.
20-40-24]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-26] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-40-24] in the needed.
Installation: Tighten the port relief anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-40- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
24] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-29

Installation (Tilt, Base End)
Figure 20-40-27
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-29]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-40-27] from the base end of the tilt section. Figure 20-40-30
Figure 20-40-28
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

(CONT'D)
Port Relief Valve Removal And Installation
Figure 20-40-31
P107628
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-33].
P107628
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-31] Figure 20-40-34
from the auxiliary circuit of the control valve.
Figure 20-40-32
1
1
P107629
2
P107630 Remove the O-ring (Item 1) [Figure 20-40-34] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
[Figure 20-40-32] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-35
P107628

P107628
Figure 20-40-36
1
1
2
P107629


(CONT'D)
Plug Removal And Installation
Figure 20-40-39
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-41].
P107631
Figure 20-40-42
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-39].
Figure 20-40-40
1
P107633

plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

plug.

HYDRAULIC CONTROL VALVE (STANDARD) End Cap Block Removal And Installation
(CONT'D)
Figure 20-40-45
Rubber Boot Removal And Installation
Figure 20-40-43
2
1
1 P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-45] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-40-43] on
the rubber boot retainer plate. Figure 20-40-46
Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-44
1
2
1 P107666
Disconnect the tubeline (Item 1) [Figure 20-40-46] from

the end cap block.
P107664
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-44].

HYDRAULIC CONTROL VALVE (STANDARD) Lift Spool And Detent Removal
(CONT'D)
End Cap Block Removal And Installation (Cont’d) procedure:
Figure 20-40-47 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap block from the control valve (See
End Cap Block Removal And Installation on Page 20-40-
15.)
Figure 20-40-48
2
1
P107773 1
Remove the end cap block mount screw (Item 1) [Figure

20-40-47].

11,6 N•m (95 - 105 in-lb) torque.
P107776
Remove the end cap block (Item 2) [Figure 20-40-47]

from the control valve. Remove the O-ring (Item 1) [Figure 20-40-48].
Installation: Replace the O-ring, and lubricate the O-ring

lightly with grease or oil before installation of the end cap
block.
Figure 20-40-49
P107775
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-49] from the lift spool.

(CONT'D)
Lift Spool And Detent Removal (Cont’d)
Figure 20-40-50
P107846
1 NOTE: Do not remove the sleeve detent (Item 1) or

retaining ring (Item 2) [Figure 20-40-52] from
P107779 the spool centering block. If removed, the
sleeve detent must be inserted with the
original orientation.
Remove the four screws (Item 1) [Figure 20-40-50] from
the spool centering block. Figure 20-40-53
Figure 20-40-51
1
P107845A
P107778
NOTE: If removed, use the following for correct
installation: for a radius lift pattern machine,
Remove the spool centering block (Item 1) [Figure 20- align the radius side (Item 1) so it faces the
40-51]. opening of the spool centering block when
seated. For a vertical lift pattern machine,
Remove the O-ring (Item 2) [Figure 20-40-51]. align the vertical side (Item 2) [Figure 20-40-
53] so it faces the opening when seated.
Install retaining ring over detent sleeve.

HYDRAULIC CONTROL VALVE (STANDARD) Lift Spool And Detent Disassembly
(CONT'D)
Figure 20-40-56
Lift Spool And Detent Removal (Cont’d)
Figure 20-40-54
2
P107739
1
P107790 Clamp the linkage end of the spool in a vise [Figure 20-
40-56].
Remove the lift spool assembly (Item 1) and O-ring (Item NOTE: Protect spool before clamping in vise.
2) [Figure 20-40-54] from the control valve.
Figure 20-40-55
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-57
1
2
P107757A
1
Remove the lift spool seal (Item 1) [Figure 20-40-55]
from the linkage end of the valve.
P107674A
Install the spring tool (Item 1) [Figure 20-40-57] over the

centering spring.

(CONT'D)
Lift Spool And Detent Disassembly (Cont'd) 1
NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-40-57] from the centering
spring, as it is under spring pressure.
3
Figure 20-40-58
4
2
P107676
1
Remove spring tool (Item 1) from the spring assembly
(Item 2) [Figure 20-40-60].
Figure 20-40-61
2
P107674
2 1
3
Remove the spring assembly / spring tool (Item 1) from 4
the spool (Item 2) [Figure 20-40-58].
NOTE: The detent adapter has two detent balls (Item

3) held under pressure from a detent spring
(Item 4) [Figure 20-40-60]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-40-59
P107677
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-61].
P107675
Remove the detent adapter (Item 1) [Figure 20-40-59]

from the spring assembly.

HYDRAULIC CONTROL VALVE (STANDARD) Lift Spool And Detent Assembly
(CONT'D)
Figure 20-40-63
Lift Spool And Detent Disassembly (Cont'd)
Figure 20-40-62
0.60 inch
(15,2 mm)
B-14712B
N-18918 Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-63].
Remove the stud from the end of the spool [Figure 20-
40-62]. Figure 20-40-64
N-18967
Clamp the collar (Item 1) [Figure 20-40-64] in a vise.

(CONT'D)
Lift Spool And Detent Assembly (Cont'd)
Figure 20-40-65 1
3
2
1 P107675

washer, spring, collar, and detent adapter.
P107677
Figure 20-40-68
Apply grease on all the detent component surfaces

before assembly [Figure 20-40-65].
Install the spring (Item 1) and detent balls (Item 2) into

the adapter (Item 3) [Figure 20-40-65] and compress
with the detent pliers (Item 1) [Figure 20-40-66].
Figure 20-40-66
P107674
Install the spring assembly to the lift spool hand tight

[Figure 20-40-68].
1
Remove the spring tool.
Inspect the alignment of the detent adapter and the

N-18968A washer.
Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).

Install the detent adapter to the collar [Figure 20-40-66].
NOTE: The adapter must fit in the center of the
NOTE: The collar and the detent adapter are held washer.
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

(CONT'D)
Lift Spool And Detent Installation
Figure 20-40-69 1
1 P107679A
3 Install a new spool seal (Item 1) [Figure 20-40-71] on the

linkage end of the valve.
P107790
Figure 20-40-72
Lubricate and install a new O-ring (Item 1) [Figure 20-40-

69].
Lubricate and install a new O-ring (Item 2) [Figure 20-40-

69].
Install the lift spool assembly (Item 3) [Figure 20-40-69]

in the spool bore.
1
Figure 20-40-70
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

1 20-40-72] on the lift spool.
P107779
Install the spool centering block (Item 1) [Figure 20-40-

70].
Install the four mounting screws (Item 2) [Figure 20-40-

70].

11,6 N•m (95 - 105 in-lb) torque.

(CONT'D)
Lift Spool And Detent Installation (Cont'd)
Figure 20-40-73
1
1
P107666
Connect the tubeline (Item 1) [Figure 20-40-75].
P107776 Figure 20-40-76
Install an O-ring (Item 1) [Figure 20-40-73] on the control

valve.
Figure 20-40-74
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
P107664A The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap block (Item 1) and the mount bolt (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
(Item 2) [Figure 20-40-74]. 45 ft-lb) torque [Figure 20-40-76].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-74].

11,6 N•m (95 - 105 in-lb) torque.

(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap block. (See End Cap
Block Removal And Installation on Page 20-40-15.) 2
Figure 20-40-77
1
P107778
Remove the spool centering block (Item 1) [Figure 20-

1 40-79] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

2
79] and lubricate the O-ring lightly with grease or oil
P107777 before installation of the spool centering block.
Figure 20-40-80
20-40-77] from the tilt spool.
Installation: Install the spacer (Item 1) and an O-ring

2
(Item 2) [Figure 20-40-77].
Figure 20-40-78
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure

20-40-80].
1
P107779 80] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.

the spool centering block.

11,6 N•m (95 - 105 in-lb) torque.

(CONT'D)
Tilt Spool Disassembly And Assembly
Figure 20-40-81
1
P107647
Remove the bolt (Item 1) [Figure 20-40-83] holding the

centering spring to the spool.
P107781
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-40-81].
Remove the spring tool from the spring assembly.
Assembly: Always use a new spool seal.
Figure 20-40-84
Figure 20-40-82
2 1
3
1 4
N-18944B
P107646
Put the linkage end of the spool in the vise [Figure 20- 3), and washer (Item 4) [Figure 20-40-84].
40-82].
NOTE: Protect spool before clamping in vise.

centering spring.

(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-85
1
3 2
4
1
2
4
P107783
Remove the spring (Item 1) and center spring retainer

3 (Item 2) [Figure 20-40-86] from the auxiliary spool.
P107782
20-40-86] from the auxiliary spool.
(Item 2) [Figure 20-40-85] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure
20-40-86] must be replaced, replace the
Remove the spacer (Item 3) and O-ring (Item 4) [Figure retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
NOTE: If the centering spring retainer (Item 2) [Figure [Figure 20-40-86].
retainer on the opposite end also. Figure 20-40-87
Installation: Lubricate and install an O-ring (Item 4)

[Figure 20-40-85].
P107784
Remove the auxiliary spool (Item 1) [Figure 20-40-87].

(CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-88 1
2
1
2
2
P107798
1
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-89] from the solenoid stem.
P107876
Use an ohmmeter to measure the solenoid coil
resistance.
Remove the screws (Item 1) [Figure 20-40-88] from both
solenoids. The correct resistance for the coil is 5.1 ohm.
Remove the solenoids (Item 2) [Figure 20-40-88] from Installation: Lubricate and install new O-rings (Item 1)
the control valves. and back-up rings (Item 2) [Figure 20-40-89].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9

in-lb) torque.

(CONT'D)
Solenoid Removal And Installation
Figure 20-40-90
1
1
2
P107876
Remove the solenoid stem (Item 1) [Figure 20-40-92].
P107875 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-90] from the Figure 20-40-93
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-90]. 3

2
Figure 20-40-91
N-18694

[Figure 20-40-93] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-91] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-93] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-94
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure

20-40-96] is threaded for easier removal and installation.
P107785
Figure 20-40-97
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-40-
94]. 1 3
2
Figure 20-40-95
P107767
Remove the O-ring (Item 1) [Figure 20-40-97].
Remove and inspect the spring (Item 2) and BICS™

P107786 valve (Item 3) [Figure 20-40-97].
Remove the lift lock valve (Item 1) [Figure 20-40-95]

from the back of the control valve.
Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-98
2
1
P107937

20-40-100] is threaded for easier removal and
P107788 installation.
Figure 20-40-101
Remove the lift spool lock solenoid (Item 1) [Figure 20-
40-98].
Remove the tilt spool lock solenoid (Item 2) [Figure 20- 1 3

40-98].
2
Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-99
P107767

valve (Item 3) [Figure 20-40-101].
1
P107789
Remove the tilt lock valve (Item 1) [Figure 20-40-99]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-104
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-102
P107787
1
P107693 Remove the main relief valve (Item 1) [Figure 20-40-

104].
Remove the fitting (Item 1) [Figure 20-40-102] from the Figure 20-40-105
valve.
Figure 20-40-103
1
2
P-51463
P-51437 Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-105] from the main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
103].
NOTE: This orifice is not removable from the valve

casting.

HYDRAULIC CONTROL VALVE (STANDARD) Check Valve Removal And Installation
(CONT'D)
Figure 20-40-108
NOTE: The auxiliary relief valve (Item 1) [Figure 20-

40-106] is an optional item and may not be
installed.
Figure 20-40-106
P107693
Remove the tubeline (Item 1) [Figure 20-40-107].
Figure 20-40-109
P107870

106].
Figure 20-40-107 1
P107786
Remove the check valve fitting (Item 1) [Figure 20-40-

109] from the hydraulic control valve.
P107627
Remove the O-rings (Item1) and back-up ring (Item 2)


(CONT'D)
Check Valve Removal And Installation (Cont’d)
Figure 20-40-110
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-40-110].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.

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

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

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

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)
Removal And Installation (Cont’d) 1

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

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

on Page 50-110-2.) P122353
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. Remove the two bolts (Item 1) [Figure 20-41-3] securing
the fuel inlet assembly mount.
NOTE: Cap and plug all hydraulic connection points
when tubelines or hoses are removed. Figure 20-41-4
Clean area around control valve.
Open rear door. 2
Figure 20-41-2
3
1
P122354
2 Move the hose clamp (Item 1) to the middle of the hose

(Item 2) [Figure 20-41-4] and place the fuel inlet
1
assembly off to the side. Plug the fuel tank inlet.
P121154
Disconnect the harness (Item 1) [Figure 20-41-2] from



(CONT’D)
Figure 20-41-5 2
1
P107219

routes from the control valve to the brake valve.
P122356
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed Figure 20-41-8
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-41-5].
Figure 20-41-6 1
P-90271
2

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

20-41-6] from the control valve.

routes from the control valve to the drain manifold.

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

(CONT’D)
Figure 20-41-9
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-41-

11] that route from the control valve to the junction block
P-90272 at the rear of the loader.
Figure 20-41-12
Disconnect the two tubelines (Item 2) [Figure 20-41-9]

that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-41-10
P-90275
1 Disconnect the hose (Item 1) [Figure 20-41-12] that

routes from the control valve to the junction block at the
rear of the machine.
P122357 Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-41-12] from the control valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-13
P-90276

routes from the bottom of the control valve to the outlet
fitting of the hydraulic pump.
Figure 20-41-14
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-14].

(CONT’D)
Actuator Removal And Installation (In Loader)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-2.) Remove the two screws (Item 1) [Figure 20-41-16] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.
Figure 20-41-17
Figure 20-41-15
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-41-17] away from

Unplug the actuator connectors (Item 1) [Figure 20-41- the control valve.
15] from the loader harness.
Use a punch to remove the actuator pin (Item 2) [Figure
20-41-17] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

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

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out Of Loader)
(CONT’D)
Actuator Removal And Installation (In Loader)
(Cont’d) Figure 20-41-19
Figure 20-41-18 1
1
2
1
P107802
P-54568
Remove the two mount bolts (Item 1) [Figure 20-41-19]
from the tilt actuator.
Remove the O-ring (Item 1) [Figure 20-41-18] on the
face of the actuator. Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Inspect the linkage pin (Item 2) [Figure 20-41-18] and
replace as needed. Figure 20-41-20
NOTE: Repeat this procedure to remove the lift

actuator.
P107803
Slide the actuator mount bracket (Item 1) [Figure 20-41-

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

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

(Cont’d)
1
Figure 20-41-21
1
P107804
1
Remove the two mount bolts (Item 1) [Figure 20-41-23]
from the lift actuator.
P107808 Installation: Tighten the mounting bolts to 10,2 - 11,3

Using a punch and a hammer, remove the actuator Figure 20-41-24

linkage pin (Item 1) [Figure 20-41-21] from the actuator
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-22
1
1
P107805
2 Slide the actuator mount bracket (Item 1) [Figure 20-41-

24] away from the control valve.
P-54340 Pull the actuator away from the control valve [Figure 20-
41-24].

face of the actuator.

replace as needed.

(CONT’D)
4
Actuator Removal And Installation (Out Of Loader)
(Cont’d)
Figure 20-41-25
2
1 3
P107807A
1
NOTE: The two long bolts (Item 1) are used to mount
the lift actuator (Item 2) to the control valve.
The two short bolts (Item 3) are used to mount
P107806 the tilt actuator (Item 4) [Figure 20-41-27].
Installation: Tighten the mounting bolts to 10,2 - 11,3

Using a punch and a hammer, remove the actuator N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-41-27].
linkage pin (Item 1) [Figure 20-41-25] from the actuator
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-26
P-54340

face of the actuator.

replace as needed.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (CONT’D)
Figure 20-41-28
AR
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1
F1 MR C1
H1
J3
J1
NA5825

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulics Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(2756 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – Without Auxiliary Relief
(276 bar) (4000 psi) Valve 24132 kPa (241 bar) (3500 psi)
Tilt (Rod End) MR Main Relief Valve - With Auxiliary Relief Valve
25511-26200 kPa (255-262 bar) (3700-3800 psi)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional) AR Auxiliary Relief Valve - If Equipped 23787-
24476 kPa (238-245 bar) (3450-3550 psi)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-29 IMPORTANT

damage the system.
I-2003-0888
1 Figure 20-41-31
P-90280
Support the mounting bracket (Item 1) [Figure 20-41-29].
Figure 20-41-30 1
2 P107848
Remove the charge tubeline (Item 1) [Figure 20-41-31]

from the BICS™ valve fitting on the top of the lift load
check valve.
P100202
Remove the two control valve mount bolts (Item 1)

[Figure 20-41-30].
Remove the two frame bolts (Item 2) [Figure 20-41-30].
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-30] to 300 - 330 ft lb (406 - 447 N•m).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-34

(Cont’d)
Figure 20-41-32
1
1
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
34].
Remove the lift load check valve (Item 1) [Figure 20-41-
32] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-41-34].
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are
Figure 20-41-33 interchangeable.
Figure 20-41-35
1
5
1
2
2
3 4 4
P107716
3
P107624
[Figure 20-41-33].
Inspect the spring (Item 3) and the free movement in the 20-41-35].
load check valve (Item 4) [Figure 20-41-33].
Inspect the orifice (Item 3) [Figure 20-41-35] in the
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-41-33].
Installation: Install a new O-ring (Item 4) [Figure 20-41-
35] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-38

Rod End)
Figure 20-41-36
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-38].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-36]. Figure 20-41-39
Figure 20-41-37
1
2
2
1
4
P107952
3
P107624
20-41-37]. Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-41-37] in the needed.
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
37] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-42

Installation (Tilt, Base End)
Figure 20-41-40
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anit-cavitation seat (Item 1) [Figure 20-41-42]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-40] from the base end of the tilt section. Figure 20-41-43
Figure 20-41-41
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat


(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-41-44
P107628

P107628
Figure 20-41-45
2
P107629


(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-48
P107628

P107628
Figure 20-41-49
1
1
2
P107629


(CONT’D)
Plug Removal And Installation
Figure 20-41-52
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-54].
P107631
Figure 20-41-55
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-52].
Figure 20-41-53
1
P107633

plug.
P107633

plug.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
(CONT’D)
The tool listed will be needed to do the following
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-6.) Remove the end cap block from the control valve [Figure
20-41-56].
Figure 20-41-56
Figure 20-41-58
1 2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-56] from

the end cap block. Remove the O-ring (Item 1) [Figure 20-41-58].
Remove the two end cap block mount screws (Item 2) Installation: Replace the O-ring, and lubricate lightly
[Figure 20-41-56]. with oil before installation of the end cap block.
Installation: Lubricate the screws and tighten to 10,4 - Figure 20-41-59

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-57
1
P107753
1
P107852 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-41-59] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-57]

from the control valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-60
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-62] from the control valve.
P107854
Figure 20-41-63

the spool centering block.

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-61
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-41-63]

from the actuator end of the valve.
P107855
Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-41-61] from the control valve.

61] and lubricate lightly with oil before installation of the
spool centering block.

(CONT’D)
Lift Spool Disassembly And Assembly
Figure 20-41-64
1
P107647

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-
41-64]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-67
Figure 20-41-65
3
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-41-67].
centering spring.

(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-41-18.)
Figure 20-41-68 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-70].
2 Figure 20-41-71
P107856

20-41-68] from the tilt spool.
Figure 20-41-69
P107770
Remove the spool seal (Item 1) [Figure 20-41-71].
P107769
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the spool centering block.

(CONT’D)
Tilt Spool Disassembly And Assembly

2 1
Figure 20-41-72
3
N-18944B
3), and washer (Item 4) [Figure 20-41-74].
P107646
Put the actuator end of the spool in the vise [Figure 20-
41-72].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-41-73
P107647


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

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-75
2
1
2 P107760

1 (Item 2) [Figure 20-41-77] from the auxiliary spool.
P107758
NOTE: If the centering spring retainer (Item 2) [Figure
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.
(Item 2) [Figure 20-41-75] from the auxiliary spool.
Figure 20-41-78
NOTE: If the centering spring retainer (Item 2) [Figure
retainer on the opposite end also.
Figure 20-41-76
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
(CONT’D)
Figure 20-41-80
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-79
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-41-80] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-41-79]. Remove the solenoids (Item 2) [Figure 20-41-80].
Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -

23.9 in-lb) torque.
Figure 20-41-81
P107798

[Figure 20-41-81] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-41-81].

(CONT’D)
Figure 20-41-82 1
P107857
Remove the solenoid stem (Item 1) [Figure 20-41-84].
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-82] from the Figure 20-41-85
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-82]. 3

2
Figure 20-41-83
N-18694

[Figure 20-41-85] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-83] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-85] may be
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-86
1 2 P107937

P107858
Figure 20-41-89
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-
86]. 1 3
Figure 20-41-87 2
1
P107767

P107859 valve (Item 3) [Figure 20-41-89].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-41-87] from the back of the control valve.


(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-90
1 P107937

P107860
Figure 20-41-92
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-41-90] from the front of the control valve.
1 3
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque. 2
P107767

valve (Item 3) [Figure 20-41-92].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-95
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-93
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-41-95].
Figure 20-41-96
Remove the fitting (Item 1) [Figure 20-41-93] from the
valve.
1
Figure 20-41-94
1 2
P107745A
Remove the O-ring (Item 1) and back-up rings (Item 2)

P-51437 [Figure 20-41-96] from the main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-41-
94].
NOTE: This orifice is not removable from the valve

casting.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Check Valve Removal And Installation
(CONT’D)
Figure 20-41-99
Figure 20-41-97
1 1
P107848
P107863 Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100
97].
Figure 20-41-98
1
2
P107864
1
Remove the check valve fitting (Item 1) [Figure 20-41-
P107627 100] from the hydraulic control valve.


HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Check Valve Removal And Installation (Cont’d)
Figure 20-41-101
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-101].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.

LIFT ARM BYPASS CONTROL VALVE Testing
Description Figure 20-50-1
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by 1

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90° clockwise. Then pull up and hold the lift arm
bypass control knob until the lift arms slowly lower. The
valve releases the hydraulic fluid from the base end of the
lift cylinder(s) which allows the lift arm to slowly come
down to the transport position.
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob should return to its normal position.

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

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

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

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

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

HYDRAULIC PUMP Start the engine and run at low idle rpm. Press the
Auxiliary hydraulics button. Engage the front auxiliary
Description with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
The hydraulic pump is attached to the end of the the tester, the hoses are connected wrong. With the
hydrostatic pumps and is located on the right side of the hoses connected correctly, increase the engine speed to
loader between the hydraulic control valve and the full rpm*.
engine.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump is a combination of gear pumps that control clockwise on the tester so it reads about 6895
provide hydraulic flow to several hydraulic systems. kPa (68,9 bar) (1000 psi).
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25511 kPa (255 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If any the tester counterclockwise to obtain free flow, the flow
of the main components of the pump are damaged, the should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The L/min (U.S. gpm) should drop
Pump Test At Quick Couplers off slightly until the pressure reaches approximately
21374 kPa (214 bar) (3100 psi). At approximately 21374
The tools listed will be needed to do the following kPa (214 bar) (3100 psi) the flow should start decreasing
procedure: rapidly until the pressure reaches 23787 - 24132 kPa
(238 - 241 bar) (3450 - 3500 psi). At 23787 - 24132 kPa
MEL10003 or MEL1744 - Hydraulic Tester (238 - 241 bar) (3450 - 3500 psi) the flow should be at 0
MEL10006 - Fitting Kit L/min (0 U.S. gpm). Turn the restrictor (Item 2) [Figure
20-60-1] counterclockwise to free flow. Shut the auxiliary
Figure 20-60-1 hydraulics off.
If flow and pressure specifications are not obtained, go to

1
2 Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-4.)

for system relief pressure and full rpm.
P106632
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,1 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

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

one operator running the tester.

HYDRAULIC PUMP (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool Kit

MEL10003 or MEL1744 - Hydraulic Tester
MEL10006 - Fitting Kit 2
WARNING 1
P106429
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) that comes from
fall or move and cause injury or death. the gear pump, and connects to the control valve fitting
W-2017-0286
(Item 2) [Figure 20-60-2].
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

support device. (See Installing on Page 10-20-2.)
WARNING 2
1

P106631
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

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

control on the tester to about 6895 kPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*.
On the Remote Start Tool engage the auxiliary

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

%=
FREE FLOW (L/min [U.S. gpm])
A low percentage may indicate a failed pump.


Direct Pump Test (Charge Section)

procedure:

MEL10006 - Fitting Kit
WARNING
P122351
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-4].
W-2017-0286
Figure 20-60-5

1.)

2
1
WARNING
P106631
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the INLET fitting on the fan
Tester, to prevent any contamination to the (Item 1) [Figure 20-60-4].
Hydrostatic Pumps.
Connect the Remote Start Tool. (See REMOTE START

TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
IMPORTANT
I-2024-0284
tester, the hoses are connected wrong. With the hoses
rpm*.

psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
*Refer to the Hydraulic Schematics for pump flow and

rpm.

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

WARNING
Figure 20-60-6
W-2059-0598 1
1
1
DANGER 1
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-6] from the hydraulic pump.
P-90328 Remove the Power Bob-Tach block (if equipped). (See

AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-60-7
support. Replace if damaged. 1
D-1009-0409
IMPORTANT 1

parts clean. Always use caps and plugs on hoses, P-90509
damage the system.
I-2003-0888
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


Figure 20-60-8
3 1
2
1
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-10] on the

P114353 hydraulic pump.
Reverse the removal procedure to install the hydraulic

Loosen the two mounting bracket bolts (Item 1) and
pump.
remove the nut and bolt (Item 2) [Figure 20-60-8].
Installation: Tighten the nut and bolt to 34 - 38 N•m (25 -

28 ft lb) torque.
Figure 20-60-9
P106594
Remove the two mounting bolts (Item 3) [Figure 20-60-8]

and [Figure 20-60-9].
Installation: Tighten the bolt to 75 - 85 N•m (55 - 60 ft lb)

torque.
Remove the hydraulic pump.

HYDRAULIC PUMP (CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-11 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.
P100685
Figure 20-60-12
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-11]to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-12].

Figure 20-60-13
1. Bolt
2. Charge Pump End Section
3. Section Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
13. Auxiliary Pump Center Section
14. Auxiliary Pump End Section
15. Shaft Seal
7
8
9 4
10 3
2
3
4
5
6
8
7
11 8
10
11
14 3
3 12
4
6 9
4 8
15
P-66540

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

the Parts Identification page (See Parts Identification on
Page 20-60-9.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 1)

NOTE: Position the wear plate (Item 4) [Figure 20-60-

13] as shown with the bronze side toward the
gears.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage, the complete
pump must be replaced.

HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6895
The high flow hydraulic pump has an additional pump kPa (68,9 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25511 kPa (255 bar) (3700
from a button on the panel in the cab. psi).
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately
The tools listed will be needed to do the following 21374 kPa (214 bar) (3100 psi). At approximately 21374
procedure: kPa (214 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
MEL10003 or MEL1744 - Hydraulic Tester (238 - 241 bar) (3450 - 3500 psi). At 23787 - 24132 kPa
MEL10006 - Fitting Kit (238 - 241 bar) (3450 - 3500 psi) the flow should be at 0
L/min (0 U.S. gpm). Turn the restrictor (Item 2) [Figure
Figure 20-61-1 20-61-1] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
2 If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

P106632
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,1 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.

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

procedure:

MEL10003 or MEL1744 - Hydraulic Tester 2
MEL10006 - Fitting Kit
WARNING 1
P106429
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) that comes from
fall or move and cause injury or death. the gear pump, and connects to the control valve fitting
W-2017-0286
(Item 2) [Figure 20-61-2].
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

WARNING 2
1

P106631
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses MEL10003 or MEL1744 - Hydraulic Tester
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

psi). DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*. Put jackstands under the front axles and rear corners
On the Remote Start Tool engage the auxiliary Failure to use jackstands can allow the machine to
hydraulics, the light will come ON. Pull the trigger on the fall or move and cause injury or death.
right handle or joystick for fluid flow to the quick coupler W-2017-0286
(fluid pressure will go over main relief). Record the
highest pressure (psi) and flow (L/min [U.S. gpm]). The Lift and block the loader. (See Procedure on Page 10-10-
high pressure flow must be at least 80% of free flow. 1.)
%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 Raise the lift arms and install an approved lift arm
FREE FLOW (L/min [U.S. gpm]) support device. (See Installing on Page 10-20-2.)

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

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

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-61-4 rpm*.

psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
1 Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=
P122351
Disconnect the inlet hose (Item 1) [Figure 20-61-4]. A low percentage may indicate a failed pump.
Figure 20-61-5 *Refer to the Hydraulic Schematics for pump flow and
rpm.
2
1
P106631
Connect the INLET hose (Item 1) [Figure 20-61-5] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the INLET fitting on the fan
(Item 1) [Figure 20-61-4].
IMPORTANT
I-2024-0284

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

front auxiliary quick couplers.
W-2059-0598
IMPORTANT
I-2024-0284

procedure:

MEL10006 - Hydraulic Test Kit

1.)

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Lower the cab.
Direct Pump Test (High Flow Section) (Cont'd) Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
Figure 20-61-7 button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
1 engine speed to full rpm*.

psi).
NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700

psi).
2
[U.S. gpm]) at full rpm. Increase the restriction and the
P-90183 flow should drop to 0 L/min (0 U.S. gpm) between 24132
kPa (241,3 bar) (3500 psi) and 25511 kPa (255,1 bar)
(3700 psi).
Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow check valve INLET fitting (Item 2) If pressure readings are not obtained go to the High Flow
[Figure 20-61-7]. Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)
Figure 20-61-8
Record the highest pressure (psi) and flow (L/min [U.S.
gpm]). The high pressure flow must be at least 80% of
free flow.

%=
2
1 A low percentage may indicate a failed pump.
*Refer to Hydraulic Schematics Legend for system relief

pressure and full rpm.
P106631
Connect the INLET hose (Item 1) [Figure 20-61-8] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
[Figure 20-61-11] will need to be turned 90° clockwise
and retested with the procedure above. (90° turn equals
approximately 1379 kPa (13,8 bar) (200 psi).)
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation 1
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been tested and is OK, go to the 2 P-45443
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-14.) Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove right rear wheel. (See Wheel Nuts on Page 10-
160-1.) Remove the plug (Item 2) [Figure 20-61-10] located on
the bottom of the high flow relief valve.
Figure 20-61-9
Figure 20-61-11
P106585 1
P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-9]

from the access cover and remove the cover from the NOTE: [Figure 20-61-11] shows adjusting the relief
loader. valve.
If the pump reaches 25511 kPa (255 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned 90° counterclockwise and retested with the
procedure above.

High Flow Relief Valve Removal And Installation
1
WARNING
W-2017-0286
Remove right rear wheel. (See Wheel Nuts on Page 10- P-45444
160-1.)
Figure 20-61-12 Locate the high flow relief valve through rear door along
the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-13] from

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

1 35 ft-lb) torque.
Figure 20-61-14
1 1
P106585
3
Remove the mounting bolts (Item 1) [Figure 20-61-12]
from the access cover and remove the cover from the 2
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-14].
If the relief valve is bad, it must be replaced as a

complete unit.
Remove the plug (Item 3) [Figure 20-61-14] and replace

the O-ring.

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

P-43958 17] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-16
Figure 20-61-18
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-16].

Replace the O-rings (Item 1) and the back-up ring (Item
Remove the solenoid (Item 2) [Figure 20-61-16]. 2) [Figure 20-61-18].
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -

72 in-lb).

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

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

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

clean the work area before disassembly and keep all Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
parts clean. Always use caps and plugs on hoses, from the back of the hydraulic pump.
damage the system. Remove the Power Bob-Tach block (if equipped). (See
I-2003-0888 Removal And Installation on Page 20-120-4.)
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


Figure 20-61-21
1
P106594
Remove the two mounting bolts (Item 3) [Figure 20-61-

22] and [Figure 20-61-23].
P-90509A
Installation: Tighten the bolt to 88 - 95 N•m (65 - 70 ft lb)

Disconnect and cap the outlet hoses (Item 1) [Figure 20- torque.
Remove the hydraulic pump.
Figure 20-61-22
Figure 20-61-24
3
2
1
P114353
P-43940 P-43938A
Loosen the two mounting bracket bolts (Item 1) and

remove the nut and bolt (Item 2) [Figure 20-61-22]. Replace the O-ring (Item 1) [Figure 20-61-24] on the
hydraulic pump.
Installation: Tighten the nut and bolt to 34 - 38 N•m (25 -
28 ft lb) torque. Reverse the removal procedure to install the hydraulic
pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-61-25 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.
P100685
Figure 20-61-26
P100352
Attach a push button starter switch (MEL1712) [Figure

20-61-25] to the starter terminal S (Item 1) and the
positive battery cable (Item 2) [Figure 20-61-26].

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Figure 20-61-27
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal
13
17. Center Housing
4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-13.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 7)

NOTE: Position the wear plate (Item 4) [Figure 20-61-

27] as shown with the bronze side toward the
gears on all wear plates.
Inspect all gears, shafts and pump end

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

replaced along with the O-rings and back-up
rings.

HYDRAULIC / HYDROSTATIC FILTERS Housing Removal And Installation
Description
The hydraulic / hydrostatic filters help to remove

DANGER
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

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

gear pumps including fluid returning from the main valve.
P-90328
The charge flow filter removes contaminants after the
charge pump. AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D) Figure 20-70-3
Housing Removal And Installation (Cont’d)

Drain the fluid from the reservoir. (See Removing And

1
Figure 20-70-1 1
P122067
Remove and plug the three hoses (Item 1) [Figure 20-

70-3] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-70-4
1
P122360 1

70-1] from the hydraulic / hydrostatic filter sender.
Figure 20-70-2
P122362
1
Remove the two bolts (Item 1) [Figure 20-70-4].
Remove the hydraulic / hydrostatic filter housing from the

loader.
P122361
Disconnect and plug the three hoses (Item 1) [Figure 20-

70-2] from the hydraulic / hydrostatic filter housing.

HYDRAULIC FLUID RESERVOIR Removal And Installation
Description Raise the lift arms and install an approved lift arm
The hydraulic fluid reservoir is a storage container for the
loader’s hydraulic / hydrostatic fluid. The reservoir Raise the operator cab. (See Raising on Page 10-30-2.)
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding Remove the rear grille, side panels and shield. (See
fluid. Removing on Page 50-60-1.)
The hydraulic fluid reservoir is located behind the Drain the fluid from the reservoir. (See Removing And
operator’s cab under the rear grille on the right side of the Replacing Hydraulic Fluid on Page 10-120-2.)
loader.
Remove the Hydraulic / Hydrostatic Filter Housing. (See
Housing Removal And Installation on Page 20-70-1.)
Figure 20-80-1
P122344
Remove the hoses (Item 1) [Figure 20-80-1].
Figure 20-80-2
P122363
Remove the two nuts/bolts (Item 1) and the bracket (Item

2) [Figure 20-80-2].
Remove the hydraulic fluid reservoir from the loader.
Installation: Tighten the mount bolts and nuts to 21,7 -

24,4 N•m (16 - 18) torque.

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen

1.)
Remove the hydraulic fluid reservoir breather cap from

the reservoir.
Figure 20-80-3
P121073A
Remove the hydraulic fluid screen (Item 1) [Figure 20-

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

replacing.

OIL COOLER Removal And Installation
Description The oil cooler and radiator are removed from the loader
as a unit. (See Radiator Removal And Installation on
The oil cooler is used to cool the loaders hydraulic and Page 70-60-1.)
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.

BUCKET POSITION VALVE Figure 20-100-1
Description
The bucket position valve is an option that allows the

operator to hold the attachment at the same angle from 3
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower

right rear side of the loader frame.
2
See Hydraulic Schematic for more circuit information.
1
P121154
IMPORTANT Disconnect the harness (Item 1) [Figure 20-100-1] from

When repairing hydrostatic and hydraulic systems, Remove the two bolts (Item 2) and reposition the fuel
clean the work area before disassembly and keep all filter assembly (Item 3) [Figure 20-100-1].
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-100-2
damage the system.
I-2003-0888
DANGER
1
P122353
P-90328
AVOID DEATH Remove the two bolts (Item 1) [Figure 20-100-2].

D-1009-0409


BUCKET POSITION VALVE (CONT'D) NOTE: Engine removed for photo clarity.
Solenoid Removal And Installation (Cont’d) Electric fuel pump removed for photo clarity.
Figure 20-100-3 Figure 20-100-5
1 3
1 P101161
P122355
Disconnect the wire harness connector (Item 1) [Figure

Remove the hose (Item 1) [Figure 20-100-3].
20-100-5] from the bucket position shut-off solenoid.
Figure 20-100-4
Disconnect and cap the two tubelines (Item 2) [Figure
20-100-5].
Remove the solenoid nut, coil, and stem (Item 3) from the
2
bucket positioning valve [Figure 20-100-5].
Installation: Put oil on O-rings and back-up rings and

tighten the solenoid stem to 40,7 - 50,2 N•m (31 - 37 ft-lb)
torque.
1
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
torque. Overtightening may cause valve failure.
Figure 20-100-6
P122354
Reposition the clamp (Item 1) and remove the fuel fill

hose (Item 2) [Figure 20-100-4] from the tank. 1
2
Cover the fuel tank inlet.
N-18191
Inspect the solenoid stem and replace the O-rings (Item

1) and the back-up ring (Item 2) [Figure 20-100-6].

BUCKET POSITION VALVE (CONT'D) Figure 20-100-8
Solenoid Testing
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
Removal And Installation 1
DANGER
P122353
Figure 20-100-9
P-90328
1
AVOID DEATH
D-1009-0409

Replacing Hydraulic Fluid on Page 10-120-2.) P122355
Figure 20-100-7
2
1
P121154



BUCKET POSITION VALVE (CONT'D) Figure 20-100-12
Figure 20-100-10
1
2
1 4 3
P101157
Disconnect and cap the tilt base end hose (Item 1), the tilt
P122354 rod end hose (Item 2), the lift rod end hose (Item 3), and
the lift base end hose (Item 4) [Figure 20-100-12] that
route from the control valve.
hose (Item 2) [Figure 20-100-10] from the tank. Figure 20-100-13
NOTE: Engine removed for photo clarity.
Electric fuel pump removed for photo clarity.
Mark all hoses and tubelines for correct

installation.
Figure 20-100-11
2
1
P-90189A
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-13]
from the valve block.
1 P101161
Disconnect the electric solenoid connector (Item 1)

[Figure 20-100-11].

BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 20-100-16
Figure 20-100-14
2
1 3
2
2
1 P-90192
P-90197A
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-16].
Disconnect and cap the lift base end hose and tubeline
(Item 1) and the lift rod end hose and tubeline (Item 2) Assembly: Tighten the nut to a maximum of 8 N•m (6 ft-
[Figure 20-100-14] that route from the lift cylinders. lb) torque. Overtightening may cause valve failure.
Figure 20-100-15 Assembly: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 54,2 N•m (30 - 40 ft-lb)
torque.
Figure 20-100-17
1
1
P101159
Remove the mounting bolts (Item 1) [Figure 20-100-15].

P-90195
Remove the bucket position valve from the loader.
Remove the flow adjustment valve and O-ring (Item 1)

[Figure 20-100-17].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new o-rings before any parts are

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

BUCKET POSITION VALVE (CONT'D)
Disassembly And Assembly (Cont’d)
Figure 20-100-18
3
1
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-18]. Inspect for
wear and replace as needed.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

ft-lb) torque.
Figure 20-100-19
1
2 3
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-19]. Inspect for wear and
replace as needed.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

ft-lb) torque.

REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts fluid from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Coil wires do not have polarity. Correct resistance
for the solenoid coil with a pigtail connector is 4.6 - 5.7
ohm.
Figure 20-110-3
P9137

is 8.6 - 9.5 ohm.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
for the solenoid coil with a molded connector is 8.1 - 9.9
ohm.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-5
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-5].
can cause lift arms to drop. Figure 20-110-6
D-1009-0409
1
Put jack stands under the rear corners of the loader.


P100810
Figure 20-110-4
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-6] from the main harness.
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20-

110-4].

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-7 assembly.
Inspect cartridges, check valves, solenoid valves and

2
sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure to dry them.
Install new O-rings and back-up rings.
1 Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.
Figure 20-110-8
P-90581
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7].
1
1
P-48751
Figure 20-110-9
P-48752
Several plugs (Item 1) [Figure 20-110-8] and [Figure 20-

110-9] are located all over the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up rings. Tighten

to 13,6 N•m (10 ft-lb) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-48755
Figure 20-110-10
Remove the differential sensing valve (Item 1) [Figure

20-110-12] and [Figure 20-110-13] from the diverter
valve.
1 Figure 20-110-13
2
2
P-48755
1
Figure 20-110-11
3
P-48757
2 2 Replace the O-rings (Item 2) and back-up rings (Item 3)

2
[Figure 20-110-13].
1
Assembly: Put oil on the O-rings and back-up rings.
Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-10]

and [Figure 20-110-11] from diverter valve and replace
the O-rings and back-up rings (Item 2) [Figure 20-110-
11].
Assembly: Put oil on the O-rings and back-up rings.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

Figure 20-110-14
P-48759
1
Figure 20-110-17
P-48753
Figure 20-110-15
1
2 2
P-48760
NOTE: Before removing the solenoid coils mark the

P-48754 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-16] and [Figure

Remove the relief valve (Item 1) [Figure 20-110-14] and 20-110-17] from the solenoid valve stem.
[Figure 20-110-15] from the diverter valve and replace
the O-rings and back-up rings (Item 2) [Figure 20-110- Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
15] for damage. torque.
Assembly: Put oil on O-ring and back-up rings. Tighten Remove the spacer (Item 2) and solenoid valve coils
to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-17].

Figure 20-110-18
1
1
P-48762
Figure 20-110-20
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-18] from the

solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

2 2
torque. 1 1
P-48763
Remove the solenoid valve stem (Item 1) [Figure 20-

110-19] and [Figure 20-110-20] and replace the O-rings
Assembly: Put oil on O-rings and back-up rings. Tighten

to 27 - 34 N•m (20 - 25 ft-lb) torque.

Figure 20-110-21
P-48765
Remove the plug (Item 1) [Figure 20-110-23].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-22 Figure 20-110-24
1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-21] and [Figure 20-110-22] and replace the O-rings 24] for dirt and debris.
Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
Assembly: Put oil on O-rings and back-up rings. Tighten torque.
to 41 - 47 N•m (30 - 35 ft-lb) torque.

Figure 20-110-25
1
1
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-110-25]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up rings.
Figure 20-110-26
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

BOB-TACH (POWER) BLOCK
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right

switch panel.
The Power Bob-Tach block is mounted on the right side

of the machine in front of the engine on the back side of
the hydraulic pump.

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-2
Testing Relief Valve
WARNING 1

enters skin or eyes, get immediate medical attention P106674
W-2072-0807
cylinder base end port.
Figure 20-120-3
WARNING
explosion or fire.
W-2103-0508 1
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-120-1
P122238
Install the gauge (Item 1) [Figure 20-120-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH “WEDGES DOWN” Switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

120-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

BOB-TACH (POWER) BLOCK (CONT'D)
Testing Relief Valve (Cont’d)
Figure 20-120-4
P122229
NOTE: Relief valve removed from block for photo

clarity.
If adjustment is required loosen the locknut (Item 1) and

turn the adjusting screw (Item 2) [Figure 20-120-4]
clockwise to increase pressure or counterclockwise to
decrease pressure.
Test the relief valve setting after adjustment has been

made.

BOB-TACH (POWER) BLOCK (CONT'D) NOTE: After repairing a machine that required the
Power Bob-Tach valve electrical connectors
Removal And Installation to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
WARNING Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.
Lift and block the loader. (See LIFTING AND BLOCKING
W-2059-0598
THE LOADER on Page 10-10-1.)

DANGER Raise the operator cab. (See Raising on Page 10-30-2.)

Remove the fan duct panels. (See Removal And

Figure 20-120-5
P-90328
AVOID DEATH
can cause lift arms to drop. 1
D-1009-0409
IMPORTANT P122161
When repairing hydrostatic and hydraulic systems, Disconnect the two wire connectors (Item 1) [Figure 20-
clean the work area before disassembly and keep all 120-5] from the solenoid coils.
damage the system.
I-2003-0888

Figure 20-120-6
2 2
P122162
Disconnect and cap the hose (Item 1) [Figure 20-120-6]

from block.
Disconnect and cap the hoses (Item 2) [Figure 20-120-6]

from block.
Figure 20-120-7
1 1
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-120-

7].

(35 - 40 ft-lb) torque.
Remove the Power Bob-Tach block.

IMPORTANT
3
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888 2
4 P122197
Figure 20-120-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-9] and inspect. Replace damaged parts
as needed.
Installation: Tighten the plug to 67,8 N•m (50 ft-lb)

torque.
1 Replace the O-ring (Item 4) [Figure 20-120-9] on the
plug.
1 Figure 20-120-10
P122196
Do not remove these plugs (Item 1) [Figure 20-120-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-120-10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.


2
Figure 20-120-11
3 P122201
Replace the O-rings (Item 1) and the back-up rings (Item

1
P122199 2) [Figure 20-120-13].
Figure 20-120-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-120-
11].
Figure 20-120-12
2
1
P122202
1 Remove the fitting (Item 2) [Figure 20-120-12] and

replace the O-ring (Item 1) [Figure 20-120-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-120-

12].
Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-120-15
P122206
1
Replace the O-ring (Item 1) and remove the screened

P122203 orifice (Item 2) [Figure 20-120-17]. Inspect and replace
as needed.
Remove the plug (Item 1) [Figure 20-120-15] and Figure 20-120-18

replace the O-ring.

torque.
1
Figure 20-120-16
P122205

1
P122205 torque.

torque.

Figure 20-120-19
2
3
1
2 P122209
1 Replace the O-ring (Item 1) and remove the orifice insert

P122207 (Item 2) [Figure 20-120-21]. Inspect and replace as
needed.
Remove the O-ring (Item 1), the spring (Item 2) and the Figure 20-120-22
check ball (Item 3) [Figure 20-120-19]. Inspect and
replace as needed.
Figure 20-120-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-120-22].

P122208
Installation: Tighten the relief valve to 20 N•m (15 ft-lb)
torque.

torque.

Figure 20-120-23
P122212
Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-23].
Figure 20-120-24
P122213
Replace the O-ring (Item 1) [Figure 20-120-24].
NOTE: After repairing a machine that required the

Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535
If unable to identify the supplier part number on the male

coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONT’D)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONT’D)
Disassembly And Assembly (FFI/FI) (Cont’d)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7].
1
Remove the O-rings (Item 2) [Figure 20-130-7] from the
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and inspect the seal

(Item 1) [Figure 20-130-8] for damage and replace as
needed.

(CONT’D)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
Remove the springs (Item 1) [Figure 20-130-13].
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].
Installation: Tighten the coupler fittings (Item 1) [Figure

20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

(CONT’D)
Disassembly And Assembly (FFH/FH) (Cont’d)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].
Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assemble if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.

AUTOMATIC RIDE CONTROL
Description
The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

AUTOMATIC RIDE CONTROL (CONT'D)

WARNING
Open the rear door.
Remove the rear grille and engine cover. (See Removing
on Page 50-60-1.)
explosion or fire.
WARNING W-2103-0508

support device. Failure to use an approved lift arm WARNING
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Drain the hydraulic fluid reservoir. (See Removing And

Figure 20-140-1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 3
D-1009-0409
2
IMPORTANT P121154
When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

AUTOMATIC RIDE CONTROL (CONT'D) Figure 20-140-4
Figure 20-140-2 2
P122354

P122353
hose (Item 2) [Figure 20-140-4] from the tank.

Figure 20-140-5
Figure 20-140-3
P128342
P122355
Disconnect the three connectors (Item 1) [Figure 20-

Remove the hose (Item 1) [Figure 20-140-3]. 140-5] from the manifold.


2
Figure 20-140-6
1
1
P128335
Remove the two nuts (Item 1) and the accumulator /

P128096 manifold assembly (Item 2) [Figure 20-140-8].
Figure 20-140-7
P128339
Remove the two hoses (Item 1) [Figure 20-140-7] from

the manifold.

AUTOMATIC RIDE CONTROL (CONT'D)
Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
reduced ride control performance, or loss of I-2003-0888
ride control function.
Remove the automatic ride control assembly. (See


WARNING
procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

WARNING
W-2059-0598
RIDE CONTROL ACCUMULATOR INSTALLED
DANGER circuit before servicing.
W-3015-0816
Figure 20-140-9
P-90328
AVOID DEATH 1
D-1009-0409
P128321

accumulator.

Checking The Pressure In The Accumulator (Cont’d)
Figure 20-140-10 1
2
1
P128489
Turn the T-handle (Item 1) [Figure 20-140-12]

P128322 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Loosen the Allen plug (Item 1) [Figure 20-140-10]
approximately 1/4 turn. Pressure in the accumulator should be 915 psi [63 bar].
Figure 20-140-11 Close the valve by turning the T-handle (Item 1) [Figure
20-140-12] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-12].
2 Remove the tool / gauge from the accumulator.
Tighten the Allen plug (Item 1) [Figure 20-140-10] to 20

N•m (15 ft-lb) torque.
1
P128488
Make sure the manual bleed valve (Item 1) is closed.

Install the tool / gauge (Item 2) [Figure 20-140-11] onto
the accumulator.

Adding Nitrogen To The Accumulator
Remove the automatic ride control assembly. (See


procedure:
1
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
P128322

of the following conditions exist: Loosen the Allen plug (Item 1) [Figure 20-140-14]
• Pressurized fluids and springs or other stored approximately 1/4 turn.
energy components.
• Flying debris or loose material is present. Figure 20-140-15
W-2505-0604
WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
2
circuit before servicing. P128488
W-3015-0816
Install the tool / gauge (Item 1) [Figure 20-140-15] onto
the accumulator.
Figure 20-140-13 Make sure the manual bleed valve (Item 2) [Figure 20-
140-15] is closed.
P128321

accumulator.

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-16
2
1
P128491
Turn the T-handle (Item 1) [Figure 20-140-18]

P128490 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Install the hose (Item 1) [Figure 20-140-16] to the tool on
the accumulator. Pressure in the accumulator should be 915 psi [63 bar].
Figure 20-140-17 Slowly open the valve on the nitrogen tank. Close the
valve by turning the T-handle (Item 1) [Figure 20-140-18]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1
Close the valve by turning the T-handle (Item 1) [Figure
20-140-18] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-18].
Remove the hose from the tank and the accumulator.
Tighten the Allen plug (Item 1) [Figure 20-140-14] to 20

P128327
Install the other end of the hose / fitting (Item 1) [Figure

20-140-17] to the nitrogen tank.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-6
HYDROSTATIC MOTOR CARRIER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-7
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-3
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-13

HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-33
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-36
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Tensioner Pulley Removal And Installation
(Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Removal And Installation
(Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
TWO-SPEED / BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
The hydrostatic motors do not have an internal brake.
Inside the end cap of the hydrostatic motor, there is a

shuttle valve. The shuttle valve helps to keep the motor
cool by mixing case drain fluid with cooled low pressure
fluid from the charge circuit. The shuttle valve is shifted
by the high pressure fluid coming from the hydrostatic
pumps. If the shuttle valve sticks, a delay or lack of drive
may or may not be felt in the controls and / or an
overheated hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (CONT'D) Drain the hydraulic reservoir. (See Removal And
Figure 30-20-1
DANGER
2
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure P106586
Remove the four bolts (Item 1) and cover (Item 2) [Figure
30-20-1].
D-1009-0409
Mark the hoses for correct installation.
Figure 30-20-2
WARNING
1
support device. Failure to use an approved lift arm 2
W-2059-0598
IMPORTANT P-90510

clean the work area before disassembly and keep all Disconnect the case drain hose (Item 1) [Figure 30-20-
parts clean. Always use caps and plugs on hoses, 2].
damage the system. Disconnect the high pressure hoses (Item 2) [Figure 30-
I-2003-0888 20-2].

1.)


HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-20-5
Figure 30-20-3
1
2 3
P5405
4 1
Remove the piston / roller section (Item 1) [Figure 30-20-

P100901 5] from the loader, if it was not removed with the motor /
cam ring.
Installation: Install both flanges and tighten the bolts to To remove the motor carrier. (See Removal And
half of the required torque in the sequence shown in Installation on Page 30-30-2.)
[Figure 30-20-3] Tighten all bolts to 34 N•m (25 ft-lb)
torque in the same sequence. Figure 30-20-6
Figure 30-20-4
12 1
11
13
1 10 2
1
2
1 1 9 3
1
1 8 4
7 5
6
N-22535
P-90495
Remove and replace O-ring (Item 13) [Figure 30-20-6]
with new O-ring
Remove the ten mounting bolts (Item 1) [Figure 30-20-
4].
Installation: Install the O-ring (Item 1) by pressing the O-
ring into the groove starting at the 12 o’clock position
Installation: Tighten the mounting bolts to 149 N•m (110
then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-20-6]
ft-lb) torque.
until the O-ring is fully seated in the groove.
NOTE: The two bolts (Item 2) [Figure 30-20-4] mount
NOTE: Do not roll, kink or stretch O-ring in to groove
the cam ring to the motor, and do not have to
and verify the O-ring is completely flush with
be removed, to remove the motor from the
no protrusions.
loader.
Remove the motor / cam ring section from the loader.

HYDROSTATIC DRIVE MOTOR (CONT'D)
1. Distributor
2. Spring
3. Seal
4. O-ring
5. Plug
6. Washer
7. Spool
8. Housing
9. Stop Pin
10. Bolt
11. Shim
12. Poppet 3
13. Cam 3
14. Roller 2
1
15. Piston
16. Block
4
5
4 4
6 2
7
2
5
4
4
3
3
9
14
15
10
4 10
4 12
11
2
4
4
5
13
16
B-17125

IMPORTANT 2 1

damage the system.
I-2003-0888
P5765
Figure 30-20-7
Apply low air pressure to each port in the cylinder block

1 to remove the roller (Item 1) and piston / ring assembly
(Item 2) [Figure 30-20-8].
Inspect the cylinder block surface and the roller / piston

assemblies for scratches or wear.
NOTE: Put all the roller / piston assembly back in

their original position.
Assembly: Install the roller (Item 1) in the piston (Item 2)

[Figure 30-20-8].
N-17861 Assembly: Dip the roller / piston assembly into fluid and
install into the bore in the cylinder.
Remove the piston / roller section (Item 1) [Figure 30-20- Repeat for each roller / piston assembly.
7] from the motor.
Assembly: Install the motor on the loader and tighten the

mount bolts to 149 N•m (110 ft-lb) torque.
NOTE: Before operating the hydrostatic motor, make

sure it is full of fluid. There are several
methods to fill the motor with fluid; (1) with
the case drain hose disconnected, fill the
motor with fluid through the case drain port;
(2) with the case drain hose disconnected,
BICS™ brake locked, engine running, stroke
the steering lever until fluid comes out of the
case drain port.

Disassembly And Assembly (Cont'd) 1
Figure 30-20-9 2
N-17864
Remove the stop pin (Item 1) [Figure 30-20-11] from the

N-17860 rear motor housing.
Assembly: Install the stop pin (Item 1) [Figure 30-20-11]

Remove the two cam ring mounting bolts (Item 1) and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.
[Figure 30-20-9].
Figure 30-20-12
Assembly: Install the two cam ring mounting bolts (Item
1) [Figure 30-20-9] and tighten to 67,8 N•m (50 ft-lb)
torque. 3
Figure 30-20-10
1
1
4
2
N-17868
NOTE: The distributor removal, is best accomplished

by lifting the housing (Item 2) [Figure 30-20-
N-17863 11] 50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing.
Remove the cam ring (Item 1) [Figure 30-20-10] from the Assembly: Install the stop pin (Item 1) [Figure 30-20-11]
motor housing. and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.
Inspect the cam ring for surface scratches or wear. Assembly: Install the distributor (Item 2) [Figure 30-20-
12] into the housing.
Assembly: Install the cam ring (Item 1) [Figure 30-20-
10] and align the mounting bolt holes. Assembly: Align the distributor hole (Item 3) [Figure 30-
20-12] with the stop pin. When aligned correctly, the
distributor can be depressed slightly.
Assembly: Install and lightly smear grease on the O-ring

(Item 4) [Figure 30-20-12].

Figure 30-20-13 5
1 2 3 4
1
N-17872
Remove, inspect and install the plug (Item 1), spring

N-17869 (Item 2), shim (Item 3) and poppet (Item 4) [Figure 30-
20-15].
Remove and replace the two seals and back-up O-rings Assembly: Remove and replace the O-ring (Item 5)
(Item 1) [Figure 30-20-13] on the distributor. [Figure 30-20-15].
Inspect the distributor and springs (Item 2) [Figure 30- Assembly: Tighten the plug to 12 - 15 N•m (9 - 11 ft-lb)
20-13] for damage or surface scratches. torque.
Assembly: Put grease on the springs to hold them in Figure 30-20-16

place.
Assembly: Install the springs into the distributor.

5
Figure 30-20-14
2 3 4 2 1
1
N-17871
Remove, inspect and install the plug (Item 1), springs

(Item 2), spool (Item 3) and washer (Item 4) [Figure 30-
N-17866 20-16].
Assembly: Remove and replace the O-ring (Item 5)

Remove the two seals (Item 1) [Figure 30-20-14] from [Figure 30-20-16].
the housing and replace with new seals.
Assembly: Tighten the plug to 25 - 30 N•m (18 - 22 ft-lb)
Remove the two O-rings and replace with new O-rings. torque.
The O-rings are located under the seals.
Assembly: Lightly smear grease over the seals.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

DANGER
the hydrostatic pumps.
This hydrostatic motor contains a spring applied pressure

release braking system. This braking system is located
on the end of the hydrostatic motor.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing case
drain fluid with cooled low pressure fluid from the charge P-90328
circuit. The shuttle valve is shifted by the high pressure
fluid coming from the hydrostatic pumps. If the shuttle AVOID DEATH
valve sticks, a delay or lack of drive may or may not be • Disconnecting or loosening any hydraulic
felt in the controls and / or an overheated hydrostatic tubeline, hose, fitting, component or a part failure
motor will result. can cause lift arms to drop.
There are two hydrostatic motors mounted to motor unless supported by an approved lift arm
carriers. The motor carriers are mounted to the support. Replace if damaged.
D-1009-0409
transmission chaincase which houses the drive chains.
WARNING
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888




HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-3
(CONT’D)
Figure 30-21-1
1
P-90257
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]

that goes to the drain manifold.
P-90256
Figure 30-21-4
Remove the motor cover mount bolts (Item 1) [Figure 30-

21-1].
Remove the motor cover from the loader. 1
Mark the hoses for correct installation.
Figure 30-21-2
1
P-90257
1
Remove the eight flange bolts (Item 1) [Figure 30-21-4]

from the high pressure hoses on the motor.
P-90258

that goes to the two-speed port on the two-speed / brake
block.

that goes to the brake port on the two-speed / brake
block.

that goes to the make-up port on the two-speed / brake
block.

(CONT’D)
Removal And Installation (Cont'd) 12 1

11
Figure 30-21-5 13
10 2
9 3
2 3
8 4
7 5
6
N-22535
4 1
Remove and replace O-ring (Item 13) [Figure 30-21-7]
with new O-ring
P100901
Installation: Install the O-ring (Item 1) by pressing the O-
ring into the groove starting at the 12 o’clock position
Installation: Install both flanges and tighten the bolts to then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-21-7]
half of the required torque in the sequence shown in until the O-ring is fully seated in the groove.
[Figure 30-21-5]. Tighten all bolts to 34 N•m (25 ft-lb)
torque in the same sequence. NOTE: Do not roll, kink or stretch O-ring in to groove
and verify the O-ring is completely flush with
Figure 30-21-6 no protrusions.
P-90496
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

21-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold

the cam ring to the motor and do not have to
be removed for motor removal.
Remove the motor from the loader.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
11
11
1. Roller
2. Piston 11
3. Ring 11
4. Clamp 11
5. Ring 11
6. Block
7. Cam 10
9
8. Quad Ring 8
9. Distributor
10. Spring
11. Seal/O-ring 1 7
12. Poppet
13. Spool 2
14. Spring
15. O-ring
16. Plug 3
17. Pin 6
18. Housing 5
19. Washer
20. Quad Ring 4 4 26
21. Bushing 24
22. Shaft 5 25
23. Dowel 18
24. Bolt
25. Shim 23
26. Brake Disc 1516
27. Snap Ring
28. Seal 14 22
19
29. Clamp 13 21
30. Piston 14 20
31 Spring 16
32. Gasket
33. Cover 18
12
13 15
27
14 19
14 24
15 33
13
32
16
24
31
17 15
30
29
15
28
MS1467S

(CONT’D)
Disassembly
Figure 30-21-8
1
2
N-22492
Remove the cover plate from the brake housing.

1
N-22489 Remove the cover plate gasket (Item 1) [Figure 30-21-
10].
NOTE: Install a mark on the motor, brake, and motor Remove the brake spring (Item 2) [Figure 30-21-10] from
carrier housings for correct assembly [Figure the brake housing.
30-21-8].
NOTE: Mark the top side of the brake spring for
NOTE: Always protect any sealing surfaces. Any proper installation.
scratches or marks will cause premature
failure. Figure 30-21-11
Place the cam sealing surface (Item 1) [Figure 30-21-8]

on a protective material.
Drain the fluid from the motor casing.

1
Figure 30-21-9 2
N-22493
1
Remove the piston from the brake housing (Item 1)

[Figure 30-21-11].
NOTE: The use of air pressure through the brake line

N-22490
connection (Item 2) [Figure 30-21-11] will aid
in piston removal.
Remove the twelve mounting bolts (Item 1) [Figure 30-
21-9] from the brake cover plate. Inspect the brake piston for damage and replace the seal.
NOTE: Remove and / or tighten the bolts one turn at

a time to maintain equal preload on the end
cap and the brake spring.

(CONT’D)
1
Figure 30-21-12
P-69985
Remove the brake disks (Item 1) [Figure 30-21-14] from

the brake shaft. Mark the position of the brake disks and
P-69973 the shims.
Figure 30-21-15
Remove the five mounting bolts (Item 1) [Figure 30-21-
12] from the brake housing.
1
Remove the brake housing (Item 2) [Figure 30-21-12]
from the rear housing. 2
Figure 30-21-13
P-69978
Remove the two-speed spool (Item 1) [Figure 30-21-15]

from the housing assembly.
1
Remove and discard the O-rings (Item 2) [Figure 30-21-
P-73062 15] on the housing.
Protect the sealing surface. Remove the snap ring (Item

1) [Figure 30-21-13] to remove the seal from the brake
housing.

(CONT’D)
Figure 30-21-16
1
P-73057
2
4
3 Remove the flushing spool assembly (Item 1) [Figure 30-
21-18] from the housing.
N-22501
Figure 30-21-19
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) [Figure 30-21-16] and
replace as needed. 1
2 4 3
NOTE: The spool (Item 1) [Figure 30-21-16] is marked
with either an A or B. The spool must be
replaced with a spool with the same mark.
Figure 30-21-17
N-22504
Remove the spring (Item 1), washer (Item 2) and rear

2 spring (Item 3) from the spool (Item 4) [Figure 30-21-19].
Inspect all parts and replace as needed.
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-21-

17] from the housing.
Installation: Tighten the plug to 30 Nm (22 ft-lb) torque.
NOTE: Current motor housings are provided with

break off plugs (Item 2) [Figure 30-21-17] on
the side of the flushing spool housing. Earlier
motors were equipped with threaded plugs.

(CONT’D)
Figure 30-21-20
1
2
1 3
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring

(Item 3) for wear and replace as needed [Figure 30-21-
P-69981 22].
Figure 30-21-23
Remove the plug (Item 1) [Figure 30-21-20] from the
housing.
Installation: Tighten the plug to 22 N•m (18 ft-lb) torque.

1 1
Figure 30-21-21
P-73058
Remove the two (8 mm) cam ring mount bolts (Item 1)

[Figure 30-21-23].
P-69982 Turn the housing, cam ring, and rotating group assembly
over and place on a stand. Remove the cam ring from the
housing.
Remove the poppet assembly (Item 1) [Figure 30-21-21]
from the housing.

(CONT’D)
Figure 30-21-24
N-22511
Protect the sealing surfaces. Remove the roller / piston

assembly (Item 1) [Figure 30-21-26] from the cylinder
N-22510 block.
Inspect all roller and piston assemblies for wear and

Protect the sealing surfaces. Inspect the cam ring inside replace as needed.
surface for wear and scratches [Figure 30-21-24].
NOTE: Put all roller / piston assembles back in the
Figure 30-21-25 original bore.
Figure 30-21-27
1
1
N-22509
P-73059
Remove the cylinder block (Item 1) [Figure 30-21-25]
from the housing.
Remove the shaft from the distributor [Figure 30-21-27].
housing. NOTE: The end of the shaft with the snap ring (Item 1)
[Figure 30-21-27] must be toward the brake
housing during assembly.
Remove the distributor from the housing.

(CONT’D)
Disassembly (Cont'd) 1
Figure 30-21-28
N-22523
Remove the bushing (Item 1) [Figure 30-21-30] from the

distributor, if worn or scratched.
P-69984
Figure 30-21-31
NOTE: The distributor removal is best accomplished

by lifting the housing (Item 1) [Figure 30-21-
28] 50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing.
Figure 30-21-29
2
1 1
2 N-22519
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) [Figure 30-21-31] from the distributor.
N-22521
Protect the sealing surfaces. Remove the locating pin

(Item 1) [Figure 30-21-29] from the distributor.
Remove the springs (Item 1) [Figure 30-21-29] from the

distributor.
Inspect the springs, distributor surface and bushing for

damage or wear and replace as needed.

(CONT’D)
Assembly 1
NOTE: Always use new O-rings and seals during

motor and brake assembly.
Figure 30-21-32
N-22525
Install a new bushing (Item 1) [Figure 30-21-34] in the

distributor if the old bushing was removed.
1
Install new O-rings and seals on the distributor [Figure
30-21-35].
N-22511
NOTE: When installing seals, apply a light coating of
fluid to the seal and the mating surfaces of the
During installation of pistons in the bore, position the distributor. Install the O-rings and seals, allow
piston ring gap 180° from one piston to the next. One 30 minutes for the seals to set on the
piston installed with the gap to the right, the next piston distributor before installing the distributor in
installed with the gap to the left. the housing.
Dip each of the roller / piston assemblies (Item 1) [Figure Figure 30-21-35
30-21-32] in fluid and replace back its original bore.
Figure 30-21-33
P-73060
N-22518 Using a small amount of grease, install the springs into

the distributor valve (Item 1) [Figure 30-21-35].
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-21-33] and install the locating pin in the
housing

(CONT’D)
Assembly (Cont'd) 1
Figure 30-21-36
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

21-38].
N-22515
Install the cam ring to the rear housing. Apply liquid
adhesive (Loctite® 243) to the two cam ring mounting
Install the distributor (Item 1) [Figure 30-21-36] in the bolts. Install the bolts finger tight.
housing. Protect the sealing surface of the distributor.
Figure 30-21-39
Figure 30-21-37
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring, and

The pin in the distributor must align with the hole in the cylinder block [Figure 30-21-39].
housing (Item 1) [Figure 30-21-37]. Use a hand press to
push the distributor in place. NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
When installed correctly, the distributor will spring back housing and the sealing surfaces are
slightly when pushed by hand into the housing. protected.
Tighten the two cam ring mounting bolts (Item 1) [Figure

30-21-39] to 35 - 39 N•m (26 - 29 ft-lb) torque.

(CONT’D)
1 2
Assembly (Cont'd)
Figure 30-21-40
P-69986
Install the brake housing (Item 1) [Figure 30-21-42] on

the motor housing.
P-69978
Apply liquid adhesive (Loctite® 243) to the five mounting
bolts. Install the bolts (Item 2) [Figure 30-21-42] and
Install new O-rings (Item 1) [Figure 30-21-40] on the tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque.
housing assembly and apply grease to the O-rings.
Figure 30-21-43
Install the two-speed spool (Item 2) [Figure 30-21-40].
Install the shaft into the distributor [Figure 30-21-40].
Figure 30-21-41
1
P-73064
If needed, install the shims first, then install the brake

disc pack starting with an outer disc (Item 1) [Figure 30-
N-18347 21-43] and alternating with an inner disc, throughout the
pack.
Clamp the disc pack in a vise and measure the height End the disc pack with an outer disc.
[Figure 30-21-41]. The height must be 31,1 mm (1.22
in).
The normal thickness of the individual brake disc is 1 mm

(0.039 in).
If any individual disc's thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

(CONT’D)
Assembly (Cont'd)
Figure 30-21-44
1
2
N-22493
Install the piston (Item 1) [Figure 30-21-46] in the brake

housing.
P-73055
Figure 30-21-47
Install the brake seal (Item 1) [Figure 30-21-44].
NOTE: Install the seal with the metal case end

towards the brake pack. 2
1
Install the snap ring (Item 2) [Figure 30-21-44] to secure
the seal in the brake housing.
Install a new O-ring (Item 3) [Figure 30-21-44] in the

seal.
Figure 30-21-45
N-22492
Install the brake spring (Item 1) [Figure 30-21-47].

1
Install the end plate gasket (Item 2) [Figure 30-21-47].
N-22498
Lightly coat the piston with oil and install a new piston

HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT’D)
Assembly (Cont'd)
Figure 30-21-48
N-22490
Install the brake end cover (Item 1) [Figure 30-21-48].
Install the twelve end cover mount bolts and tighten

evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.
NOTE: Remove and / or tighten the bolts one turn at

a time to maintain equal preload on the end
cap and the brake spring.

HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission chain
case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONT’D) Remove the control pedal linkages. (See Linkage
Figure 30-30-1
DANGER
1
P-90328
AVOID DEATH
P5467A
• Keep out of this area when lift arms are raised Remove the six mounting bolts (Item 1) [Figure 30-30-1]
unless supported by an approved lift arm from the carrier.
D-1009-0409 Installation: Tighten the mounting bolts to 461 - 488
Figure 30-30-2
WARNING 2 2

W-2059-0598
1

1.)
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-2.) P5489A

Slide the motor carrier toward the rear and remove the
Remove the fluid from the chain case. (See CHAINCASE
rear drive chain from the sprocket.
on Page 40-30-1.)
NOTE: For removal and installation of the motor
Remove the center chain case cover. (See Center Cover
carrier secure the front drive chain to the
chain case with a wire (Item 1) [Figure 30-30-
Remove the front axle sprocket. (See Chain Removal 2].
And Installation on Page 40-20-9.)
Slide the motor carrier out of the chain case far enough to
If the motor carrier is removed from the right side, remove install a chain (Item 2) [Figure 30-30-2] and chain hoist
the lift arm bypass valve, (See Removal And Installation to the carrier.
on Page 20-50-2.) and remove the control panel. (See
Removal And Installation on Page 50-110-2.) Pull the motor carrier away from the chain case and out
of the loader [Figure 30-30-2].

HYDROSTATIC MOTOR CARRIER (CONT'D)
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Snap Ring
2
3
2
6
TS-1227B

HYDROSTATIC MOTOR CARRIER (CONT'D) Figure 30-30-5
Disassembly
Figure 30-30-3
P-76544
Remove the snap ring (Item 1) [Figure 30-30-5] from the

P5760 shaft.
Figure 30-30-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-30-3] in the housing.
Figure 30-30-4
P5766
Use a hydraulic press to remove the shaft from the

housing [Figure 30-30-6].
P5768
Put the motor carrier in a hydraulic press [Figure 30-30-

4].
Put a small amount of pressure on the shaft to release

the preload on the snap ring.

Disassembly (Cont’d)
Figure 30-30-7
P5761
Install the bearing puller tool under the bearing flange,

use the hydraulic press to remove the bearing from the
shaft [Figure 30-30-7].
Figure 30-30-8
2
1
P5763
Remove the two seals (Item 1) [Figure 30-30-8] from the

housing.
NOTE: Some machines use a one piece double lip

seal.
Remove the bearing race (Item 2) [Figure 30-30-8] from

both sides.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Figure 30-30-11
Assembly
Clean all parts in solvent and dry with compressed air. 1

Replace any worn or damaged parts. Apply oil to and
install new O-rings.
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool

7343752 - Seal Protector Tool
Figure 30-30-9
2 P5767
1 Install the bearing on the shaft [Figure 30-30-11].
Use a pipe (Item 1) [Figure 30-30-11] with O.D. that

seats on the I.D. of the bearing.
Figure 30-30-12
1
P5764
Install the first seal (Item 1) [Figure 30-30-9] into the

housing with the seal lip facing down.
Use the tool (Item 2) [Figure 30-30-9] to install the seal.
Figure 30-30-10
P135120
1
Install the seal protector tool (7343752) (Item 1) [Figure

30-30-12] on the shaft to protect the seal during
installation.
P5762
Install the second seal (Item 1) [Figure 30-30-10] into the

housing with the seal lip facing up.

Assembly (Cont’d)
Figure 30-30-13
P5769
Install the shaft / bearing assembly into the housing.
Install the bearing (Item 1) using the tool (Item 2) [Figure

30-30-13] (MEL1431).
After the bearing is seated. Install the snap ring on the

shaft and reposition the motor carrier to allow back press
operation.
NOTE: Slight press pressure may be used to preload

both bearings. After installation of the snap
ring a back press operation may be necessary
to reduce the preload and remove the
clearance from between the snap ring and the
main bearing.
Use the press and apply pressure to the end of the spline
shaft to reduce preload and clearance.

HYDROSTATIC MOTOR CARRIER (SJC)
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission chain
case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Remove the drive motor. (See Removal And Installation
on Page 30-20-2.)
If the motor carrier is removed from the right side, remove
the lift arm bypass valve, (See Removal And Installation
on Page 20-50-2.) and remove the control panel. (See
DANGER Removal And Installation on Page 50-110-2.)
Remove the actuators. (See Actuator Removal And

Installation (In Loader) on Page 20-41-6.)
Figure 30-31-1
P-90328
1
AVOID DEATH
1
D-1009-0409
P5467A
WARNING Remove the six bolts (Item 1) [Figure 30-31-1] from the
carrier.
Never work on a machine with the lift arms up unless Installation: Tighten the bolts to 461 - 488 N•m (340 -
the lift arms are secured by an approved lift arm 360 ft-lb) torque.
W-2059-0598

1.)
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-2.)
Remove the fluid from the chain case. (See Removing

And Replacing Fluid on Page 10-130-1.)
Remove the two-speed / brake valve. (See Valve Block

Remove the center chain case cover. (See Center Cover

Remove the front axle sprocket. (See Chain Removal


HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D)
Figure 30-31-2
2 2
P5489A
Slide the motor carrier toward the rear and remove the
rear drive chain from the sprocket.
NOTE: For removal and installation of the motor

carrier secure the front drive chain to the
chain case with a wire (Item 1) [Figure 30-31-
2].
Slide the motor carrier out of the chain case far enough to
install a chain (Item 2) [Figure 30-31-2] and chain hoist
to the carrier.
Pull the motor carrier away from the chain case and out
of the loader [Figure 30-31-2].

HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D)
1. Housing
2. Seal
3. Race
4. Bearing
5. Snap Ring
6. Shaft
2
2
3
4
3
NA5767S

Disassembly
Figure 30-31-3
P-28155

P5760 shaft.
Figure 30-31-6
Figure 30-31-4
P5766
P106444
Press the shaft out of the housing [Figure 30-31-6].
Position the motor carrier in a hydraulic press [Figure 30-

31-4].
Apply a small amount of pressure on the shaft to release

the preload on the snap ring.

Figure 30-31-7 2
1 1
P-28164
Remove the two seals (Item 1) [Figure 30-31-9] from the

P-28157 housing.
NOTE: Some machines use a one piece double lip

Install the bearing puller tool (Item 1) [Figure 30-31-7] seal.
under the bearing.
Remove the bearing race (Item 2) [Figure 30-31-9] from
Figure 30-31-8 both sides.
P-28158
Press the bearing off of the shaft [Figure 30-31-8].

Assembly

Replace any worn or damaged parts. Apply oil to and
install new O-rings.
1

7343752 - Seal Protector Tool
Figure 30-31-10
P10645
2
Press the bearing (Item 1) [Figure 30-31-12] on the
shaft.
1
Install the shaft / bearing assembly into the housing.
Figure 30-31-13
P5764
Install the first seal (Item 1) [Figure 30-31-10] into the

housing with the seal lip facing down.
Figure 30-31-11
P135120
1
Install the seal protector tool (7343752) (Item 1) [Figure
30-31-13] on the shaft to protect the seal during
installation.
P5762
Install the second seal (Item 1) [Figure 30-31-11] into the

housing with the seal lip facing up.

Assembly (Cont'd)
1
Figure 30-31-14
3 2
P-76467
Install a dial indicator (Item 1) [Figure 30-31-16] as

shown.
Use a pry bar (Item 2) to lift the carrier shaft (Item 3)

[Figure 30-31-16]. Measure the end play on the dial
indicator.
The carrier shaft must turn free and end play must not
exceed 0,33 mm (0.013 in)
P-5769
Press the bearing (Item 1) on the shaft using the tool

(MEL1431) (Item 2) [Figure 30-31-14].
NOTE: Do not press the bearing on the shaft farther

than is needed to install the snap ring.
Figure 30-31-15
P-28155
Install the snap ring (Item 1) [Figure 30-31-15] on the

shaft.

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

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

CHARGE PRESSURE (CONT’D) Figure 30-40-2
Testing
1
procedure:
MEL1355-2 - Pressure gauge 6895 kPa (68,9 bar) (1000

psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler

3
2 3
locally. Must be rated for pressures above 6895 kPa (68,9
bar) (1000 psi). P-43196D
Figure 30-40-1
Assemble the gauge (Item 1), hose (Item 2) and the
correct test coupler (Item 3) [Figure 30-40-2]. Tighten all
fittings.
1 3
WARNING
2 Never work on a machine with the lift arms up unless
4 the lift arms are secured by an approved lift arm
P121789 W-2059-0598
Test ports have changed on the Main valve. If your test Raise the loader lift arms and install an approved lift arm
port looks like (Item 2) use test coupler (Item 1). If your support device. (See Installing on Page 10-20-2.)
test port looks like (Item 4) Use test coupler (Item 3)
[Figure 30-40-1]. Raise the operator cab. (See Raising on Page 10-30-2.)
WARNING
immediately.
W-2145-0290

CHARGE PRESSURE (CONT’D) Connect the Remote Start Tool. (See REMOTE START
Testing (Cont’d) REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)
Figure 30-40-3
Start the loader and warm the hydraulic fluid to 60°C
(140°F).
1
On non-SJC equipped loaders the charge pressure at
high idle, with the fluid temperature of 60°C (140°F) is
2689 - 3378 kPa (26,8 - 33,8 bar) (390 - 490 psi) with the
pump in NEUTRAL.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 2860 -
3550 kPa (28,6 - 35,5 bar) (415 - 515 psi) at
60°C (140°F) fluid @ High idle.
P109149B
Figure 30-40-4
P107933
Connect the test coupler (Item 1) [Figure 30-40-4] to the

test port (Item 1) [Figure 30-40-3].

CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-40-5
P122351
Disconnect the wire (Item 1) [Figure 30-40-5] from the

sender.
Remove the sender (Item 2) [Figure 30-40-5] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Replace the O-ring on the sender before

installation.

CHARGE PRESSURE (CONT’D) Figure 30-40-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-40-6 Remove the plug, spring and poppet [Figure 30-40-7].
Inspect the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-40-8
P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-40-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item 1)
[Figure 30-40-8] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55 kPa

(0,55 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2689 - 3378 kPa (26,8 - 33,8 bar) (390 - 490 psi) with the
pump in NEUTRAL.

CHARGE PRESSURE (CONT'D) Figure 30-40-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
P-64435
I-2003-0888
Figure 30-40-9 Inspect the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-10] used to adjust the charge pressure.
1 NOTE: One shim (Item 1) [Figure 30-40-10] = 300,0

kPa (3,0 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2860 - 3550 kPa

(28,6 - 35,5 bar) (415 - 515 psi) at 60°C (140°F) fluid @
P-64431 High idle.
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.

HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-15.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-50-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-50-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-50-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two mounting bolts and nuts (Item 1) [Figure
ft-lb) torque. 30-50-3].
Installation: Tighten the mounting bolts and nuts to 88 -

95 N•m (65 - 70 ft-lb) torque.
Remove the hydrostatic pump from the drive belt

housing.

Hydrostatic Pump Startup

1
Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-8.)
Replenishing / High Pressure Relief Valve Removal

And Installation
Figure 30-50-4
P-66670
1
Remove the high pressure relief valve (Item 1) [Figure

30-50-4] and [Figure 30-50-5] from the pump.
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)

torque.
Inspect for damage and replace as needed.

P-43857
There are four replenishing / high pressure relief valves If the high pressure relief valve must be replaced, it must
(Item 1) [Figure 30-50-4] in the hydrostatic pump be replaced as a complete unit.
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function. The pressure setting for a new high pressure relief valve
is 36500 kPa (365 bar) (5294 psi).
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block
19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10
18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

HYDROSTATIC PUMP (CONT'D) Figure 30-50-8
Disassembly
Figure 30-50-6
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-50-8].

P-43858
Remove the large O-ring (Item 2) [Figure 30-50-8].
Remove the four mounting bolts (Item 1) [Figure 30-50- Remove the two small O-rings (Item 3) [Figure 30-50-8].
6].
Figure 30-50-9
Figure 30-50-7
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-50-9] from the

Separate the two hydrostatic pumps [Figure 30-50-7]. pump housing end cap.

2
1
Figure 30-50-10
N-17194
2
Inspect the valve plate locating pin (Item 1) [Figure 30-
N-19551 50-12] for wear and replace if needed.
Inspect the needle bearing (Item 2) [Figure 30-50-12] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
50-10].
Figure 30-50-13
Remove the gasket (Item 2) [Figure 30-50-10].
Figure 30-50-11
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-50-13]

from the pump.
Remove the valve plate (Item 1) [Figure 30-50-11].
Inspect the valve plate for wear. (Both Sides.)

3 3
Figure 30-50-14
1 1
3 2
3
2
N-17200
Inspect the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-50-16] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-50-16] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-50-14] from the cylinder block.
Inspect the cylinder block for wear and replace as
Inspect all the pistons (Item 2) [Figure 30-50-14] for needed.
wear and replace the rotating group as needed.
Inspect pins (Item 3) [Figure 30-50-16] to see if they are
Figure 30-50-15 all the same length.
Figure 30-50-17
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-50-
15] from the cylinder block.
Remove the thrust plate (Item 1) [Figure 30-50-17] from
the pump housing.

Figure 30-50-18
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-20] from
N-17481 the pump housing and remove the drive shaft and
bearing from the housing.
Remove the drive shaft key (Item 1) the snap ring (Item Figure 30-50-21
2) and the support washer (Item 3) [Figure 30-50-18]
from the drive shaft end of the pump.
Figure 30-50-19
N-17241
Remove the snap ring (Item 1) [Figure 30-50-21] from

N-17239 the drive shaft and remove the bearing.
Inspect the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-50-19] from the pump housing.

Figure 30-50-22
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-50-24] from the pump housing.
Figure 30-50-25
Inspect the pump shaft (Item 1) [Figure 30-50-22] for
wear and replace if needed.
Figure 30-50-23
N-17245
1 1
Inspect the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-50-25] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-50-23]

from the lower trunnion cover. Remove the cover.

Figure 30-50-26
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-50-28] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-50-29
Inspect the dust seal on the pintle shaft.
Remove the four mount bolts (Item 1) from the pump

housing and remove the linkage bracket (Item 2) [Figure
30-50-26].
Figure 30-50-27
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-29] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-50-

27].

1
Figure 30-50-30
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-50-32] and

N-17249 remove the swash plate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-30] and replace as needed.
Figure 30-50-31
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-50-31] from
the swash plate shaft.

Assembly
Figure 30-50-33
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-50-35] on

N-17253 the swash plate shaft.
Figure 30-50-36
Install the lower bearing (Item 1) [Figure 30-50-33] on
the swash plate.
Figure 30-50-34
N-17248
Install the bearing race (Item 2) and O-ring (Item 3)

N-17252 [Figure 30-50-35] as shown in [Figure 30-50-36].
Install the swash plate and bearing into the pump

housing [Figure 30-50-34].

Assembly (Cont’d)
Figure 30-50-37
1 N-17245
Figure 30-50-40
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-50-37]

and cover.
Figure 30-50-38
1
N-17244
2 Install the bearing race (Item 1) and O-ring (Item 2)

2
[Figure 30-50-39] at the lower trunnion as shown in
[Figure 30-50-40].
N-17246
Install the linkage bracket (Item 1) and the four mounting

bolts (Item 2) [Figure 30-50-38] and tighten to 24 - 30
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-50-41
N-17241
1 1
Install the bearing and snap ring (Item 1) [Figure 30-50-
N-17243 43] on the pump shaft.
Figure 30-50-44
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-50-41].
Install the four mounting bolts (Item 1) [Figure 30-50-41]

and tighten to 24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-50-42
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
50-44].
Install the snap ring (Item 1) [Figure 30-50-44].

N-17242
Install the snap ring (Item 1) [Figure 30-50-42] on the

pump shaft.

Assembly (Cont’d)
1
1
Figure 30-50-45
1
1 3
1 2
N-17200
Install the four slipper pins (Item 1) [Figure 30-50-47]

N-17239 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the seal (Item 1) [Figure 30-50-45] into the pump and install into the ball guide retainer (Item 3) [Figure 30-
housing. 50-47].
Figure 30-50-46 Figure 30-50-48
3
2
N-17481 N-17199
Install the washer (Item 1), snap ring (Item 2) and the Install the ball guide retainer and washer (Item 1) [Figure
drive shaft key (Item 3) [Figure 30-50-46]. 30-50-48] onto the slipper holddown pins.

Assembly (Cont’d)
1
2
Figure 30-50-49
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-51] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-52
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
50-49].
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. 2
1
Figure 30-50-50
N-17196
The bearing cage (Item 1) [Figure 30-50-52] will

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

N-17197 50-52] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-50-50].

Assembly (Cont’d)
1 1
Figure 30-50-53
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-55] to 47 - 61
Coat the backside of the valve plate with petroleum jelly Figure 30-50-56
to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-50-53].
The notch (Item 1) [Figure 30-50-53] on the valve plate

must engage the locating pin.
Figure 30-50-54 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-50-56].
Install the large new O-ring (Item 2) [Figure 30-50-56].
N-19551 Install the pump coupler (Item 3) [Figure 30-50-56].
Coat a new end cap gasket (Item 1) [Figure 30-50-54]

with petroleum jelly and install onto the end cap.

HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-57
N-19570
Install the two pumps together [Figure 30-50-57].
Figure 30-50-58
1
P-43858
Tighten the four bolts (Item 1) [Figure 30-50-58] to 47 -


HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The hydrostatic pump is a fully proportional dual piston forward or reverse drive motor rotation is obtained.
pump in one pump casing. The end caps are removable
to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are supplied with charge
pressure from an external charge pump. 12 volt electrical Ports are labeled on the hydrostatic pump casting.
solenoids shift a spool in the hydraulic controller that
directs flow to a servo piston.
Figure 30-51-1
P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the wire harness (Item 1) [Figure 30-51-3]
10-10-1.) from both sides of the hydrostatic pump.
WARNING IMPORTANT
Put jackstands under the front axles and rear corners When repairing hydrostatic and hydraulic systems,
of the frame before running the engine for service. clean the work area before disassembly and keep all
Failure to use jackstands can allow the machine to parts clean. Always use caps and plugs on hoses,
fall or move and cause injury or death. tubelines and ports to keep dirt out. Dirt can quickly
W-2017-0286 damage the system.
I-2003-0888
Figure 30-51-4
Figure 30-51-2
1
1
1
P-90208
P-90207

Locate the two hydraulic controllers (Item 1) [Figure 30- hydraulic controller.
51-2] on the hydrostatic pumps.
Installation: Tighten the bolts to 10,4 N•m (7.7 ft-lb).

HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Removal And Installation

(Cont'd)
Figure 30-51-5
3
2
1
4
P-90210
Remove the cover (Item 1) gaskets (Item 2) and control

(Item 3) [Figure 30-51-5] from the pump.
Figure 30-51-6
2 2
P-90209
Install the controller with the feedback lever (Item 4)

[Figure 30-51-5] in the center of the servo piston groove
(Item 1) [Figure 30-51-6].
NOTE: Do NOT remove the three screens (Item 2)

[Figure 30-51-6] they will be damaged during
removal and must be replaced.
NOTE: When a hydraulic controller is replaced, the

hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Page 30-51-36.)


Page 70-10-15.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-51-8] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-51-7 Remove the pump pulley from the pump drive shaft.
Figure 30-51-9
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-7] on the
hydrostatic pump drive shaft.
Remove the two bolts and nuts (Item 1) [Figure 30-51-9].
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque. Installation: Tighten the bolts and nuts to 88 - 95 N•m

Remove the hydrostatic pump from the drive belt

housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-51-6.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump must be filled with hydrostatic fluid.
This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry will cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Fill the hydrostatic pump by removing a plug at the top of

the hydrostatic pump. A clean funnel should be used to
avoid washing contaminants into the hydrostatic pump.
Fill the hydrostatic pump case as much as possible
before startup.
Figure 30-51-10
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-51-10].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic fluid until the hydraulic fluid flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Installation: Tighten plugs to 25 N•m (18 ft-lb) torque.
NOTE: The hydrostatic pump is removed from the

loader for photo clarity.

1. O-ring 3
2. Bolt 4 1
1
3. End Housing
4. Right Rotating Assembly
5. Timing Pin 6
5
6. Bearing 7
7. Spacer/Coupler
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover 9
13. Hydraulic Controller 8 2
14. High Pressure Relief 1
15. Case Housing 1
10
16. Plug
17. Dowel Pin 11
18. Charge Pressure Relief 2
19. Left Servo 12
20. Right Servo
21. Left Rotating Assembly 16 2
2 14
22. End Housing 16 17
15
13
17
13
18 20
14
22 19
5
2 6
21
8 1 1
9 1
11
10
2
12 2
P-90240

High Pressure Relief And Bypass Valve
Figure 30-51-11
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-13]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-13] for

There are four system high pressure relief valves (Item 1) breakage.
[Figure 30-51-11] in the back of the hydrostatic pump.
Inspect the seats inside the case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-11].
Do not disassemble the relief valve assembly. If
Installation: Tighten cap to 150 - 170 N•m (111 - 125 ft- replacement is required, replace as an assembly.
lb) torque.
Factory setting on the relief valve is 36500 kPa (365 bar)
Figure 30-51-12 (5294 psi).
4
3
2 1
P-64436
Replace the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-12].
Remove relief valve assembly (Item 3) [Figure 30-51-12]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-51-12] for

damage.

Charge Relief Valve

1 4 5
Figure 30-51-14 6
2 3
1 P-64435
Inspect the O-ring (Item 1) [Figure 30-51-15].

P-64431
Inspect the poppet (Item 2) and the spring seat (Item 3)
[Figure 30-51-15] for damage or foreign material. Must
The charge relief valve (Item 1) [Figure 30-51-14] is move freely in the relief valve bore.
located on the back of the hydrostatic pump.
Inspect the sealing ring (Item 4) [Figure 30-51-15] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Installation: Tighten the charge relief valve to 70 N•m
(52 ft-lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-51-15].
NOTE: One shim = 300 kPa (3 bar) (43.5 psi) in

pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.

Disassembly

the loader. (See Engine Removal And Installation on 1
Page 70-10-15.)
Remove the hydrostatic pump. (See Removal And

Figure 30-51-16 1
2
P-90228
Remove the bolts (Item 1) for the swash plate angle

1 sensor (Item 2) [Figure 30-51-18].
1
Figure 30-51-19
P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-51-

16]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-17
3 3
2 2 P-90218
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-17].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-17] from both sides.

Figure 30-51-20
P-64464
1
Remove the end housing / rotating group assembly
P-64445 [Figure 30-51-22] from both ends of the pump.
Figure 30-51-23
Remove the bolts (Item 1) from the right end housing
(Item 2) [Figure 30-51-20]. 1
Figure 30-51-21
P-64465
1
Remove O-ring (Item 1) [Figure 30-51-23].
P-64447
Remove the four bolts (Item 1) from the left end housing
(Item 2) [Figure 30-51-21].

Figure 30-51-24
RIGHT SIDE
B25012
Disassemble the right side rotating group [Figure 30-51-

P-64454 26].
Figure 30-51-27
Remove valve plate (Item 1) [Figure 30-51-24] from the
right side pump.
NOTE: The valve plates are NOT interchangeable

between the right and left sides.
Figure 30-51-25
LEFT SIDE
B25011
Disassemble the left side rotating group [Figure 30-51-

27].
P-64501
Remove valve plate (Item 1) [Figure 30-51-25] from the

left side pump.
NOTE: The valve plates are NOT interchangeable

between the right and left sides.

1
Figure 30-51-28
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64475 30].
Figure 30-51-31
Remove the pistons (Item 1) [Figure 30-51-28] from the
rotating block.
1
Figure 30-51-29
1
P-64472
Do Not remove the pins (Item 1) [Figure 30-51-31] from

P-64476 the cylinder block.
Remove the pistons (Item 1) [Figure 30-51-29] from the

piston retainer.

1 1
Figure 30-51-32
3
1
2
P109266
Figure 30-51-35
P109265
Remove the swash plate (Item 1) from the end cap

housing (Item 2) [Figure 30-51-32].
Remove the link (Item 3) [Figure 30-51-32].
Figure 30-51-33 2
P109268
Remove the shell bearing races (Item 1) [Figure 30-51-

34].
2
Remove the positioning pin (Item 2) [Figure 30-51-34]
and [Figure 30-51-35].
P109269
Remove the shell bearing (Item 1) [Figure 30-51-33].
Remove the pin (Item 2) [Figure 30-51-33].

Figure 30-51-36
LEFT SIDE
1
P-76742
Remove the pump seal (Item 1) [Figure 30-51-38] by

P-64486 inserting a screw into the seal and prying out.
Figure 30-51-39
Figure 30-51-37
RIGHT SIDE 1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-36] and a rubber mallet.
[Figure 30-51-37] from the end housing.
Remove the snap ring (Item 1) and remove the bearing
(Item 2) [Figure 30-51-39].

Figure 30-51-40
P-90231
Rotate the servo piston cover (Item 1) [Figure 30-51-42].

P-64490
Figure 30-51-43
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-40].
Figure 30-51-41
1 1
P-90237
Slide the servo piston assembly out of the bore. [Figure

30-51-43].
P-90232
Remove servo piston bolts (Item 1) [Figure 30-51-41].

Figure 30-51-44 1
2
1 2
P-64496
Remove the servo cover (Item 1) [Figure 30-51-46] from

P-64493 the servo piston.

Remove the bushings (Item 1), seals and O-rings (Item 2) cover.
[Figure 30-51-44] from the pump housing.
Figure 30-51-47
Figure 30-51-45
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-51-47] from the

Remove the locknut (Item 1) [Figure 30-51-45] from the servo piston.
servo piston.

Figure 30-51-48
1
2
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-51-48] from the servo piston.
Figure 30-51-49
2
1
P-64502
Remove the bearings (Item 1) [Figure 30-51-49].
Remove the coupler (Item 2) [Figure 30-51-49].

Inspection
Figure 30-51-50
P-64477
Inspect the mating surface of the piston retainer for

P-86718 scoring or scratches (Item 2) [Figure 30-51-52].
Figure 30-51-53
Inspect the valve plates (Item 1) [Figure 30-51-50] for
scratches or scoring. Replace a valve plate if the 1
scratches are deep enough to catch with a fingernail. 1
Figure 30-51-51
P-64472
1
Inspect the pins (Item 1) [Figure 30-51-53]. The pins

must be all the same length.
P-64476
Inspect the pistons for scoring and scratches. The holes

(Item 1) [Figure 30-51-51] in the slippers must not be
plugged.

Inspection (Cont’d)
Figure 30-51-54
P109265
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-51-56].
Figure 30-51-57
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-51-54].
2
Figure 30-51-55
2
1
3
P-64482
Inspect individual roller bearings (Item 1) and machined

P-64478 surfaces (Item 2) [Figure 30-51-57] on swash plate.
Inspect the back surface of the rotating block (Item 1)

[Figure 30-51-55] where the valve plate seals. There
must be no scratches or scoring.
Inspect that the spring (Item 2) and snap ring (Item 3)

[Figure 30-51-55] are not bent or damaged.

Figure 30-51-58 1
1
P-64498
Inspect the servo piston stop adjustment (Item 1) [Figure

P-86723 30-51-60] for broken parts.
Figure 30-51-61
Inspect bearing surfaces (Item 1) [Figure 30-51-58] for
scratches or scoring.
Figure 30-51-59
1
2
3 1
P109268
Inspect the positioning pin (Item 1) [Figure 30-51-61] for

P-64488 wear or damage.
Inspect the bearing (Item 1) [Figure 30-51-59].
Inspect wear surfaces (Item 2) for scratches. Inspect the

splines (Item 3) for excessive wear.

Figure 30-51-62
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-62]

for scratches.
Inspect the spring (Item 2) [Figure 30-51-62] for

breakage.
Inspect the seats inside the case housing.
Do not disassemble the relief valve assembly. If

replacement is required, replace as an assembly.

Assembly
Figure 30-51-63
P-64497
2
Install the snap ring (Item 1) [Figure 30-51-65].

P-64502
Figure 30-51-66
Install the coupler (Item 1) [Figure 30-51-63].
Install the bearings (Item 2) [Figure 30-51-63].
Figure 30-51-64
1
1
2
P-64496
Install the O-ring (Item 1) [Figure 30-51-66] on the servo

cover.
P-64498
Install the piston stop adjustment mechanism (Item 1) in

to the servo piston (Item 2) [Figure 30-51-64].

Assembly (Cont’d)
Figure 30-51-67
P-90237
2 Install the servo piston assembly [Figure 30-51-69].

P-64495
Figure 30-51-70
Install the servo cover (Item 1) on the servo piston to the

dimension recorded earlier. Install the locknut (Item 2)
[Figure 30-51-67].
Figure 30-51-68
1
1
2
1
2 P-64466
Align the servo piston with the guide slot (Item 1) [Figure
30-51-70] parallel to the drive shaft center line.
P-64493
Install the bushings (Item 1), seals and O-rings (Item 2)

[Figure 30-51-68] in the pump housing.

Assembly (Cont’d)
Figure 30-51-71
1 1
P-90232
Install the bolts (Item 1) [Figure 30-51-71].
Tighten the bolts to 10,4 N•m (7.7 ft-lb) torque.

Assembly (Cont’d) LEFT SIDE

Figure 30-51-72 1
2
RIGHT SIDE
1 P-64503
2
Align the timing pin (Item 1) [Figure 30-51-72] and
P-64455 [Figure 30-51-73] in the case housing with the notch
(Item 1) [Figure 30-51-74] and [Figure 30-51-75] that
does not go through the valve plate.
Figure 30-51-73
Align the shoulder of the roller bearing (Item 2) [Figure
LEFT SIDE 30-51-72] and [Figure 30-51-73] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-74] and [Figure
30-51-75].
NOTE: Valve plate must sit FLUSH with the case

housing when properly installed.
Figure 30-51-76
1
2
P-64502
2
1
Figure 30-51-74
RIGHT SIDE
1
2
P-64488
Install the bearing (Item 1) and snap ring (Item 2) [Figure

30-51-76] on the shaft.
Install the shaft in both end housings.
P-64456

Assembly (Cont’d)
Figure 30-51-77
LEFT SIDE
P-64486
Install the snap ring (Item 1) [Figure 30-51-77] on both

sides of the pump.
Figure 30-51-78
RIGHT SIDE 2
P-76743
Install the seal (Item 1) and snap ring (Item 2) [Figure

30-51-78] on the right side pump.

Assembly (Cont’d)
Figure 30-51-79 1 1
2
2 2
1 P-64480A
Install the swash plate assembly over the shaft and into
P109266 the end cap housing. The locating wires (Item 1) must
engage the holes (Item 2) [Figure 30-51-81] of the end
cap housing.
Install the positioning pin (Item 1). Install the bearing
races with the tall edge (Item 2) [Figure 30-51-79] of the Figure 30-51-82
race towards the outside of the housing.
Figure 30-51-80
2
2 1
P109273
4 3
P109271 Install the positioning wire (Item 1) into the positioning pin
(Item 2) [Figure 30-51-82].
Install the locating wires (Item 1) through the bearings

and into the hole (Item 2) [Figure 30-51-80] in both sides
of the swash plate.
Install the positioning wire (Item 3) into the hole (Item 4)

[Figure 30-51-80] in the side of the swash plate.

Assembly (Cont’d)
Figure 30-51-83
2
1 1
P-64476
Install the pistons (Item 1) [Figure 30-51-85] in the piston

P109274 retainer.
Figure 30-51-86
The swash plate (Item 1) must move smoothly on the
bearings. Install the feedback link (Item 2) [Figure 30-51-
83] on the swash plate.
1
Figure 30-51-84
P-64475
Install the piston / retainer (Item 1) [Figure 30-51-86]

assembly in the cylinder block.
P-64471
Install the ball guide (Item 1) [Figure 30-51-84] on the

cylinder.

Assembly (Cont’d)
Figure 30-51-87
1
1
P-64466
Install the end housing assembly into the pump housing.

P-64469 The feedback link (Item 2) [Figure 30-51-88] must
engage the notch in the servo piston (Item 1) [Figure 30-
51-89].
Install the cylinder block / piston assembly (Item 1)
[Figure 30-51-87] on the shaft. Figure 30-51-90
Figure 30-51-88
1 2
1
P-64463
P-64465
Align the dowel pin (Item 1) with the hole in the case
(Item 2) [Figure 30-51-90] as the end cap is installed.
Install the O-ring (Item 1) [Figure 30-51-88].

Assembly (Cont’d)
1
Figure 30-51-91
1 1
1 1 P-90218
Install the O-ring (Item 1) [Figure 30-51-93].

P-64445
Figure 30-51-94
Figure 30-51-92
1 1
2
1 1
P-64476
P-64447
Install the swash plate angle sensor (Item 1) into the slot
of the positioning pin (Item 2) [Figure 30-51-94].
Install the bolts (Item 1) [Figure 30-51-91] and [Figure
30-51-92]. Tighten the bolts to 130 N•m (96 ft-lb) torque.

Assembly (Cont’d)
Figure 30-51-95
P-90228
Install the bolts (Item 1) [Figure 30-51-95]. Tighten the

bolts to 3,1 N•m (27.4 in-lb) torque.
Figure 30-51-96
2 2
1 1
2 2
P-90227
Install the covers (Item 1) and bolts (Item 2) [Figure 30-

51-96] Tighten the bolts to 51 N•m (38 ft-lb) torque.
Install the hydraulic controllers. (See Hydraulic Controller


Mechanical Neutral Adjustment

WARNING
procedure:
The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
immediately.
relative to the hydraulic controller. This procedure should W-2145-0290
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted. Figure 30-51-97
1
Place the loader on jackstands. (See Procedure on Page
10-10-1.) 1
WARNING
W-2017-0286
P-64973
Raise the lift arms, and install an approved lift arm
Connect a hydraulic hose (Item 1) [Figure 30-51-97]
Raise the operator cab. (See Raising on Page 10-30-2.) between port X1 and port X2 on each side of the
hydrostatic pump, to equalize the pressures on both ends
Connect the Remote Start Tool. (See REMOTE START of the servo pistons.
7217666 on Page 10-61-1.)
Disconnect the swash plate angle sensors in the 1

electrical harness. This prevents unwanted swash plate 1
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
If equipped disconnect the speed sensors located on the

motor. This prevents uncommanded wheel movement
error codes from occurring during adjustments.
P-90242
Remove the plugs (Item 1) [Figure 30-51-98] from the

MB ports on the front side of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-99
P-90226
Loosen the pump neutral adjustment locknut (Item 1)

P-64438 [Figure 30-51-101].
Start the loader using the Remote Start Tool and run at
Remove the plugs (Item 1) [Figure 30-51-99] from the idle.
MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

1
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
Figure 30-51-102
P115932
Remove the drive hoses from the A and B ports (Item 1)

[Figure 30-51-100]. Plug the ports with metal caps. The
1
caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the P-90238
pump mechanical neutral setting.
Turn the adjustment screw (Item 1) [Figure 30-51-102]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-103
P-90238
1
While holding the adjustment screw (Item 1) in position,

P-90238 tighten the locknut (Item 2) [Figure 30-51-105] to 30 N•m
(22 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-103] Shut the loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the hydraulic hose from the X1 and X2 ports on
adjustment screw. the pump. Install the plugs and tighten to 25 N•m (18 ft-
lb) torque.
Figure 30-51-104
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
NOTE: The Hydraulic Controller Neutral Adjustment

must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-50-
36.)
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

Hydraulic Controller Neutral Adjustment
The Hydraulic Controller Neutral Adjustment aligns the

pump swash plate and the control spool so that a zero 1
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted, removed or after the pump mechanical neutral
setting is adjusted. The pump mechanical neutral setting
must be correct before performing the Hydraulic
Controller Neutral Adjustments.
NOTE: Procedure is shown for the left side hydraulic 1

controller. Procedure is the same for the right P-90239
side hydraulic controller, with the exception
of the following procedures. Disconnect the
electrical connectors for the right side Disconnect the wire harness (Item 1) [Figure 30-51-106]
hydraulic controller and connect pressure from the controller being adjusted.
gauges in the X1 and X2 ports on the right
side of the pump. Figure 30-51-107
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
1
WARNING
2
W-2017-0286
P-90226
Raise the lift arms, and install an approved lift arm
Remove the X1 plug (Item 1) and X2 plug (Item 2)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 30-51-107] from the side of the hydrostatic pump
being adjusted.
7217666 on Page 10-61-1.)

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-108
P-90236

P-64975 clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Install 3447 kPa (34 bar) (500 psi) pressure gauges in the
X1 and X2 ports [Figure 30-51-108]. Figure 30-51-111
Figure 30-51-109
1
1
P-90236
P-90236
counterclockwise, until the other gauge registers an
Loosen the screw (Item 1) [Figure 30-51-109]. increase in system pressure. Mark the position of the
adjustment screw.
Start the loader using the Remote Start Tool and run at
an idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-112
P-90236

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
Figure 30-51-113
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

tighten the locking screw (Item 2) [Figure 30-51-113] to
6,1 N•m (4.5 ft-lb) torque.
Shut the loader OFF.
Remove the pressure gauges from the X1 and X2 ports

on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the wire harness to the controller.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

DRIVE BELT Figure 30-60-3
Belt Adjustment Earlier Models
The drive belt does not need adjustment. The belt has a 1
spring loaded idler that constantly maintains the correct
belt tension. The spring loaded idler stop adjustment, 2
detailed below, is critical for long belt life.
Stop Adjustment


P109784A
Figure 30-60-1
Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-60-3].
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-2] to 105 – 115 N•m (78 – 85 ft-lb) torque.
Figure 30-60-4
Later Models
1
2
P121107A
The spring loaded idler is located above the battery on

the left side of the engine [Figure 30-60-1].
Figure 30-60-2
P126273
1 Allow the stop arm (Item 1) to contact the top of the

spring loaded idler (Item 2) [Figure 30-60-4].
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-2] to 105 – 115 N•m (78 – 85 ft-lb) torque.
P121579
Loosen the spring loaded idler adjustment and pivot bolt

(Item 1) [Figure 30-60-2].

DRIVE BELT (CONT’D) Figure 30-60-7
Belt Replacement
1
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
Figure 30-60-5
2
P109783
Loosen the spring loaded idler adjustment and pivot bolt

(Item 1). Insert a breaker bar (Item 2) [Figure 30-60-7]
into the slot provided in the stop arm as shown and push
the breaker bar down to release tension on the drive belt.
Tighten the adjustment bolt (Item 1) [Figure 30-60-7] to

P121086
hold the spring loaded idler off the drive belt.
Remove the drive belt from the hydrostatic pump pulley

Remove the drive belt shield bolt (Item 1) [Figure 30-60- and flywheel pulley. Inspect the pulleys for wear.
5].
Install new drive belt.
Figure 30-60-6
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-7] and allow the idler to contact the drive
belt.
1
2 Continue the procedure on the next page.
P121188
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
[Figure 30-60-6] toward the back of the loader to unseat
the shield from the top and bottom drive belt shield
mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-60-6].

DRIVE BELT (CONT’D) Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
Belt Replacement (Cont’d) of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-60-9].
Figure 30-60-8
Figure 30-60-10
1 1
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
P121086
torque wrench (Item 2) [Figure 30-60-8] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated. Install the drive belt shield bolt (Item 1) [Figure 30-60-
10].
Maintain torque on the stop arm and tighten the spring
loaded idler adjustment and pivot bolt (Item 1) [Figure Install the battery. (See Removal And Installation on
30-60-8] to 105 – 115 N•m (78 – 85 ft-lb) torque. Page 60-20-1.)
NOTE: This procedure is required to preload a new Close the rear door.
drive belt in order to achieve the correct stop
adjustment after the initial belt break-in NOTE: The stop arm MUST be adjusted after 50 hours
period. operation with the new drive belt. (See Stop
Adjustment on Page 30-60-1.)
Figure 30-60-9
See the SERVICE SCHEDULE for the correct
Top Mounting Bolt service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)
1
P107207A
Bottom Mounting Bolt
P107206

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation Figure 30-60-13

(Earlier Models)
Remove the battery. (See Removal And Installation on 2

Page 60-20-1.) 1
Remove the drive belt. (See Belt Replacement on Page

30-60-2.)
Figure 30-60-11
1 P114387
2 Remove the nut (Item 1) from the tensioner assembly

and remove the wheel (Item 2) [Figure 30-60-13].
3 Figure 30-60-14
P114385
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-60-11].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 – 115 N•m (78 – 85 ft-lb) torque.
Figure 30-60-12
1
2
P117155
Disassemble the tensioner assembly as shown [Figure

30-60-14].
Inspect the parts for wear and replace as needed.

1
NOTE: The wheel (Item 1) and the tensioner arm (Item
2) [Figure 30-60-14] are not serviceable and
must be replaced as a complete assembly.
P114384
Remove the tensioner assembly (Item 1) [Figure 30-60-

12].

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation Figure 30-60-17

(Later Models)

1
Remove the battery. (See Removal And Installation on 3
Page 60-20-1.)
2
30-60-2.)
Figure 30-60-15
1
P126275
2
Remove the nut (Item 1), bolt (Item 2) and tuned weight
(Item 3) [Figure 30-60-17] from the tensioner assembly.
3
Figure 30-60-18
P126273
2
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-60-15].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 – 115 N•m (78 – 85 ft-lb) torque
Figure 30-60-16
P126277
Remove the bolt (Item 1) and wheel (Item 2) [Figure 30-

60-18] from the tensioner assembly.
1
P126274
Remove the tensioner assembly (Item 1) [Figure 30-60-

16].

DRIVE BELT (CONT’D)
Tensioner Pulley Disassembly And Assembly

(Later Models) (Cont’d)
Figure 30-60-19
1 2
P126284
Disassemble the tensioner assembly as shown [Figure

30-60-19].
NOTE: The wheel (Item 1) and the tensioner arm (Item

2) [Figure 30-60-19] are not serviceable and
must be replaced as a complete assembly.

TWO-SPEED / BRAKE VALVE
Description
Figure 30-70-1
P122392
The two-speed / brake valve (Item 1) [Figure 30-70-1] is

located on top of the chaincase in front of the hydrostatic
pump. The high range is selected by a switch located on
the right handle for manual loaders and on the left
joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure fluid to the shift spool in
each motor. The charge pressure hydraulic fluid shifts the
spools allowing the motors to move into high range.
When low range is selected, the solenoid is de-energized
and the shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE Figure 30-70-2
(CONT'D)
Valve Block Removal And Installation
1
DANGER 2
P122392
P-90328
Remove the steering shocks (Item 1), the bolts (Item 2)
AVOID DEATH
[Figure 30-70-2] and set the steering levers to the side.
Mark all hydraulic hoses for proper installation.
Figure 30-70-3
D-1009-0409
WARNING
2
1
W-2059-0598
P122393

WARNING 30-70-3] from the two-speed solenoid.

30-70-3] from the brake solenoid.
W-2017-0286


(CONT'D)
Valve Block Removal And Installation (Cont’d)
Figure 30-70-4
1
2 2
P122394
Remove the hydraulic lines (Item 1)and the hoses (Item

2) [Figure 30-70-4].

and remove the valve block.

TWO-SPEED / BRAKE VALVE Figure 30-70-7
(CONT'D)
Valve Block Disassembly And Assembly
Mark all hydraulic hoses and fittings for proper

installation.
Figure 30-70-5 1
1
1 P107100
Use a test meter and test the solenoid coils (Item 1)

[Figure 30-70-7] for resistance.
The resistance value for the solenoid coil can be found on

the electrical schematic.
P107098
Figure 30-70-8
Remove the hydraulic fittings (Item 1) [Figure 30-70-5]

from the valve block.
Figure 30-70-6 1
4
P107101
2
3
Use a test meter and test the solenoid coils (Item 1)
[Figure 30-70-8] for resistance.
P107099
The resistance value for the solenoid coil can be found on
the electrical schematic.
Remove the two bolts (Item 1) from the two-speed valve
solenoid (Item 2) [Figure 30-70-6]. Assembly: Always install new O-rings [Figure 30-70-8].
Remove the electrical solenoid nut (Item 3) from the

brake solenoid (Item 4)[Figure 30-70-6].
Assembly: Tighten the bolts (Item 1) [Figure 30-70-6] to

2,7 N•m (2 ft-lb) torque.
Assembly: Tighten the nut (Item 3) [Figure 30-70-6] to

6,78 - 9,49 N•m (60 - 84 in-lb) torque.

(CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-9
P107104
Remove the brake solenoid valve (Item 1) [Figure 30-70-

9] from the valve block.
Assembly: Always install new O-rings and back-up rings

[Figure 30-70-9]. Tighten the solenoid valve to 27,1 N•m
(20 ft-lb) torque.
Figure 30-70-10
1
1
2 2 2
P107103
Replace the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-70-10].

DRAIN MANIFOLD Figure 30-80-2
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic fluid to the reservoir.
Drain Manifold Removal And Installation
IMPORTANT 1

P-90485
damage the system. Remove the two bolts (Item 1) [Figure 30-80-2].
I-2003-0888

Figure 30-80-1
P-90484
Remove and plug all hoses from the drain manifold (Item
1) [Figure 30-80-1].
Disconnect the wiring harness from the fluid temperature

switch (Item 2) [Figure 30-80-1].

DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3

BRAKE (SINGLE SPEED) Disc Removal And Installation
Description Raise the loader lift arms and install an approved lift arm
Figure 40-10-1
WARNING
1 W-2059-0598
Raise the loader operator cab. (See Raising on Page 10-

30-2.)
P-85491
Remove the control panel from the loader. (See Removal
The brake is used to hold the machine in place. The
brake is operated by a switch (Item 1) [Figure 40-10-1] Remove the center chaincase cover. (See Center Cover
located on the front accessory panel. Removal And Installation on Page 40-30-2.)
The brake is applied by a spring-loaded wedge that drops Remove the traction lock assembly.
into two notched brake discs attached to the motor carrier
shafts. An electric solenoid is sent power from a relay to Figure 40-10-2
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the
discs.
The hold signal will be interrupted and the wedge will 1

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake. (See TRACTION

LOCK on Page 60-120-1.)
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.

BRAKE (SINGLE SPEED) (CONT’D) Figure 40-10-4
Disc Removal And Installation (Cont’d)
Figure 40-10-3
N-19082A
1 Figure 40-10-5
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-10-3]

and the brake disc for damage or wear and replace as
necessary. (See Inspecting on Page 60-120-3.)
N-19083A
A snap ring pliers with 90° tips are necessary for

removing the parking brake disc.

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

BRAKE (TWO-SPEED)
Description
Figure 40-11-1
P-90668E
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-11-1]
located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure fluid
to the brakes. The charge pressure fluid pushes the
spring away from the brake discs allowing the drive motor
to move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure fluid to hold the spring away from the brake
discs.
When the hold signal is interrupted the solenoid will close

the circuit and the charge fluid will be shut off an the
spring will apply the brakes. This will happen if the engine
rpm drops below a set rpm, the seat bar sensor fails or if
there is a break in the wires for the brake block solenoid.
For more information on the brake. (See TWO-SPEED /

BRAKE VALVE on Page 30-70-1.)

DRIVE COMPONENTS
Description
NA1285
The drive components consist of the chaincase, drive chains, sprockets, axle shafts, hubs and drive motor carrier.
The chaincase is partially filled with hydraulic fluid to lubricate the chains and bearings.

DRIVE COMPONENTS (CONT'D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

MEL1242 - Hydraulic Ram (May be used if desired)

1.)
1
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
the chaincase before lifting and blocking the P4849
loader. (See Axle, Sprocket And Bearings
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.
Remove the tire / wheel assembly. (See Mounting on
Page 10-160-2.)
Remove the front chaincase cover. (See Front Cover

WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
Remove the fluid from the chaincase. (See Removing
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
Figure 40-20-1
W-2186-0395
Remove the hub from the axle.
2 Figure 40-20-3
1
2
P4850
Remove the bolts (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolts to 240 - 260 N•m (175 - P4848

190 ft-lb) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1] Remove the key (Item 1) [Figure 40-20-3] from the axle.
across from each other.

DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
P4817
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end into the axle seal.
Remove the axle seal.
Figure 40-20-5
P4814
Installation: Place the seal with the lip facing in [Figure

40-20-5].
Installation: Use a hammer, install the new axle seal

until the tool (MEL1714) is flush with the edge of the axle
tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT'D) Remove the control panel. (See Removal And Installation
on Page 50-110-2.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the fluid from the chaincase. (See Removing
MEL1242 - Port-a-power Ram
MEL1202 - Axle Bearing Service Set Figure 40-20-6
NOTE: The procedure shown for removal and

installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the 2
same for the rear axle.
DANGER 1
P-68196
Remove the axle sprocket bolt (Item 1) and backing

P-90328 washer (Item 2) [Figure 40-20-6].
AVOID DEATH Installation: Tighten the axle sprocket bolt to 699 - 726
• Disconnecting or loosening any hydraulic N•m (515 - 535 ft-lb) torque.
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
• Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
support. Replace if damaged. Figure 40-20-7
D-1009-0409
WARNING
W-2059-0598
Raise the lift arms and install an approved lift arm P-4158A
Lift and block the loader. (See Procedure on Page 10-10- Install a hydraulic ram between the two sprockets [Figure
1.) 40-20-7].

DRIVE COMPONENTS (CONT'D) NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
Axle, Sprocket And Bearings Removal And the mounting surface.
Installation (Cont'd)
Figure 40-20-10
Figure 40-20-8
P-4171
P5406A
Press the splined end of the axle free from the bearing
Push the axle out until the ram is at the end of the stroke. [Figure 40-20-10].
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)

[Figure 40-20-8].
Installation: Pack the inner and outer bearing with

grease before installing them.
Figure 40-20-9
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed to

do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-9].


Figure 40-20-11
P4812
Use the tools provided in the MEL1202 Axle Bearing

Service Set. A slide hammer is also needed.
P-4175
Use the long driver handle (Item 1) [Figure 40-20-12]
and the bearing cup removal tool to remove the inner
Installation: Put the spline end of the axle shaft into the bearing cup.
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it

will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-11] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-11].


Installation (Cont'd) 2
1
Figure 40-20-13
P5468A
Use the bearing cup installation tool (Item 1) [Figure 40-

20-15] and (Item 1) [Figure 40-20-16].
P5637
Put the inner cup (Item 2) [Figure 40-20-15] in the axle
tube.
To remove the outer bearing, install a bearing cup
removal tool on the slide hammer. Install the long threaded rod (Item 2) [Figure 40-20-16]
into the axle tube and through the installation tool (Item
Install the slide hammer / tool assembly behind the 1) [Figure 40-20-15].
bearing cup [Figure 40-20-13].
Install the nut (Item 3) [Figure 40-20-15].
Figure 40-20-14
Figure 40-20-16
P4816
P4811
Use the slide hammer to remove the bearing cup from

the axle tube [Figure 40-20-14]. Install the installation tool (Item 1) [Figure 40-20-16] on
the threaded rod. Install the nut.
Hold the inside nut (Item 3) [Figure 40-20-15] with a

wrench and tighten the outside nut [Figure 40-20-16].
Tighten the nut until the bearing cup is seated.
Remove the installation tool and threaded rod.


Figure 40-20-17
P4813
To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-17].

DRIVE COMPONENTS (CONT'D) Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Chain Removal And Installation Page 40-20-4.)
Figure 40-20-18
DANGER
Front Drive
P-90328 Chain
Rear Drive
Chain
AVOID DEATH
tubeline, hose, fitting, component or a part failure P-68194

• Keep out of this area when lift arms are raised NOTE: It is necessary to remove the rear axle and
unless supported by an approved lift arm drive chain if the front chain has to be
support. Replace if damaged. removed.
D-1009-0409
WARNING
W-2059-0598


1.)

on Page 50-110-2.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover

Remove the fluid from the chaincase. (See Removing


Chain Removal And Installation (Cont’d)
The tools listed are needed for the following procedure:
MEL1269 - Chain Breaker

MEL1246 - Chain Link Press Tool
MEL1364 - Chain Link Installation Tool
Figure 40-20-19
B-13504A
Use the chain breaker MEL1269 to separate the chain.
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use the chain link installation
n tool MEL1364 to hold both ends of the chain.
Secure the tool MEL1246 and place the connector link in

the tool as shown [Figure 40-20-19].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-19]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
Raise the loader lift arms and install an approved lift arm
support device. (See Description on Page 40-20-1.) 2

30-2.) 3
3

on Page 50-110-2.) P-34255
Remove the front chaincase cover mounting bolts (Item

DANGER 1) [Figure 40-30-1].
NOTE: There are tabs (Item 3) [Figure 40-30-1] on the

side of the cover to help pry the covers off.
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.
Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 bolt threads to stop fluid leakage. Tighten the mounting
bolts to 34 - 38 N•m (25 - 28 ft-lb) torque.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-2.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH
Figure 40-30-3
3
D-1009-0409
2

on Page 50-110-2.)
Figure 40-30-2 1
P-90048
Remove the chaincase cover mounting bolts (Item 1)

[Figure 40-30-3].
2 1
3 side of the cover to help pry the covers off.
Remove the center chaincase cover (Item 2) [Figure 40-

30-3] from the loader.
P-90047 Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
bolt threads to stop fluid leakage. Tighten the mounting
If loader is equipped with SJC, skip to [Figure 40-30-3]. bolts to 34 - 38 N•m (25 - 28 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.) 2
3
1
30-2.) 2
2
1
DANGER
P-90056
Remove the rear chaincase cover mounting bolts (Item 1)

[Figure 40-30-4].

P-90328 side of the cover to help pry the covers off.
AVOID DEATH Remove chain case cover (Item 3) [Figure 40-30-4].
tubeline, hose, fitting, component or a part failure Installation: Apply polyurethane sealer to mating
can cause lift arms to drop. surfaces. Polyurethane sealant should be applied to the
• Keep out of this area when lift arms are raised bolt threads to stop fluid leakage. Tighten the mounting
unless supported by an approved lift arm bolts to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Block Removal And Installation
on Page 30-70-2.)
Remove the drain manifold. (See Drain Manifold Removal

Disconnect the front steering linkage bars from the rear

linkage bars. (See Linkage Removal And Installation on
Page 50-110-7.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Tailgate Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-11
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-12
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-16
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-20
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-142-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1


RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
FAN DUCT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1


SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
Lower the operator cab. (See Lowering on Page 10-30-
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P-90021
2 Remove the seat bar (Item 1) [Figure 50-10-3] from the

operator cab.
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P122374
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

SEAT BAR (CONT'D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023
4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT'D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)
Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Figure 50-20-1
2
1
1 3
P-85652A
Remove the retaining clip (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Removal And Installation
Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.)
Figure 50-20-5
3
2
1
1
1
2
P-85661
P100756
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4]. Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: Apply a small amount of thread-locker on
the threads of the gas spring rod before installing the Installation: (See Installing on Page 80-150-1.)
clevis (Item 1) [Figure 50-20-4].
Figure 50-20-6
WARNING 1
AVOID INJURY 2
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only 1
qualified service personnel can remove the cylinder.
W-2112-0987
1
P100879A
Disconnect the expansion / heater unit wiring connectors

(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve

with plugs to prevent coolant loss from the
system.

OPERATOR CAB (CONT’D) Figure 50-20-8

1
Figure 50-20-7
1
1
1 P107406
Disconnect the cab harness connectors (Item 1) [Figure

P103082 50-20-8].
Figure 50-20-9
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].
Cap and plug the hoses and expansion valve fittings with
proper A/C caps and plugs.
NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to
damage O-rings when installing the hose
fittings.
Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb) 1

torque.
WARNING P-85658
Remove the two cab mount bolts and nuts (Item 1)

AVOID INJURY OR DEATH [Figure 50-20-9] from both sides of the cab.
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas Installation: Tighten the cab mount bolts and nuts to
spring(s). If the operator cab is tilted forward without 24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Remove the engine speed control cable from the cab.

(See Removal And Installation on Page 70-20-1.)
Remove the operator cab gas spring(s). (See Gas Spring

NOTE: Use the hoist connected to the operator cab

grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

OPERATOR CAB (CONT’D)
Figure 50-20-10
P-85662
Using a strap and a hoist remove the cab from the loader
[Figure 50-20-10].

OPERATOR SEAT Seat Belt Removal And Installation (Retractable)
Removal And Installation Figure 50-30-2
Figure 50-30-1
P-90355
P-85776
Remove the mounting nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the seat belt.
Remove the four seat mounting nuts (Item 1) [Figure 50- Installation: Tighten the mounting nut to 73 N•m (54 ft-
30-1] and washers from the operator seat mounting lb) torque.
studs.

3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.

OPERATOR SEAT (CONT’D) Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation Figure 50-30-4

(Standard)
Figure 50-30-3
3 1
P101250
P101249 Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the bracket mounting bolts (Item 1) [Figure 50-

Remove the lower mounting nut, washer and bolt (Item 30-4].
1). Remove the upper mounting nut and bolt (Item 2)
[Figure 50-30-3]. Remove the bracket (Item 3) [Figure 50-30-3].
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting nut and bolt to 73 N•m

(54 ft-lb) torque.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure
Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3

3.)
Remove the seat. 2
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-31-6
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.
Figure 50-31-5
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-31-9
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
31-7]. the seat back to the upright position.
Figure 50-31-8 Remove the back cushion from the seat.
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-31-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) Remove the mounting nut (Item 1) [Figure 50-31-11].
Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-31-10]. Figure 50-31-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-31-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-31-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-31-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
13].
Figure 50-31-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-31-14].

BOB-TACH (HAND LEVER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
1
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.
P-85554
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.


Figure 50-40-2
P-85649

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5
Figure 50-40-3
1 P-31405
Replace O-ring (Item 1) [Figure 50-40-5] on the grease

P-31402 plug.
Figure 50-40-6
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug (Item 1) [Figure 50-40-4] out of
the Bob-Tach (both sides).

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Removal And Installation (Cont’d) Figure 50-40-9
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Figure 50-40-10
Installation: Tighten the retainer nut and bolt (Item 1)

35,3 mm
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330
(1.39 in)
ft-lb) torque.
Figure 50-40-8
P127544
Installation: Tighten the lever mounting nut until the

1 spring is compressed to 35,3 mm (1.39 in) [Figure 50-
40-10].
P-31407
With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-40-8]

and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.
Remove the Bob-Tach from the loader.
NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd)
Figure 50-40-11
P-85667
Remove the wedge (Item 1) [Figure 50-40-13] out the

2 bottom of the Bob-Tach.
P-85665
Always replace bent or broken wedges.
Remove the washer and spring, (Item 1) and the lever Earlier Design
assembly (Item 2) [Figure 50-40-11].
Figure 50-40-14
Figure 50-40-12
1
1
2
2
P19287
P-85666
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Use a punch and hammer to remove the roll pin (Item 1) or clevis (Item 4) are damaged, put the assembly in a
[Figure 50-40-12] from the Bob-Tach wedge and spring vise. Remove the bolt (Item 1) [Figure 50-40-14] and
clevis. replace the damaged parts as needed.
Remove the spring clevis assembly (Item 2) [Figure 50- Assembly: Clean the threads and apply Loctite® 242 to
40-12]. the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135

BOB-TACH (HAND LEVER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-40-16

(Cont'd)
Later Design
Figure 50-40-15 2 1
P-85669
3 Remove the Bob-Tach. (See Removal And Installation on

2 Page 50-40-1.)
P121303
Use a seal pick to remove seal (Item 1) [Figure 50-40-
16] from the Bob-Tach.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a Remove and replace bushing (Item 2) [Figure 50-40-16]
vise. Remove the bolt (Item 1) [Figure 50-40-15] and with a driver tool and hammer.
replace the damaged parts as needed.
Figure 50-40-17
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54 3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-40-17].

BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug (Item 1) [Figure 50-41-5] out of
the Bob-Tach (both sides).
P-85649

BOB-TACH (POWER) (CONT’D) Figure 50-41-8
Figure 50-41-6
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Replace the O-ring (Item 1) [Figure 50-41-6] on the [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
grease plug. ft-lb) torque.
1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.
NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

BOB-TACH (POWER) (CONT'D) Figure 50-41-12
Lever And Wedge Disassembly And Assembly

35,3 mm
(1.39 in)
Figure 50-41-10
1 1
P127544
Installation: Tighten the lever mounting nut until the

P-85570 spring is compressed to 35,3 mm (1.39 in) [Figure 50-
41-12].
Remove the washers and bolts (Item 1) [Figure 50-41- Figure 50-41-13
10] from the cylinder (both ends).

lb) torque.
Remove the cylinder from the lever pivots.
Figure 50-41-11
1
2
P-85665
1
Remove the washer and spring, (Item 1) and the lever
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

11].

BOB-TACH (POWER) (CONT'D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Remove the bolt (Item 1) [Figure 50-41-16] and
Use a punch and hammer to remove the roll pin (Item 1) replace the damaged parts as needed.
[Figure 50-41-14] from the Bob-Tach wedge and spring
clevis. Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
Remove the spring clevis assembly (Item 2) [Figure 50- N•m (90 - 100 ft-lb) torque.
41-14].
Later Design
Figure 50-41-15
Figure 50-41-17
3
P-85667 2
P121303
Remove the wedge (Item 1) [Figure 50-41-15] out the

bottom of the Bob-Tach. If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
Always replace bent or broken wedges. vise. Remove the bolt (Item 1) [Figure 50-41-17] and
replace the damaged parts as needed.
Assembly: Clean the threads and apply Loctite® 242 to

the bolt (Item 1) [Figure 50-41-17], tighten to 48 - 54

BOB-TACH (POWER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-41-18
2 1
P-85669
Remove the Power Bob-Tach. (See Removal And

Use a seal pick to remove seal (Item 1) [Figure 50-41-

18] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-18]

with a driver tool and hammer.
Figure 50-41-19
3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-41-19].

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4
P-90592A

1] from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

2] from the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].
Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer nut and bolt (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT'D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
P-90611

P122544 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining nut and bolt (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being
removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.

REAR GRILLE Installing
Removing Figure 50-60-3
Stop the engine.
Figure 50-60-1
1 P109931
Insert the front tab of the two hood covers into the slots in
P121151A
the loader frame and lower [Figure 50-60-3]. (Left side
shown.)
Remove the clamping knob (Item 1). Lift using the handle Figure 50-60-4
(Item 2) [Figure 50-60-1] and pull the rear grille
backward to remove from the loader.
Figure 50-60-2
P109722
Insert the edge of the rear grille under the loader frame
P121215A
and slide rear grille in while lowering [Figure 50-60-4].
Install the clamping knob (Item 1) [Figure 50-60-1].

Lift and remove the two hood covers (Item 1) [Figure 50-
60-2].

REAR GRILLE (CONT’D)
Shield Removal And Installation
Figure 50-60-5
P122118
Remove the two bolts (Item 1) [Figure 50-60-5] and

remove the shield.

ENGINE COVER Figure 50-70-3
Remove the rear grille. (See Removing on Page 50-60- 1

1.)
Figure 50-70-1
1 1
P122494
Remove the engine cover from the loader.
P122491
Remove the bolts (Item 1) [Figure 50-70-1].
Figure 50-70-2
P122492
Remove the bolt (Item 1) [Figure 50-70-2] and [Figure

50-70-3].

REAR DOOR (TAILGATE) Figure 50-80-3

1
Figure 50-80-1
2 2
P115841
Remove the top and bottom door hinge mounting nut and
P115837 bolt (Item 1) [Figure 50-80-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) in the top hinge as shown
50-80-1] from the main frame harness. [Figure 50-80-3].
Remove both rear lights (Item 2) [Figure 50-80-1] from Installation: Tighten the mounting nut and bolt to 34 - 38
the door. (See Rear Removal And Installation on Page N•m (25 - 28 ft-lb) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-80-2 flat on the floor.
1 2
1
P115840
Secure the chain hooks (Item 1) [Figure 50-80-2] to the

door as shown.
Connect a chain hoist to the lifting chain (Item 2) [Figure

50-80-2].

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation
Figure 50-80-4
WARNING
1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-80-6
1
1
P85698B
Remove the two striker mount bolts (Item 1) [Figure 50-

80-4].
Remove the striker assembly from the loader.
Striker Disassembly And Assembly 1

P-85698B
Figure 50-80-5
Loosen the striker assembly mount bolts (Item 1) [Figure

5
50-80-6].
4 Align the striker assembly in the center of the mounting

3 holes.
1
2
NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
P106584
Open the door.
Tighten both striker mount bolts (Item 1) [Figure 50-80-

Remove the locknut (Item 1) [Figure 50-80-5]. 6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the bolt (Item 2), spacer (Item 3) and roller (Item Close the rear door.
4) form the bracket (Item 5) [Figure 50-80-5].
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-80-9
Latch Removal And Installation
Figure 50-80-7
1
1
2
P109094
Remove the door handle (Item 1) [Figure 50-80-9] from

P109092 the rear door.

Remove the nut (Item 1) and bolt (Item 2) [Figure 50-80-
7] from the latch.
Installation: Tighten the nut (Item 1) and bolt (Item 2) to

34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-80-8
2
1
P109093
Remove the spacer (Item 1) [Figure 50-80-8] from the

latch.
Remove the spring (Item 2) [Figure 50-80-8] from the

latch.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-80-12
Tailgate Fan Removal And Installation

2
Figure 50-80-10
1
2
P121146
Remove the twelve nuts and bolts (Item 1) and tailgate

P121144 protector (Item 2) [Figure 50-80-12] from the tailgate.
Installation: Tighten the nuts and bolts (Item 1) [Figure

Cut the tie strap (Item 1) and disconnect the wire 50-80-12] and [Figure 50-80-11] to 50 - 54 N•m (37 - 40
connector (Item 2) [Figure 50-80-10] (both sides). ft-lb).
Figure 50-80-11 Figure 50-80-13
1 1
1
2
1 1
P121145 P121147
Remove the twelve nuts (Item 1) [Figure 50-80-11]. Remove the nuts and bolts (Item 1) and the tailgate fan
(Item 2) [Figure 50-80-13] from the rear door.
Installation: Tighten the nuts and bolts to 12,2 - 13,5


FUEL TANK Figure 50-90-2

1
WARNING

explosion or fire.
P122353
W-2103-0508

THE LOADER on Page 10-10-1.) Transfer the fuel into a container and plug the fuel tank
inlet.
Remove the engine / hydrostatic pump assembly from
Page 70-10-15.)

1 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
Figure 50-90-3
4
2
P114311
2 3
Remove the fuel vent hose (Item 1) and the fuel inlet
hose (Item 2) [Figure 50-90-1].
1
P-85708
Mark and remove the two fuel lines (Item 1) and

disconnect the wire harness (Item 2) [Figure 50-90-3].
Remove the two mounting bolts (Item 3) and remove the

bracket (Item 4) [Figure 50-90-3].

FUEL TANK (CONT’D) Fuel Level Sender Removal And Installation
Removal And Installation (Cont'd) Lift and block the loader. (See LIFTING AND BLOCKING
Figure 50-90-4
Remove the engine / hydrostatic pump assembly from
Page 70-10-15.)
2 1
Figure 50-90-6
1
1
P-85710
Remove the bolts (Item 1) [Figure 50-90-4] from the

battery hold down plate.
P106480
Remove the hold down plate (Item 2) [Figure 50-90-4]
from the loader.
Figure 50-90-5 50-90-6] from the fuel level sender.
Remove the fuel level sender.
Figure 50-90-7
1 1
2
P-85709
Remove the two mounting bolts (Item 1) and the bracket

(Item 2) [Figure 50-90-5].
P-85716
Lift the fuel tank and remove it from the loader frame.
Inspect the fuel level sender and replace if worn or
NOTE: When installing the fuel tank, avoid striking damaged [Figure 50-90-7].
the tank with heavy objects to prevent
damage.

FUEL TANK (CONT'D) Figure 50-90-10
Fuel Fill Screen Removal And Installation

2
NOTE: The fuel filter is removed for photo charity.
Figure 50-90-8
1
1
P122354

hose (Item 2) [Figure 50-90-10] from the tank.
P122353 Figure 50-90-11
Figure 50-90-9
1
1
P122375
Remove the fuel fill screen (Item 1) [Figure 50-90-11].
P122355 Inspect and replace as needed.
Remove the vent hose / clamp (Item 1) [Figure 50-90-9]

from the filler neck.

CONTROL PEDALS AND LINKAGES Figure 50-100-1
Description
The control pedals and linkages are connected to the 1

control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING P100782
Never work on a machine with the lift arms up unless Remove the nut and bolt (Item 1) [Figure 50-100-1] from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-100-2
DANGER
1
P100783
P-90328 Remove the two nuts (Item 1) [Figure 50-100-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-100-5
Linkage Removal And Installation
Figure 50-100-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-100-

P100786 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the nut and bolt (Item 1) [Figure 50-100-3] to 100-6].
disconnect the lift pedal linkage from the crossbar.
Figure 50-100-6
Figure 50-100-4
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-100-6] for wear and replace as needed.
[Figure 50-100-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-100-7 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
2 while properly sitting in the loader seat.
Figure 50-100-9
P100782
Remove the nut and bolt (Item 1) [Figure 50-100-7] from

the pedal linkage.
Remove the linkage (Item 2) [Figure 50-100-7]. 1

P100783
Figure 50-100-8
Loosen the two mounting nuts (Item 1) [Figure 50-100-9]
from the pedal mounting bracket.
1
Figure 50-100-10
2
2
P-85675A
Remove the nut and bolt (Item 1) [Figure 50-100-8] from

the pedal linkage. P100782
Remove the linkage (Item 2) [Figure 50-100-8]. Loosen the nut and bolt (Item 1) [Figure 50-100-10] on
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable

“NEUTRAL” angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-100-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-110-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-100-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-130-1.)
Figure 50-100-11
1
1
P-85859 P-85860
Figure 50-100-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-100-11] and

[Figure 50-100-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-100-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-101-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
P-85675
WARNING Remove the nut and bolt (Item 1) [Figure 50-101-1] from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.
to fall and cause injury or death. Figure 50-101-2
W-2059-0598

DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-101-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-101-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-101-5
1 1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
101-3] from the foot sensor.
Figure 50-101-4
P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-101-5]

from the pedal mounting bracket.
Figure 50-101-6
1
1
P-90981 2
Remove the linkage (Item 1) [Figure 50-101-4] and the

rubber boot.
P-85675
Repeat for other side.
Loosen the nut and bolt (Item 1) [Figure 50-101-6] on
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable

“NEUTRAL” angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-101-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-110-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-101-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-130-1.)
Figure 50-101-7
1
1
P-85859 P-85860
Figure 50-101-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-101-7] and [Figure

50-101-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-101-8].

CONTROL PANEL
Description
Figure 50-110-1
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the NEUTRAL or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set NEUTRAL of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-110-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-110-3

• Keep out of this area when lift arms are raised 2
D-1009-0409
1
WARNING
P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598
the back-up alarm wires (Item 2) [Figure 50-110-2] and
[Figure 50-110-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation on
Page 50-110-2.)
Figure 50-110-4
Two Piece Shaft
Remove Control Panel. (See Removal And Installation on

2 Page 50-110-2.)
1 Figure 50-110-6
2
1 1
P-90612
2
2
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-110-4] which are connected to the
steering shaft on the control panel.
1 1
P-85864
Remove the four steering linkage mounting bolts, nuts
and rubber isolators (Item 2) [Figure 50-110-4].
Remove the nuts (Item 1) and the steering stabilizers
Inspect and replace any damaged parts. (Item 2) [Figure 50-110-6].
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-110-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-110-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-110-5].

Two Piece Shaft (Cont’d) 2
Figure 50-110-7
1
2 2
P-85867
1
3 1 3 3
3 Remove the four bolts (Item 1) [Figure 50-110-9] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-110-9].
Figure 50-110-8 Figure 50-110-10
4
3
1
1
P-85861 P-85868
Remove the nut and bolt (Item 1), steering link, (Item 2), Remove the tie straps (Item 1), the four nuts (Item 2), and
and washers (Item 3) [Figure 50-110-7] and [Figure 50- the plate (Item 3) [Figure 50-110-10].
110-8].
Remove the control handle (Item 4) [Figure 50-110-10].
Installation: Verify correct orientation of components
[Figure 50-110-7] and [Figure 50-110-8].

CONTROL PANEL (CONT'D) One Piece Shaft
Disassembly And Assembly (Cont’d) Remove Control Panel. (See Removal And Installation on
Page 50-110-2.)
Two Piece Shaft (Cont’d)
Figure 50-110-13
Figure 50-110-11
1 1
2
2
1 2 1
1 1
P-85864
P-85872
Remove the nuts (Item 1) and the steering stabilizers

Remove the two bolts (Item 1) from the bellcrank (Item 2) (Item 2) [Figure 50-110-13].
[Figure 50-110-11].
Remove the bellcrank from the bracket [Figure 50-110-

11].
Figure 50-110-12
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-110-12] for wear and
replace as needed.
Repeat the procedure for the other control handle

assembly.

CONTROL PANEL (CONT’D) Figure 50-110-16

1
One Piece Shaft (Cont’d) 2 2
Figure 50-110-14
1 1
2 2
P-85867
1
3 1 3 3
3 Remove the eight bolts (Item 1) [Figure 50-110-16] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-110-16].
Figure 50-110-15 Figure 50-110-17
4
3
1 1
P-85861 P-85868
Remove the bolts and nuts (Item 1), steering link, (Item Remove the tie straps (Item 1), the four nuts (Item 2), and
2), and washers (Item 3) [Figure 50-110-14] and [Figure the plate (Item 3) [Figure 50-110-17] on both sides.
50-110-15].
Remove the control handles (Item 4) [Figure 50-110-17].
Installation: Verify correct orientation of components
[Figure 50-110-14] and [Figure 50-110-15].

CONTROL PANEL (CONT’D) Figure 50-110-20

4
One Piece Shaft (Cont’d)
Figure 50-110-18
1
P126303
1 1
2
Inspect the shaft (Item 1), bellcrank (Item 2), four
bushings (Item 3) and the two torsion bushings (Item 4)
[Figure 50-110-20] for wear and replace as needed.
P126302
Linkage Removal And Installation
Figure 50-110-19
WARNING
2
2 Never work on a machine with the lift arms up unless
W-2059-0598
1
1
P126301
WARNING
P126310

Remove the two bolts (Item 1) from the bellcrank (Item 2) of the frame before running the engine for service.
[Figure 50-110-18] and [Figure 50-110-19]. Failure to use jackstands can allow the machine to
Remove the bellcrank assembly (Item 2) [Figure 50-110- W-2017-0286
18] and [Figure 50-110-19] from the bracket.
1.)


Linkage Removal And Installation (Cont’d)

1
Figure 50-110-21
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-110-22].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-110-21] which are connected to the Installation: Tighten the centering spring bolt and a
steering shaft on the control panel. NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-110-23
and rubber isolators (Item 2) [Figure 50-110-21].
Inspect and replace any damaged parts.

1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-110-12.)
P-48632
Slide the centering plate (Item 1) [Figure 50-110-23] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-110-24
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect the wear on the centering blocks (Item 1) [Figure
P-48630 50-110-25].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-110-25]. Remove the centering
of the following parts: blocks.
ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -

54,2 N•m (35 - 40 ft-lb) torque.
1 Bolt
2 Bushings NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer NOTE: If the centering blocks are worn, they can be
5 Spring removed and rotated 180 degrees and
6 Locknut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-110-26
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-110-28].

P-54617
Remove the pintle base (Item 2) [Figure 50-110-28].
Remove the bolts and washers (Item 1) [Figure 50-110- Figure 50-110-29
26] from the pintle.

ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-110-26].
Figure 50-110-27 2
1 3
1
2 P-48659
4
3 NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-110-29].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-110-29]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the nut and bolt (Item 1) [Figure 50-110-27].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the linkage neutral
steering control lever (Item 4) for damage and replace as adjusting procedure must be performed. (See
needed [Figure 50-110-27]. Linkage Neutral (Adjusting) on Page 50-110-
12.)
NOTE: The washers (Item 2) [Figure 50-110-27] are
hardened, and should only be replaced
through Bobcat Parts.

Pintle Arm Disassembly And Assembly

1
Earlier Model
Figure 50-110-30
4
2 2
4
3
P-54626
2
3 Remove the base pintle (Item 1) [Figure 50-110-32] from

the pump shaft.
1 Remove the retaining bolt (Item 2), adjusting screw (Item

P-54624 3) and neoprene dampener (Item 4) from the base pintle
[Figure 50-110-32].
Remove the nut (Item 1) from the pintle roller cams (Item Inspect parts for wear and damage, replace as needed
2) and inspect the pintle roller cams and washers (Item 3) [Figure 50-110-32].
for damage [Figure 50-110-30].
NOTE: Anti-seize should be used on the adjusting
Inspect the torsion bushing (Item 4) [Figure 50-110-30] screw to prevent corrosion and allow free
for damage and replace as needed. movement while adjusting.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40 Figure 50-110-33
ft-lb) torque.
Later Model
Figure 50-110-31
2 1
1
2
3
P-48619
Using a bushing driver (Item 1) remove the torsion

1 2 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-110-33].
NA15142
Installation: Install the torsion bushing (Item 2) [Figure

Later models have roller bearings (Item 1) and wear 50-110-33] into the pintle arm using the same procedure
cams (Item 2) [Figure 50-110-31]. as the removal.
NOTE: When the torsion bushing is installed, the

amount of bushing on each side of the pintle
arm should be the same.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
MEL1563 Remote Start Tool or 7217666 Remote Start 1

Tool (Service Tool) Kit.
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10- P-85845
1.)
Figure 50-110-34 Loosen the nut and bolt (Item 1) [Figure 50-110-35] only
until the tension is released from the torsion bushing.
3
Figure 50-110-36
2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
110-34].
To make this tool use a locking grip C-clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-110-36].
[Figure 50-110-34] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-110-34] is torsion bushing (Item 2) [Figure 50-110-36] to
also needed. The centering block can be placed as turn freely between the torsion bushing and
shown and welded to the C-clamp if desired. the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-110-37
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-110-37] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine startup to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-110-38
Tighten bolts (Item 3) [Figure 50-110-38] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-110-37] and
[Figure 50-110-38].
1
P-48451
A modified locking grip C-clamp and steering block

shown in [Figure 50-110-34] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-clamp (Item 2) [Figure 50-110-38]
around both centering blocks.
Lock the C-clamp in place.

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-110-39
2 1
1
P-54610
Move the engine speed control to high idle.
NOTE: The NEUTRAL range (dead-band) will vary

between the hydrostatic pumps.
P-48632 NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
Loosen the left pump pintle adjustment lock bolts NEUTRAL adjustment.
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-110-39].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-110-40]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
Turn the adjustment screw (Item 1) [Figure 50-110-40] to
NOTE: If the bolts are too loose or too tight, the a point between forward and reverse where there is zero
neutral adjustment may be affected. creep.
Stroke the left steering lever to forward and allow the

lever to return to NEUTRAL. Stroke the left steering lever
to reverse and allow the lever to return to NEUTRAL.
Check that there is zero creep when the lever returns
from either direction, on the left side. Turn the adjustment
screw (if necessary) until zero creep is obtained.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-110-41
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-110-41] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-110-41] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to NEUTRAL by the return spring
force.
If the levers do not return to NEUTRAL and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

110-41] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and reinstall the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with preapplied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-110-16.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, inspect the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the nut and bolt (Item 1) [Figure 50-110-42] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-110-43
1
WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-110-43].
Preload tension in the torsion bushings must be removed The bolts must be loose enough to allow the torsion
before adjusting the steering linkage. bushing (Item 2) [Figure 50-110-43] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-110-44
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
110-46].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-110-44] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-110-45 Figure 50-110-47
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-110-45]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-110-47].
Verify the cam mounting nuts (Item 4) [Figure 50-110-45]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-110-48
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-110-50].

P-85844
Figure 50-110-51
Loosen the two bolts and nuts (Item 1) [Figure 50-110-
48] on each steering linkage bar. 2
Figure 50-110-49
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-110-51].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-110-
49]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Inspect the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-110-52 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-110-53] and [Figure
50-110-54] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,05 m (10

ft) of “drift” in 30,48 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-110-53] and [Figure
50-110-54] in.
Tighten the two bolts and nuts (Items 1) [Figure 50-110- If the drift is excessive to the right, turn the left
52] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspection on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-110-53 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-110-55
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-110-55]

from the end of the shocks connected to the steering
linkages.
Remove the mounting nuts (Item 2) [Figure 50-110-55]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-111-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-111-1]

DANGER that secure the controller.
Figure 50-111-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-

111-2].
WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-111-2].
Never work on a machine with the lift arms up unless Remove the control panel (Item 3) [Figure 50-111-2].
W-2059-0598

CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-120-1
2
3
P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-120-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-120-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-120-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-120-2
P-85883A
Remove the rubber boot (Item 1) [Figure 50-120-2].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-121-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-121-1] that are Loosen the nuts (Item 1) [Figure 50-121-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-121-5
Handle Sensor Removal And Installation (Cont'd)
Figure 50-121-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-121-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector [Figure 50-121-3].
Figure 50-121-6
Disconnect the harness connector (Item 2) [Figure 50-
121-3] from the handle lock solenoid connector. 1
Figure 50-121-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-121-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-121-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-121-6].

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-121-9
Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-121-7
2
P-21878
1 Figure 50-121-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-121-7] from the handle sensor.
Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)

torque.
Figure 50-121-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, inspect the routing of the switch handle
4 wire harness (Item 1) [Figure 50-121-9] and [Figure 50-
3 121-10] to assure proper return of the control handle to
7 NEUTRAL and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-121-9] and
2
P-21882 [Figure 50-121-10] as shown away from stop
strap (Item 3) [Figure 50-121-9] and [Figure 50-
121-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-121-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-121-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-121-8] and
replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-121-13
Handle Removal And Installation
Figure 50-121-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 121-13] from the handle.
Figure 50-121-14
Remove the handle sensor (Item 1) [Figure 50-121-11].
(See Handle Sensor Removal And Installation on Page
50-121-1.)
Figure 50-121-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the Allen head screws (Item 2) [Figure
P16534 50-121-14] from the handle assembly.
Installation: Tighten the Allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-121-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT'D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-121-17
Figure 50-121-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-121-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-121-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-121-17] used to mount the control lever.
Figure 50-121-16 Remove the control lever (Item 4) [Figure 50-121-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-121-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT'D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-121-18
P-85883A
Remove the rubber boot (Item 1) [Figure 50-121-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC) Joystick Testing
Description See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to test function.
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.
50-122 - 1 S770 Service Manual

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-122-3
Joystick Removal And Installation

Figure 50-122-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

122-3] from the harness connector.
P-85890
Lift the rubber boot (Item 1) [Figure 50-122-1].
Figure 50-122-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-122-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.
50-122 - 2 S770 Service Manual

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-100-1.) Figure 50-130-2
Figure 50-130-1
1 1
1
1 2
3
2
3
P-85677A
P100732
Remove the four bolts (Item 1), washer (Item 2), and
remove the right access panel (Item 3) [Figure 50-130-
Remove the four bolts (Item 1), washer (Item 2), and 2].
remove the left access panel (Item 3) [Figure 50-130-1].

ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-131-3
Figure 50-131-1
2 2
1
P106589
P100731
Remove the two mounting nuts (Item 1) and remove the
footrest (Item 2) [Figure 50-131-3].
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-131-1]. Figure 50-131-4
Figure 50-131-2
1 1
2
P106590
2
P100732
NOTE: Mark the location of the foot pedal before
removal for correct assembly.
Remove the four bolts (Item 1), and remove the access
panel (Item 2) [Figure 50-131-2]. Loosen the bolt (Item 1) and remove the engine speed
control foot pedal (Item 2) [Figure 50-131-4].

ACCESS PANEL (INSIDE) (SJC) (CONT’D)
Removal And Installation (Right) (Cont’d)
Figure 50-131-5
2
1
1
P106591
Remove the four bolts (Item 1) and lay the right inside
access panel (Item 2) [Figure 50-131-5] down.
Figure 50-131-6
P107707
Disconnect the electrical connector (Item 1) from the

engine speed control (Item 2) [Figure 50-131-6].
Remove panel assembly from the loader.

WINDOW (REAR) There are two different procedures for removing the rear
window from your machine:
The front opening on the operator cab and rear window
provide exits. 1. This window is equipped with latches [Figure 50-140-
1].
Rear Window Identification
2. This window is equipped with a rubber cord and tag
Figure 50-140-1 [Figure 50-140-1].
Latches Rubber Cord NOTE: Use these procedures to remove the rear
window only under emergency conditions.
Damage to machine may occur.
2
1
P-85309B P-64994D
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 50-140-2 Figure 50-140-4
P-85309A P-64994C
Turn both latches (Item 1) [Figure 50-140-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 50-140-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 50-140-3 Figure 50-140-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 50-140- Exit through the rear of the operator cab [Figure 50-140-
3]. 5].

WINDOW (REAR) (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 50-140-6
Figure 50-140-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 50-140-8] up and out
[Figure 50-140-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
OR
Figure 50-140-7
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.
Turn both knobs (Item 1) [Figure 50-140-7]

counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.

WINDOW (TOP) Figure 50-141-3
Figure 50-141-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-141-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-141-1].
Figure 50-141-4
Figure 50-141-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-141-4] through the
adhesive (Item 2) [Figure 50-141-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-141-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-141-5].
Tighten the nuts (Item 1) [Figure 50-141-5] to 9 - 10 N•m

NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-142-3

1 1
Figure 50-142-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-142-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

142-3] to 9 - 10 N•m (80 - 90 in-lb) torque.
Figure 50-142-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-142-1] and [Figure 50-142-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-142-1]

flush to the end of the bolt.

CAB DOOR Figure 50-150-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Open the cab door.
Figure 50-150-1
P-85828
Lift the door (Item 1) [Figure 50-150-3] off the hinges.
Figure 50-150-4
2 1
P-85781A
NOTE: Later models route the washer fluid hose

differently and will not require this step.
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) (if equipped) [Figure 50-150-1].
Figure 50-150-2
2
3
2 1
1 P-85837
Remove the four bolts and nuts (Item 2) [Figure 50-150-

4] from the cab.
P-85588A P-85589A
Remove the hinges (Item 1) [Figure 50-150-4] from the

Rotate and pull the clip (Item 1) out of the gas spring cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-150-2]. Installation: Install the hinges (Item 1) on the cab and
use the bolts and nuts (Item 2) [Figure 50-150-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

CAB DOOR (CONT’D) Figure 50-150-7

2
Figure 50-150-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-150-7].
Figure 50-150-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-150-5].
2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

150-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-150-1.) P-85835
Figure 50-150-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-150-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-150-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-150-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-150-11
Figure 50-150-9 WRONG WRONG
1 1
4
3 P106381
4
P-85836
Figure 50-150-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-150-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

Figure 50-150-10
1 1
3
P106382
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-150-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-150-

4.)
2
2 When the striker or latch is adjusted properly there will be
P106380 no gap (Item 1) [Figure 50-150-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-150-10]. After verifying alignment inspect for proper operation.
(See Checking Operation on Page 50-150-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-150-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-150-15
Figure 50-150-13
2
1
P-85413F
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-150-13] and LOADER button (Item 1) [Figure 50-150-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-150-14 [Figure 50-150-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-150-15] will go out and the display will return
to machine hours.
P106587
Loosen the striker and adjust as needed (Item 1) [Figure

50-150-14].
After adjusting the striker and latch inspect the alignment

of the door sensor. (See Aligning on Page 50-150-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-160-1
P-90837
Adjustable armrests (Item 1) [Figure 50-160-1].

ARMREST (CONT’D) Figure 50-160-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Figure 50-160-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-160-4] from the seat.
1 Repeat for the other side.
P-90835

2].
Figure 50-160-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-160-3].
Remove the nut (Item 3) [Figure 50-160-3].
Remove the armrest (Item 4) [Figure 50-160-3] from the

seat.

Remove the Joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-160-2.)
Figure 50-160-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-160-7].
Figure 50-160-8
1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-160-5].
Figure 50-160-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-160-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-160-6].

Figure 50-160-9
3 1 1
2 2
1 P-90844
Remove the two nuts (Item 1) and the slide rail (Item 2)
P100825 [Figure 50-160-11] from the armrest mount.
Repeat for the other side.

Figure 50-160-10
7 4
6 3
5 2
1
P100824
Remove the nut (Item 1), washer (Item 2) and spring

(Item 3) [Figure 50-160-9].
Remove the spacer (Item 4), washer (Item 5), plastic

washer (Item 6) and the bolt (Item 7) [Figure 50-160-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

LEFT SIDE LOWER PANEL Figure 50-170-3
Raise the operator’s cab. (See Raising on Page 10-30-2.)
Figure 50-170-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1
[Figure 50-170-3] from the left side lower panel.
P-90897 Figure 50-170-4
Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1
31-4.)
Lower the operator’s cab. (See Lowering on Page 10-30- 1

3.)

P-90856
Figure 50-170-2
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-170-7
Figure 50-170-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-170-7] from the panel.
Figure 50-170-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-170-5].
Figure 50-170-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-170-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-170-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-9 1
1 1
1 1
1
1 P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-170-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-170-9] (if equipped). Figure 50-170-11
P-90865
NOTE: If the three clips (Item 1) [Figure 50-170-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-170-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.
Figure 50-170-13
P-90864
Remove the three screws (Item 1) [Figure 50-170-13]

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-180-3
Removal And Installation 2
Raise the operator’s cab. (See Raising on Page 10-30-2.)

1
Figure 50-180-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-180-3].
P-90897 Figure 50-180-4
Remove the five plastic rivets (Item 1) [Figure 50-180-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.) 2
Lower the operator’s cab. (See Lowering on Page 10-30-

1
3.)
Figure 50-180-2
1 P106595
1
1 Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-180-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-180-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-180-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-180-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-180-5] power port from the right side lower panel.
rear out and away from the side of the cab.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new lock washer when it has been
side of the cab far enough to access the wire removed.
harness.
Figure 50-180-8
Figure 50-180-6
2 1
1
2 P-90877
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-180-8] and remove

Disconnect the wire harnesses (Item 1) and the antenna the radio from the right side lower panel.
(Item 2) [Figure 50-180-6] (if equipped with radio).
Installation: Insert a screwdriver into the slot (Item 2)
NOTE: Install the right side lower panel with the radio [Figure 50-180-8] to lock the tab into place.
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-180-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

180-9] from the input.
Remove the input from the right side lower panel.
Figure 50-180-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.

HEADLINER Figure 50-190-3
Figure 50-190-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-190-3] (if

P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation on Page 60-60-2.)
2) [Figure 50-190-1] (if equipped).
Figure 50-190-4
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
1
1
Figure 50-190-2
1
1
2
1 P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-190-4].
Installation: Route the cab light wire harness in the

P-90894 groove on the topside of the headliner (if equipped with
HVAC).
Remove the air duct (Item 1) [Figure 50-190-2] (if NOTE: Replace the retainers if needed.
equipped).

FAN DUCT PANELS Figure 50-200-3

1
Remove the fan duct. (See Fan Duct Removal And 2

Figure 50-200-1
P122398
2 Remove the bolt (Item 1) and remove the bracket (Item 2)

[Figure 50-200-3].
Figure 50-200-4
1
1
P122396
Remove the bolts (Item 1) and remove the panel (Item 2) 1

[Figure 50-200-1].
Figure 50-200-2
P122399
Remove the bolt (Item 1) [Figure 50-200-4].
P122397
Remove the hose clamp bolt (Item 1) [Figure 50-200-2].

FAN DUCT PANELS (CONT’D)
Figure 50-200-5
3 2
P122400
Remove the bolt (Item 1) and move the hose (Item 2) out
of panel slot (Item 3) [Figure 50-200-5].
Figure 50-200-6
1
2
P122401
Remove the bolt (Item 1) and the panel (Item 2) [Figure

50-200-6].

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Manual Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Mainframe SJC, AHC, ACS Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-11
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-11
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
DOSING CONTROL UNIT (DCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
Removal And installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-4
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
CAMSHAFT AND CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

ENGINE COMPARTMENT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 60-240-1

TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-2

CONNECTOR ASSIGNMENTS
NUM NUM NUM NUM
CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 T1 BATT GROUND 1 6
C103 TAILGATE HARNESS 8 6,14,15,17 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 T2 BUZZER GROUND 1 12
C104 TAILGATE FANS 4 9 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 T3 FLASHER 2 17
C105 HYD CHARGE PRESSURE 3 11 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6
T4 MEGAFUSE 1 4
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C350 AC EVAPORATOR SWITCH 2 16 C499 PTOL 4 12 T6 BATT GROUND 1 6
C111 MFR-BCT ENG HARN CONN 3 9 C355 FUEL HARNESS 6 9,17 C500 RH KEY SWITCH 6 12 T8 BATT GROUND 1 6
C112 HYD OIL FILTER SWITCH 2 11 C404 BACK UP ALARM 2 5,14 T10 ENGINE SYSTEM GROUND 1 6
C113 RIGHT TAILGATE FAN CONN 2 9 C405 AIR FILTER SWITCH 2 9 C503 RH DLX PANEL 6 7,12 T13 BUZZER POWER 1 12
C114 HAND THROTTLE 6 9 C406 FUEL SENDER 2 9 C602 LEFT REAR TAIL LIGHT 2 15 T14 PRE HEATER 1 9
C116 FOOT THROTTLE INTMD 3 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C603 RIGHT REAR TAIL LIGHT 2 15 T15 RIGHT REAR WORK LIGHT(+) 1 15
15,17
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C606 POWER BOBTACH OPEN 2 17 T16 RIGHT REAR WORK LIGHT(-) 1 15
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C607 POWER BOBTACH CLOSE 2 17 T17 LEFT REAR WORK LIGHT (+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C610 HVAC DUCT FAN 2 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C611 BLOWER MOTOR 4 16 T19 BACKUP ALARM 1 14
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C630 THERMOSTAT 3 16 T20 BACKUP ALARM (GND) 1 14
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C635 HEATER VALVE 6 16 T26 FUSE 150 AMP 1 9
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C667 DOOR HARNESS 6 13 T27 PRE HEATER CONTACTOR PWR 1 9
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C670 EXTERIOR BEACON HARNESS 6 17 T29 BATTERY 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C676 RADIO 6 17
T32 ECU CASE GND 1 6
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15,
T31 PREHEATER 1 9
16
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 J1A GATEWAY CONTROLLER 34 5,9,11,12, T33 DCU CASE GND 1 10
14,15,16,17
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 1 13
T37 DOME LIGHT +
VALVE 12,14,13,17
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J2A AUX CONTROLLER 34 11,14,17 1 13
T38 DOME LIGHT -
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 9
T42 PREHEATER FDBK
14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 SW2 BEACON SWITCH 6 17
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW3 HAZARD SWITCH 6 17
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW5 POWER BOBTACH SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW6 BUCKET POSITION SWITCH 6 17
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW9 TRAVEL CONTROL SWITCH 6 12
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW10 BLOWER SWITCH 5 16
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW11 AC SWITCH 3 16
C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW12 DPF SWITCH 10 12
WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 1 of 18
(PRINTED DECEMBER 2016)

Printed In U.S.A. 7226989 (B)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN (BASE) B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL A-4 RIGHT BLINKER RELAY B-4
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5
A-6 B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK A-7 B-7
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE A-10 REAR AUX (M) RETURN B-10
A-11 AC SENSE B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL A-12 RH PADDLE LEFT B-12
A-13 TRACTION PULL FDBK RELAY- D B-13 BICS HYD LOCK HOLD A-13 RH RIGHT ROCKER UP B-13 FRONT AUX (F) (BASE)
A-14 B-14 CAN HI 2 A-14 B-14 CAN HI 2
A-15 B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR A-17 B-17 RH PWM LO
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M) (ROD)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 FLOAT B-20 CAN LO 2
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY A-21 B-21 RH TRIGGER RETURN
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED PWR
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 RH PWM HI
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 RIGHT FAN FDBK RELAY - C B-25 TWO SPEED MAKEUP A-25 B-25
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED MAKE-UP RETURN A-27
A-28 REAR LIGHT FDBK RELAY - E A-28 LH RIGHT ROCKER UP
A-29 A-29
A-30 HVAC FDBK RELAY - B A-30 RH LEFT ROCKER UP
A-31 FRONT LIGHTS FDBK RELAY - K A-31 RH LEFT ROCKER DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 FOOT THROTTLE A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

LF MFR MAN
DLX CAB
7267010
7253375
WIRING SCHEMATIC Printable Version Click Here
DLX FUEL
BCT ENG
7266824
7242470
(MANUAL MACHINE)
TAILGATE DOM
SUSP JSTK
7267103
7163706
S770 (S/N AT5A11001 - AT5A11533)
BRAKE ADAPTER
WHL 2 SPD ADP
7234968
7159366
S770 (S/N B3BV11001 - B3BV11242)
TRK 2 SPD ADP 7243409
Sheet 2 of 18

LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
3 SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
SIGNAL OPTIONS PAGE 17
13 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
14
15
19 ECU RUN SIGNAL

21
24
25
26
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
33
34 WATER FUEL SENSOR

GROUND
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL
WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 3 of 18

Printed In U.S.A.
7226989 (B)
UNSWITCHED BATT POWER C408
(BLACK)
1240 RED/WHT
SHEET 12
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 12
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 12
SP2 C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36
1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
T4
SHEET 9
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FUSE 3 30 A FRC1 HVAC RELAY
1310 RED 1360 RED/WHT SHEET 11
FRC 1 TRACTION LOCK RELAY
FUSE 1 15 A 1320 RED/WHT
SHEET 15
1350 RED/WHT FRC1 REAR LIGHT RELAY
FUSE 2 20 A SHEET 15
SP26 SHEET 15 FRC1 FRONT LIGHT RELAY
FRC1 FRONT LIGHT RELAY
1335 RED FUSE 20 5 A

1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
1325 RED FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
SHEET 5
1445 RED/WHT FRC 1 ENGINE ECU RELAY
SHEET 9
FUSE 18 25 A FRC1 PRE HEATER RELAY
C426 REMOTE RUN, ACD

1095 RED 1100 RED/WHT HEATER HOSE RELAY
SHEET 10
1220 RED 1230 RED/WHT DCU POWER

WIRING SCHEMATIC
SHEET 10
1045 RED 10 1105 RED/WHT 10 SHEET 9

(MANUAL MACHINE)
1460 RED/WHT
SHEET 17
1040 RED FUSE 22 25 A
TAILGATE FANS RELAY PWR
1490 RED/WHT
C412 LH HANDLE HORN
1410 RED/WHT
S770 (S/N AT5A11001 - AT5A11533)
SHEET 17
1055 RED
SP60
1290 RED
FUSE 24 25 A
1370 RED/WHT
SP24
SHEET 13
C408 CAB-MFR CONN
(OPTIONS) S770 (S/N B3BV11001 - B3BV11242)
C408 CAB-MFR CONN
(ACCESSORIES) Sheet 4 of 18
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
1030 RED
SHEET 9
Printed In U.S.A. FRC1 STARTER RELAY
7226989 (B)
FRC1
1525 RNG
SCR INTERCONNECT
SHEET 8
SWITCHED POWER
J7A ENGINE ECU
ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP54
87 1540 RNG/WHT SP73 1545 RNG/WHT 1507 RNG/WHT 3
1535 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45
FRC1 FUSE RELAY CENTER

SHEET 4 1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT SHEET 9
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A SP50 C489

1750 RNG/WHT 1780 RNG/WHT A MFR ACCESSORY
FUSE 6 25 A 1850 RNG/WHT
1760 RNG/WHT SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL
1940 RNG/WHT
1520 RNG/WHT SHEET 12 T13 LH PANEL BUZZER
SHEET 14 C410 LEFT HANDLE 1930 RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1530 RNG/WHT SHEET 14 C409 RIGHT HANDLE 1775 RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1570 RNG/WHT SP11
1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 13 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT SP42 1590 RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
1765 RNG/WHT FUSE 7 25 A
1795 RNG/WHT 1730 RNG/WHT SP65 1735 RNG/WHT
SP25 SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN Printable Version Click Here
POWER RELAY - A FUSE 8 25 A
+12V 1580 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR
SHEET 4 1050 RED 30
87 1815 RNG/WHT
SHEET 9 ALT EXCITATION
WIRING SCHEMATIC
SHEET 6
2055 BLK GND 85 86
(MANUAL MACHINE)
3450 LBL 21
J1A
GWY CTRLR
C428
(LT GRAY) S770 (S/N AT5A11001 - AT5A11533)
3380 LBL 4 CAB-MFR HARN CONN 2
1920 RNG/WHT 9 1920 RNG/WHTSP37 1840 RNG/WHT SHEET 7

C449 LH JOYSTICK
S770 (S/N B3BV11001 - B3BV11242)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 18
Printed In U.S.A.
7226989 (B)
2320 BRN
SHEET 11
GROUND
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 11
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 9
C405 AIR FILTER SWITCH
T32 2004 BLK
ECU CASE GND SHEET 9 2690 BRN
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C120 SCR-MFR CONN
2430 BRN 18
SHEET 9
SHEET 7 2080 BLK
ENGINE TEMP GND
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL SHEET 15
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SP3 SHEET 16
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
2250 BLK GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES)
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SP47 1 SP28
2830 BLK 2900 BLK 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK
SP51 2600 BLK 2390 BLK 10
T20 BU ALARM B 2600 BLK T1 2015 BLK T10
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 SP6
SHEET 9 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2455 BLK
2630 BLK SHEET 17
SHEET 15 C423 BKT POSITION SOLENOID
T18 LH REAR LIGHT 2710 BLK 2300 BLK
SHEET 7
C426 REMOTE RUN, ACD SP27
2715 BLK Printable Version Click Here
SHEET 8
C169 ENGINE CAN
2290 BLK
SHEET 15 2045 BLK

SHEET 16
D4 COMPRESSOR DIODE WIRING SCHEMATIC
FRC1 REAR LIGHT RELAY 2295 BLK 18
SHEET 11 2035 BLK SHEET 9
TAILGATE FANS RELAY GND (MANUAL MACHINE)
FRC1 TRACTION LOCK RELAY
SHEET 15
2115 BLK SP55 2105 BLK
2520 BLK
SP5 2000 BLK
S770 (S/N AT5A11001 - AT5A11533)
2055 BLK SHEET 14
SHEET 5
FRC1 SWITCHED POWER RELAY
C410 LEFT HANDLE
SHEET 14
2530 BLK
S770 (S/N B3BV11001 - B3BV11242)
SHEET 16 2030 BLK C409 RIGHT HANDLE
FRC1 HVAC RELAY
2005 BLK
Sheet 6 of 18
SHEET 9
FRC1 STARTER RELAY
2120 BLK
SHEET 15 (PRINTED DECEMBER 2016)
J1B
GWY CTRLR
C408
(BLACK)
CAB-MFR HARN CONN 1
CAN BUS
8 SP31 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO 9260 PUR 9230 PUR C479
9 9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
AUX CTRLR SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426 Printable Version Click Here

AUX CTRLR Remote Run Tool, ACD
CAN HI
20
14 9500 PUR/WHT
9600 PUR
A
B
WIRING SCHEMATIC
CAN LO
(MANUAL MACHINE)
J1B
S770 (S/N AT5A11001 - AT5A11533)
GWY CTRLR
S770 (S/N B3BV11001 - B3BV11242)
21 3090 LBL D
C
REMOTE RUN KEY
Sheet 7 of 18
1735 RNG/WHT E
SHEET 5 SWITCHED POWER
1165 RED/WHT F
SHEET 4 UNSWITCHED POWER
2710 BLK G
SHEET 6 GROUND (PRINTED DECEMBER 2016)
J7A
ECU CNTRLR
ENGINE CAN BUS C121
DOSING CONTROL UNIT
SP81 SP90
47 9200 PUR 9215 PUR 9415 PUR 9210 PUR SP67 9265 PUR SP71 9275 PUR SP70 9245 PUR 65
CAN LO 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR
NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
SHEET 10 2870 BLK

NOx GROUND SP78 C164
NOx POST TREATMENT
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1
1525 RNG 1645 RNG/WHT

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
C169
1640 RNG/WHT 4
ENGINE CAN
9225 PUR 1
1 1725 RNG/WHT 2
SHEET 5 9125 PUR/WHT
2 2715 BLK 2825 BLK 3
SHEET 6 SHEET 10
3 9155 PUR/WHT
4 9255 PUR C121
DOSING CONTROL UNIT
5 9720 PUR/WHT 82 CAN HI
6 9820 PUR 60
CAN LO
(MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 8 of 18

SHEET 4 1030 RED
PWR 30
FRC1
STARTER RELAY - M
+12V
87
ENGINE 8200 TAN
3560 LBL
C111
MFR-BCT HARN CONN
A
B
8220 TAN
3560 LBL
STARTER
S
R
M
B SHEET 4
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND AIR FILTER 2015 BLK
SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
FRC1
TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 C171 LEFT TAILGATE
87 TAILGATE FANS CONN
A B
FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 68105 TAN 14 3 8105 TAN 14 FUSE 15 A
TAILGATE FANS RELAY GND
4 C113
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 2405 BLK 14
SHEET 6 C172 RIGHT TAILGATE
TAILGATE A B
J1B FAN CONN
C355 FANS GND
GWY CTRLR FUEL HARN 8135 TAN 14 A
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
10 2180 BRN D 2180 BRN B GND
3690 LBL SHEET 6 (30 - 270 OHM)
C120 C428 INTAKE HEATER

SHEET 6 (LT GRAY) +12V
ENGINE CONTACTOR
2430 BRN 18 2 C114 PWR
TEMP CAB-MFR HARN CONN 2 HAND THROTTLE FUSE 150 A
18 T29 30
3110 LBL 18 1 SENSOR SHEET 13 5690 YEL 1060 RED 1 2 1065 RED 87 SP77 8500 TAN
7 5690 YEL C +5V PWR 8515 TAN T14
(950-4400 OHM)
T26 T27 85
3690 LBL 6 3690 LBL A 86 1445 RED/WHT
SIG
4 2690 BRN 8 2690 BRN B GND SHEET 4
8007 TAN
8510 TAN 8505 TAN T31
SHEET 6 D
E
J7A F
ENG ECU CTRLR 8020 TAN SP74
SHEET 10
WIRING SCHEMATIC
19 8008 TAN
C100
(MANUAL MACHINE)
9
34
3865 LBL
2865 BRN
1
2
SIG WATER IN FUEL SENSOR
(FUEL FILTER)
S770 (S/N AT5A11001 - AT5A11533)
GND
56 S770 (S/N B3BV11001 - B3BV11242)
C118
28 8013 TAN ENG-CROSSOVER Sheet 9 of 18
1511 RNG/WHT 1
35 8014 TAN SHEET 5
8013 TAN 2 FREQ
8014 TAN 3 TEMP (PRINTED DECEMBER 2016)
3420 LBL 4
Printed In U.S.A. T42 7226989 (B)
DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
DCU CASE GND
85 86
2915 BLK
C121
DOSING CONTROL UNIT
SP62
1230 RED/WHT 1245 RED/WHT 5 93 8310 TAN
SHEET 4 1265 RED/WHT 6
71 C123
1255 RED/WHT 73 HOSE 1 HEATER
67
2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
SHEET 6 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 SP88 8330 TAN 30
8140 TAN
SHEET 8 72 8340 TAN
Nox Ground 87 2955 BLK SP86
2870 BLK 2855 BLK 29
C124
SHEET 8 85 86 HOSE 2 HEATER
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 8260 TAN 8250 TAN 30
SP89 87 2965 BLK
C156 C125
2140 BRN 85 86 HOSE 3 HEATER
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
CATALYST TEMPERATURE
2 2025 BRN 61 2125 BRN 85 86
SCR INLET
28 8600 TAN
C158
1 8520 TAN 62
C122
SCR OUTLET 2 2160 BRN 84
SUPPLY MODULE
WIRING SCHEMATIC
C159 11
ENVIRONMENTAL TEMPERATURE
1 8800 TAN 31
4 1690 RNG/WHT
12
HEATER BATT+ (MANUAL MACHINE)
3 8650 TAN
2 9 HEATER SIGNAL
2050 BRN
55 1695 RNG/WHT
3
PUMP MOTOR BATT +
S770 (S/N AT5A11001 - AT5A11533)
C160 2
1 8530 TAN 18 TXL 34
76 8700 TAN
4
PUMP MOTOR CONTROL SIGNAL S770 (S/N B3BV11001 - B3BV11242)
54 2095 BRN PUMP MOTOR GND
DOC INLET 2 2075 BRN 18 TXL 12
77 1680 RNG/WHT 5
PURGING PUMP BATT +
Sheet 10 of 18
78 8750 TAN 6
PURGING PUMP SIGNAL
10
17 1685 RNG/WHT PRESSURE SENSOR BATT+ (PRINTED DECEMBER 2016)
39 9
Printed In U.S.A.
3000 LBL PRESSURE SENSOR SIGNAL 7226989 (B)
40 2085 BRN 8
PRESSURE SENSOR GND
PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
C425
B C308
BRAKE
SHEET 4 1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
WIRING SCHEMATIC
J2A 18 2 FRONT ROD
AUX CTRLR
2330 BRN
4330 LGN 1
GND
SIG SOLENOID (MALE) (MANUAL MACHINE)
3.3 OHM PWM
C419 S770 (S/N AT5A11001 - AT5A11533)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM
S770 (S/N B3BV11001 - B3BV11242)
Sheet 11 of 18
19 13
J2B (PRINTED DECEMBER 2016)
AUX CTRLR
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
T2
LEFT PANEL
BUZZER
C479
CAB DISPLAY C499
Press To Operate Loader
(PTOL)
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408
2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 14
SHEET 6 LEFT PANEL (GRAY) 3040 LBL 3040 LBL 4
GWY CTRLR RUN/ENTER SWITCH
3620 LBL 12
SHEET 13 DOOR SIGNAL
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
8060 TAN 1 6
3
WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 12 of 18

SW4
*
HAND/FOOT
CAB
(ACS)
H/ISO
(SJC, AWS)
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3
C438 2060 BLK 5 6
SHEET 13
(DK GRAY)
CAB-MFR HARN CONN 3
4 * DLX CAB HARN 7253375 ONLY
7 4235 LGN (NOT IN STD CAB HARN)
8 4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* T37
DOME LIGHT (+)
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR
11 3370 LBL 5 3370 LBL B SIG
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR WIRING SCHEMATIC Printable Version Click Here
HARNESS WASHER PUMP
SHEET 9 5690 YEL 7253378 (MANUAL MACHINE)

S770 (S/N AT5A11001 - AT5A11533)
* C252
A
C253
1
PWR
WASHER
S770 (S/N B3BV11001 - B3BV11242)
7310 WHT
MOTOR
2845 BLK B 2845 BLK 2 GND Sheet 13 of 18

MANUAL CONTROLS J2A SHEET 6
2530 BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
K
AUX CTRLR G
C404 A
C103 1530 RNG/WHT
BU ALARM-MFR HARN SHEET 5
TAILGATE HARN 30 4940 LGN H
T19 TERMINAL (+)
(SEE ADDITIONAL 31 4930 LGN J SKI CTRL
A 7100 WHT C 7100 WHT
OPTIONS DWG) 4920 LGN E DETENT FLOW
BACK UP
2650 BLK ALARM 13 4910 LGN F
SHEET 6 TWO SPD
4310 LGN C
T20 TERMINAL (-) 4320 LGN D
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 TILT SPOOL LOCK 20 4640 LGN D
SIG
2 7.8 OHM 12V 28 4840 LGN C
22 4830 LGN B SKI CTRL
C422 12 4820 LGN G
2 2990 BRN 3 11 4810 LGN F SIDE SHIFT
GND
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG SHEET 5
7.8 OHM 12V J
2
H
2520 BLK E
SHEET 6
7 5 WIRING SCHEMATIC
J1B
GWY CTRLR (MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 14 of 18

LIGHTS
C434-1
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
2760 BLK B GND WORK LIGHT
FRC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - J C435-2
(DK GRAY)
6130 PNK A SIG
CAB-MFR HARN CONN 3 RIGHT FRONT
87 6610 PNK 13 50.00 Watts
6610 PNK
2120 BLK 85 86 SP64

SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SP10 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
6210 PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
+12V RELAY - E
PWR 30 T17 TERMINAL (+)
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SP96 6220 PNK SIG LEFT REAR
2630 BLK GND WORK LIGHT
GND 85 86 SHEET 6
SHEET 6 2045 BLK
T18 TERMINAL (-)
(MANUAL MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 15 of 18

2440 BLK * C610
2 GND HVAC DUCT
7440 WHT 1 SIG FAN
HVAC 2560 BLK

7420 WHT
7425 WHT
* C483
C
A
B
BLK
DBL
WHT
POTENTIOMETER
(TEMP CONTROL
SWITCH)
C635
* D SIG
* DLX CAB HARN 7253375 ONLY 2130 BLK

7430 WHT
C GND
A +12V PWR
HEATER
VALVE
SP48
B
(NOT IN STD CAB HARN) E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 6
3 7530 WHT * C611
1 14.00 Amps High
3 7410 WHT 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
AC SWITCH 2580 BLK 4
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT Printable Version Click Here
AC EVAPORATOR C350 2570 BLK 2
SWITCH B
A
7023 WHT
7024 WHT
7020 WHT 1
WIRING SCHEMATIC
C486 (MANUAL MACHINE)
7025 WHT 1 SIG
2 GND
MAGNET CLUTCH
(COMPRESSOR)
S770 (S/N AT5A11001 - AT5A11533)
2290 BLK 2280 BLK
SHEET 6
D4 S770 (S/N B3BV11001 - B3BV11242)
Sheet 16 of 18
#
SIG
C607
1 4470 LGN
C355
FUEL HARN
E 4470 LGN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
11 4470 LGN
#
OPTIONS
DLX FUEL HARN 7266824 ONLY
POWER BOB 2 B
GND 2470 BLK 2770 BLK 2770 BLK
CLOSE SHEET 6
SW5
4480 LGN
(NOT IN STD FUEL HARN 7149219)
*POWER 2 1
# C606 BOBTACH 3
POWER BOB
GND 2 2480 BLK SWITCH 5 4
6
* DLX CAB HARN 7253375 ONLY
SIG 1 4480 LGN F 4480 LGN 10
OPEN
6010 PNK 13 6010 PNK
(NOT IN STD CAB HARN)
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT
C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* FLASHER
T3
LEFT HANDLE CONN

C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 *BUCKET
SW6
6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2
RIGHT
*- C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
SHEET 13
4 + 1 2210 BLK 5 GND
SHEET 13 1885 RNG/WHT SHEET 13
3 2 6
J2A
SHEET 13 2885 BLK
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW
4460 LGN A SIG
SOLENOID
7.5 OHM 12 V WIRING SCHEMATIC Printable Version Click Here
J2B
AUX CTRLR
26
(MANUAL MACHINE)
J1A 26 2350 BRN
C441
2 GND TWO SPEED TRACK 2 SPEED
S770 (S/N AT5A11001 - AT5A11533)
ADAPTER
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V (SEE ADDITIONAL
OPTIONS DWG)
S770 (S/N B3BV11001 - B3BV11242)
J1B 26
GWY CTRLR Sheet 17 of 18

TO C118 - Pin 4
See Sheet 9 of 18
PRE HEATER 179 J7B
ENG ECU CTRLR
ENGINE
(DOOSAN HARNESS)
106
123
TEMP SENSOR 2
SENSOR RETURN 2
2
1
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
HARNESS WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
C136 BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1 EGR VREF3 164 TO C113 PIN 3
4 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
See Sheet 9 of 18
5 POSITION SIGNAL 116 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
120 SENSOR GROUND 3
EGR VALVE 3 172 MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
POSITION RETURN MAF
DC MOTOR 137 5V 2 HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
6 H BRIDGE POS 192 SENSOR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
TO C113 PIN 2 1
2 H BRIDGE NEG 193 LIGHTS 6000 THROUGH 6999 PINK PNK
See Sheet 9 of 18
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999 TAN TAN
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
SCHEMATIC INDEX
COOLANT TEMP 1 COOLANT TEMP SENSOR 109 OVERVIEW PAGE 1-3
SENSOR
165 VREF3 OIL PRESSURE POWER PAGE 4-5
2 COOLANT RETURN 145
111 OIL TEMPERATURE SENSOR OIL PRESSURE & GROUND PAGE 6
TEMPERATURE CAN BUS PAGE 7
148 RETURN GRD SENSOR
FUEL TEMP 1 FUEL TEMP SENSOR 110 ENGINE PAGE 8-9
SENSOR 104 OIL TEMPERATURE SENSOR HYDRAULICS PAGE 10
2 FUEL RETURN 146
CAB DISPLAY PAGE 11
CAB PAGE 12
2 SENSOR SIGNAL 131 MANUAL CONTROLS PAGE 13
ENGINE BLOCK
ACCELEROMETER 1 LIGHTS PAGE 14
1 SENSOR RETURN 130
HVAC PAGE 15
SHIELD 128
OPTIONS PAGE 16
LEGEND
2 SENSOR SIGNAL 132
ENGINE BLOCK . PARTIAL CONNECTOR
ACCELEROMETER 2 1 SENSOR RETURN 133 169 1
RETURN INTAKE
SIGNAL 129 MANIFOLD
194 SENSOR 2
TEMPERATURE
CRANKSHAFT 1 CRANK POSITION SENSOR 160

POSITION CONNECTOR
SENSOR 2 CRANK SENSOR NEG 136
NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141 C138
1 SENSOR RETURN 147 WIRE BREAK
141 INTAKE MANIFOLD PRESSURE B
CAM SHAFT (TWO WIRE BREAKS
2 POS SENSOR 159
SENSOR 112 INTAKE PRESSURE SENSOR A JOIN ONE WIRE)
TO C118 - Pin 1 INLET TEMP
3 VREF1 CAM SHEET #
167 INTAKE PRESSURE RETURN D PRESSURE
See Sheet 9 of 18 SENSOR
RAIL PRESSURE
1 RAIL PRESS URE SENSOR 135 WIRING SCHEMATIC Printable Version Click Here
2 SENSOR RETURN 119
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA 1 (MANUAL MACHINE)
CYL 1
1 FUEL INJECTOR HSDB 151

126 FUEL INJECTOR LSD1A 2
S770 (S/N AT5A11001 - AT5A11533)
CYL 3
FUEL INJECTOR LSD1B 175
2 150
174
FUEL INJECTOR HSDB 2
1 CYL 2
S770 (S/N B3BV11001 - B3BV11242)
FUEL INJECTOR LSD2B
CYL 4 1
FUEL INJECTOR HSDA
FUEL INJECTOR LSD2A
103
125
Sheet 18 of 18
2 177 2
PWM INLET METERING
1 VALVE
TO C118 - Pin 1
See Sheet 9 of 18
NUM NUM NUM NUM
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW12 DPF SWITCH 10 12
C103 TAILGATE HARNESS 8 6,14,15,17 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 T1 BATT GROUND 1 6
C104 TAILGATE FANS 4 9 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 T2 BUZZER GROUND 1 12
C105 HYD CHARGE PRESSURE 3 11 C350 AC EVAPORATOR SWITCH 2 16 C499 PTOL 4 12 T3 FLASHER 2
17
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C355 FUEL HARNESS 6 9,17 C500 RH KEY SWITCH 6 12 T4 MEGAFUSE 1 4
C111 MFR-BCT ENG HARN CONN 3 9 C404 BACK UP ALARM 2 5,14 T6 BATT GROUND 1 6
C112 HYD OIL FILTER SWITCH 2 11 C405 AIR FILTER SWITCH 2 9 C503 RH DLX PANEL 6 7,12 T8 BATT GROUND 1 6
C113 RIGHT TAILGATE FAN CONN 2 9 C406 FUEL SENDER 2 9 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C114 HAND THROTTLE 6 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C603 RIGHT REAR TAIL LIGHT 2 15
15,17 T13 BUZZER POWER 1 12
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C606 POWER BOBTACH OPEN 2 17 T14 PRE HEATER 1 9
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C610 HVAC DUCT FAN 2 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C676 RADIO 6 17 T27 PRE HEATER CONTACTOR PWR 1 9
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15, T29 BATTERY 1 9
16
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 J1A GATEWAY CONTROLLER 34 5,9,11,12,
T31 PREHEATER 1 9
14,15,16,17
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11
VALVE 12,13,14,17
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J2A AUX CONTROLLER 34 11,14,17 T33 DCU CASE GND 1 10
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 13
T37 DOME LIGHT +
14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9 1 13
T38 DOME LIGHT -
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 RC1 FRONT WORK-LIGHTS RELAY 4 15 T42 PREHEATER FDBK 1 9
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 RC2 FRONT WORK-LIGHTS RELAY 4 15
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW2 BEACON SWITCH 6 17
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW3 HAZARD SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW5 POWER BOBTACH SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW6 BUCKET POSITION SWITCH 6 17
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW9 TRAVEL CONTROL SWITCH 6 12
C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW10 BLOWER SWITCH 5 16
C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW11 AC SWITCH 3 16

WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 1 of 18
Printed In U.S.A. 7281509
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN (BASE) B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL A-4 RIGHT BLINKER RELAY B-4
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5
A-6 B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK A-7 B-7
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE A-10 REAR AUX (M) RETURN B-10
A-11 AC SENSE B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL A-12 RH PADDLE LEFT B-12
A-13 TRACTION PULL FDBK RELAY- D B-13 BICS HYD LOCK HOLD A-13 RH RIGHT ROCKER UP B-13 FRONT AUX (F) (BASE)
A-14 B-14 CAN HI 2 A-14 B-14 CAN HI 2
A-15 B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR A-17 B-17 RH PWM LO
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M) (ROD)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 FLOAT B-20 CAN LO 2
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY A-21 B-21 RH TRIGGER RETURN
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED PWR
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 RH PWM HI
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 RIGHT FAN FDBK RELAY - C B-25 TWO SPEED MAKEUP A-25 B-25
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED MAKE-UP RETURN A-27
A-28 REAR LIGHT FDBK RELAY - E A-28 LH RIGHT ROCKER UP
A-29 A-29
A-30 HVAC FDBK RELAY - B A-30 RH LEFT ROCKER UP
A-31 FRONT LIGHTS FDBK RELAY - K A-31 RH LEFT ROCKER DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 FOOT THROTTLE A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

LF MFR MAN 7281511 WIRING SCHEMATIC Printable Version Click Here
DLX CAB 7253375
DLX FUEL 7266824
(MANUAL MACHINE)
7242470
BCT ENG
TAILGATE DOM 7267103
S770 (S/N AT5A11534 - AT5A11719)
SUSP JSTK
BRAKE ADAPTER
7163706
7234968
S770 (S/N B3BV11243 - B3BV11289)
WHL 2 SPD ADP
TRK 2 SPD ADP
7159366
7243409
Sheet 2 of 18

LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
PARTIAL CONNECTOR
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
3 SW POWER
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
SIGNAL OPTIONS PAGE 17
19 ECU RUN SIGNAL COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
SENSOR FREQUENCY
GROUND
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL
WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 3 of 18
Printed In U.S.A.
7281509
UNSWITCHED BATT POWER C408 1240 RED/WHT SHEET 12
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
SHEET 12
FUSE 11 25 A J1B
SHEET 12
SP2 C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36
1150 RED/WHT 3
J2B
100.0 Amps
T4
SHEET 9
STARTER
FUSE 4 25 A
SHEET 16
SHEET 15
FRC1 REAR LIGHT RELAY
1340 RED SHEET 15
SP26 1330 RED/WHT FRC1 FRONT LIGHT RELAY
SHEET 15
FUSE 20 5 A
1325 RED FUSE 16 25 A
SHEET 5
FRC 1 ENGINE ECU RELAY

SHEET 10 Printable Version Click Here
1230 RED/WHT DCU POWER

1220 RED SHEET 10 WIRING SCHEMATIC
1045 RED 10 1105 RED/WHT 10 SHEET 9
1460 RED/WHT
SHEET 17
C412 LH HANDLE HORN
(MANUAL MACHINE)
1040 RED FUSE 22 25 A 1410 RED/WHT
1490 RED/WHT
SP60 FUSE 24 25 A
SP24
SHEET 17
C408 CAB-MFR CONN S770 (S/N AT5A11534 - AT5A11719)
1055 RED 1290 RED 1370 RED/WHT (OPTIONS)
SHEET 13
C408 CAB-MFR CONN S770 (S/N B3BV11243 - B3BV11289)
(ACCESSORIES)
1050 RED
SHEET 5 Sheet 4 of 18
1030 RED
FRC1 STARTER RELAY
FRC1
ENGINE ECU
1525 RNG
SCR INTERCONNECT
SHEET 8 SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A SP50 C489

FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (FR WIPER)
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
1950 RNG/WHT
1765 RNG/WHT FUSE 7 25 A
1795 RNG/WHT 1730 RNG/WHT SP65 1735 RNG/WHT
SP25 SHEET 7 C426 REMOTE RUN, ACD Printable Version Click Here
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A
+12V
FUSE 8 25 A
1580 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) WIRING SCHEMATIC
PWR
1050 RED 30
SHEET 4
87 1815 RNG/WHT
FUSE 23 15 A
1800 RNG/WHT
SHEET 9 ALT EXCITATION (MANUAL MACHINE)
GND 85 86
SHEET 6 2055 BLK
3450 LBL 21
S770 (S/N AT5A11534 - AT5A11719)
J1A C428
3380 LBL 4
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
S770 (S/N B3BV11243 - B3BV11289)
C449 LH JOYSTICK Sheet 5 of 18
1830 RNG/WHT (PRINTED DECEMBER 2016)
SHEET 7
C450 RH JOYSTICK
GROUND SHEET 11
SHEET 13
2320 BRN
2370 BRN
J1B
GWY CTRLR
2220 BRN SP12 2230 BRN 17

SHEET 11
2190 BRN
2 2001 BLK SHEET 11
J7A SHEET 9
2150 BRN
SHEET 9
T32 2004 BLK
ECU CASE GND 2690 BRN
SHEET 9
SHEET 10
C120 SCR-MFR CONN
2430 BRN 18
2080 BLK SHEET 9
SHEET 7 ENGINE TEMP GND
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
SHEET 12 2765 BLK
C479 LH PANEL SHEET 15
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
2745 BLK
C499 PTOL SHEET 16
2960 BLK SP3 C408 CAB-MFR CONN (HVAC)
SHEET 12 16 2510 BLK 2110 BLK
GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
SW12 DPF SWITCH
(LT GRAY) 2540 BLK 2730 BLK
SP47 1 SP28
2830 BLK 2900 BLK 2900 BLK
SHEET 17
2700 BLK 2770 BLK
SHEET 12 SHEET 17
2785 BLK 2200 BLK
SHEET 17 SHEET 11
2620 BLK
SHEET 15 C103 C489
SHEET 14 2650 BLK
SP51 2600 BLK B 2390 BLK 10 T1 T10
T20 BU ALARM 2600 BLK 2015 BLK
SHEET 15 2400 BLK 14 SP6
SHEET 9 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
2455 BLK
2630 BLK SHEET 17
T18 LH REAR LIGHT 2710 BLK 2300 BLK
SHEET 7
SHEET 8 2715 BLK
C169 ENGINE CAN Printable Version Click Here
2290 BLK
SHEET 16
2045 BLK D4 COMPRESSOR DIODE
SHEET 15
FRC1 REAR LIGHT RELAY SHEET 9 2295 BLK 18 WIRING SCHEMATIC
SHEET 11 2035 BLK
SHEET 15
2115 BLK SP55 2105 BLK SP5 2000 BLK
(MANUAL MACHINE)
SHEET 5
2055 BLK SHEET 14
C410 LEFT HANDLE
2520 BLK
S770 (S/N AT5A11534 - AT5A11719)
FRC1 SWITCHED POWER RELAY 2530 BLK
SHEET 16 2030 BLK
SHEET 14
C409 RIGHT HANDLE S770 (S/N B3BV11243 - B3BV11289)
FRC1 HVAC RELAY
SHEET 9
FRC1 STARTER RELAY
2005 BLK
Sheet 6 of 18
2120 BLK
SHEET 15
CAN BUS
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1
8 9260 PUR 9230 PUR SP31 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
2080 BLK 2
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426
14 9500 PUR/WHT A Printable Version Click Here

CAN HI
20 9600 PUR B
CAN LO
WIRING SCHEMATIC
J1B
(MANUAL MACHINE)
GWY CTRLR
S770 (S/N AT5A11534 - AT5A11719)
21 3090 LBL D
C
REMOTE RUN KEY
S770 (S/N B3BV11243 - B3BV11289)
1735 RNG/WHT E
SHEET 4
1165 RED/WHT
2710 BLK
F
G UNSWITCHED POWER Sheet 7 of 18
SHEET 6 GROUND

ENGINE CAN BUS C121
J7A
ECU CNTRLR DOSING CONTROL UNIT
SP81 SP90
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR
NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
SHEET 10 2870 BLK

NOx POST TREATMENT
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
C169
1640 RNG/WHT 4
ENGINE CAN
9225 PUR 1
1 1725 RNG/WHT 2
2 2715 BLK 2825 BLK 3
SHEET 6 SHEET 10
3 9155 PUR/WHT
4 9255 PUR C121
DOSING CONTROL UNIT
5
6
9720 PUR/WHT
9820 PUR
82 CAN HI
60
CAN LO
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 8 of 18
1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M C111
MFR-BCT HARN CONN
STARTER
ENGINE
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND AIR FILTER 2015 BLK
SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
FRC1
TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 C171 LEFT TAILGATE
87 TAILGATE FANS CONN
A B
FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 68105 TAN 14 3 8105 TAN 14 FUSE 15 A
4 C113
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 2405 BLK 14
SHEET 6 C172 RIGHT TAILGATE
TAILGATE A B
J1B C355 FAN CONN
FANS GND
GWY CTRLR FUEL HARN 8135 TAN 14 A
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
10 2180 BRN D 2180 BRN B GND (30 - 270 OHM)
3690 LBL SHEET 6

2 ENGINE C114 CONTACTOR
2430 BRN 18 TEMP CAB-MFR HARN CONN 2 PWR
FUSE 150 A
HAND THROTTLE T29 30
18 3110 LBL 18 1 SENSOR 1060 RED 1 2 1065 RED 87
SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 8515 TAN SP77 8500 TAN T14
(950-4400 OHM)
T26 T27 85 86
3690 LBL 6 3690 LBL A 1445 RED/WHT
SIG
8007 TAN
8510 TAN 8505 TAN T31
SHEET 6 D
E
J7A
8020 TAN SP74 F Printable Version Click Here
ENG ECU CTRLR SHEET 10
19 8008 TAN WIRING SCHEMATIC

C100
1
(MANUAL MACHINE)
9 3865 LBL SIG WATER IN FUEL SENSOR
34 2865 BRN 2 GND (FUEL FILTER)
S770 (S/N AT5A11534 - AT5A11719)
56
C118 S770 (S/N B3BV11243 - B3BV11289)

ENG-CROSSOVER
8013 TAN
28
35 8014 TAN SHEET 5 1511 RNG/WHT 1 Sheet 9 of 18
8013 TAN 2 FREQ
8014 TAN 3 TEMP (PRINTED DECEMBER 2016)
3420 LBL 4
T42
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
DCU CASE GND
85 86
2915 BLK
C121
DOSING CONTROL UNIT
SP62
71 C123
1255 RED/WHT 73 HOSE 1 HEATER
67
2310 BRN
1275 RED/WHT 51 68 SP87 1
7998 WHT 8120 TAN
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
7 SP88 8330 TAN 30
8140 TAN
SHEET 8 2945 BLK 72 8340 TAN
2870 BLK 2855 BLK 29
C124
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 SP85
C155 2135 BRN
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 30
8260 TAN 8250 TAN
SP89 87 2965 BLK
C156 C125
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
2 61 85 86
SCR INLET 2025 BRN 2125 BRN
28 8600 TAN
C158
1 8520 TAN 62
2 84 C122
SCR OUTLET 2160 BRN Printable Version Click Here
SUPPLY MODULE
C159 11
1 8800 TAN 31
4 1690 RNG/WHT
12
HEATER BATT+ WIRING SCHEMATIC
3 8650 TAN
2 9 HEATER SIGNAL
2050 BRN
55 1695 RNG/WHT 3
PUMP MOTOR BATT +
(MANUAL MACHINE)
C160 2
1 8530 TAN 18 TXL 34
76 8700 TAN
4
PUMP MOTOR CONTROL SIGNAL S770 (S/N AT5A11534 - AT5A11719)
54 2095 BRN PUMP MOTOR GND
77 1680 RNG/WHT
5
PURGING PUMP BATT +
S770 (S/N B3BV11243 - B3BV11289)
6
78 8750 TAN PURGING PUMP SIGNAL Sheet 10 of 18
17 10
1685 RNG/WHT
9
PRESSURE SENSOR BATT+ (PRINTED DECEMBER 2016)
39 3000 LBL PRESSURE SENSOR SIGNAL
Printed In U.S.A. 40 2085 BRN 8 7281509
PRESSURE SENSOR GND
FRC1
TRACTION LOCK
HYDRAULICS C425
+12V RELAY - D B C308
4100 LGN BRAKE
1360 RED/WHT PWR 30
SHEET 4 4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035 BLK OPTIONS DWG)
8 4110 LGN
13 3430 LBL
C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A
AUX CTRLR
18 2330 BRN 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330 LGN
3.3 OHM PWM
C419
(MANUAL MACHINE)
1 2 GND
2340 BRN
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) S770 (S/N AT5A11534 - AT5A11719)
3.3 OHM PWM
S770 (S/N B3BV11243 - B3BV11289)
19 13 Sheet 11 of 18
J2B
AUX CTRLR (PRINTED DECEMBER 2016)
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
C479
CAB DISPLAY C499
Press To Operate Loader
(PTOL)
T2
10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 4 8070 TAN
1 SHEET 6 GROUND
8060 TAN 1 6
3
WIRING SCHEMATIC
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 12 of 18
*SW4
HAND/FOOT
(ACS)
CAB
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
SHEET 13
(DK GRAY) 4
CAB-MFR HARN CONN 3 * DLX CAB HARN 7253375 ONLY
7
8
4235 LGN
4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
*POWER
C212
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
* DOME
T37
LIGHT (+)
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * DOME
T38
LIGHT (-)
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1 WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG Printable Version Click Here
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR
HARNESS WASHER PUMP
WIRING SCHEMATIC
SHEET 9 5690 YEL 7253378
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
* C252 A 7310 WHT
C253
1
PWR
WASHER S770 (S/N B3BV11243 - B3BV11289)
MOTOR
2845 BLK B 2845 BLK 2 GND Sheet 13 of 18

MANUAL CONTROLS
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 6
AUX CTRLR G
C404 A
C103 SHEET 5 1530 RNG/WHT
BU ALARM-MFR HARN
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
OPTIONS DWG) BACK UP
4920 LGN E DETENT FLOW
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
SIG
2 7.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
SIG SHEET 5
7.8 OHM 12V J
2
H
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 14 of 18
C434-1
LIGHTS
C408
(BLACK)
C434-2
SHEET 6 LEFT FRONT
50.00 Watts
C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
6000 PNK
RC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - 1 C435-2
(DK GRAY)
6130 PNK A SIG
6620 PNK SP23 2705 BLK B GND WORK LIGHT
87 13 6610 PNK 50.00 Watts
6610 PNK
2120 BLK 85 86 SP64

SHEET 6
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SP10 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK 6630 PNK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
+12V RELAY - E
1320 RED/WHT
GND 85 86 SHEET 6
2045 BLK
SHEET 6 T18 TERMINAL (-)
(MANUAL MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 15 of 18

2440 BLK * C610
2
HVAC
GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483

C BLK
7420 WHT A DBL POTENTIOMETER
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT
(TEMP CONTROL
SWITCH)
(NOT IN STD CAB HARN) * C635
D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
SP48
B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10

PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2030 BLK
SHEET 6 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT
SWITCH B
A
7023 WHT
7024 WHT
7020 WHT 1
WIRING SCHEMATIC
C486 (MANUAL MACHINE)
7025 WHT 1 SIG
2 GND
MAGNET CLUTCH
(COMPRESSOR)
S770 (S/N AT5A11534 - AT5A11719)
2290 BLK 2280 BLK
SHEET 6
D4 S770 (S/N B3BV11243 - B3BV11289)
Sheet 16 of 18
C428
(LT GRAY)
OPTIONS
# C607
C355
FUEL HARN CAB-MFR HARN CONN 2
#
POWER BOB
SIG
GND
1
2
4470 LGN
2470 BLK 2770 BLK
E
B
4470 LGN
2770 BLK
11 4470 LGN
4480 LGN
CLOSE SHEET 6
SW5
*POWER 2 1
# C606 BOBTACH 3
SWITCH 5 4
2 2480 BLK
POWER BOB
OPEN
GND
SIG 1 4480 LGN F 4480 LGN 10
6
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
INTERNALLY
6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
RIGHT
*-
C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
SHEET 13
4 + 1885 RNG/WHT 1 2210 BLK 5 GND
SHEET 13 SHEET 13
J2A 3 2885 BLK 2 6
SHEET 13
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW Printable Version Click Here
A SIG
SOLENOID
4460 LGN
J2B
7.5 OHM 12 V
WIRING SCHEMATIC
26
AUX CTRLR
(MANUAL MACHINE)
C441
J1A 26 2350 BRN 2 GND TWO SPEED TRACK 2 SPEED
ADAPTER
S770 (S/N AT5A11534 - AT5A11719)
(SEE ADDITIONAL
J1B 26
5.1 OHM 12 V
OPTIONS DWG) S770 (S/N B3BV11243 - B3BV11289)
GWY CTRLR
Sheet 17 of 18
ENGINE
T14 PRE HEATER 179 J7B
PRE HEATER C130
ENG ECU CTRLR 105 TEMP SENSOR 1
C153 EXHAUST GAS
(DOOSAN HARNESS)
1 122 TEMP SENSOR
SENSOR RETURN 1
WASTE GATE BEFORE DPF
2 186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
SUPPLIED
1 POSITION SENSOR 161 123 TEMP SENSOR
SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
2 POSITION FEEDBACK 113
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR
SENSOR RETURN
TEMP SENSOR AIR RETURN 171
C135
C149 184 5
H BRIDGE POS
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
163 VREF 3 THROTTLE POSITION 1
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
132 C137
1 SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
129 157 VM 2
SHIELD & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B
CAM SHAFT 2 159 Printable Version Click Here
POS SENSOR 112 A
SENSOR INTAKE PRESS SENSOR INLET TEMP
3 VREF1 CAM 140
C143
167
134
INTAKE PRESS RETURN
INTAKE AIR TEMP SENSOR
D
C
PRESSURE
SENSOR WIRING SCHEMATIC
RAIL PRESSURE
1
2
RAIL PRESSURE SENSOR
SENSOR RETURN
135
119
168 INTAKE AIR TEMP RETURN ? (MANUAL MACHINE)
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA
C139
S770 (S/N AT5A11534 - AT5A11719)
C141 126 CYL 1
FUEL INJECTOR LSD1A
CYL 3
FUEL INJECTOR HSDB 151
C140
S770 (S/N B3BV11243 - B3BV11289)
C142
150
174
FUEL INJECTOR HSDB
FUEL INJECTOR LSD2B CYL 2 Sheet 18 of 18
FUEL INJECTOR HSDA 103
CYL 4 C154
FUEL INJECTOR LSD2A 125 (PRINTED DECEMBER 2016)
Printed In U.S.A. 177 PWM 2
INLET METERING
1 VALVE 7281509
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
9 SH09 - DOSING CONTROL UNIT LEGEND
10 SH10 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
11 SH11 - CAB DISPLAY CONNECTOR
12 SH12 - CAB BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
13 SH13 - MANUAL CONTROLS 1 1
14 SH14 - LIGHTS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
15 SH15 - HVAC
PARTIAL CONNECTOR
16 SH16 - OPTIONS 1
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
17 SH17 - OPTIONS 2
1 1
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HARNESS PART NUMBER LGN
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN 1 1
LF MFR MAN 7300237
DLX CAB 7301237 * CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX FUEL 7266824 SHT1/F2
WIRE BREAK
SHT1/F2
BCT ENG 7242470 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
TAILGATE DOM 7267103 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
SUSP JSTK 7163706
WHL 2 SPD ADP 7159366 ENGINE 8000 THROUGH 8999 TAN TAN
TRK 2 SPD ADP 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
DEF JUMPER 7305995
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
* CAB HARNESSES USED ON S/N AT5A11720-AT5A12586

B3BV11290-B3BV11649
WARNING PROPRIETARY NOTICE ECN 102537

Wiring Schematic S750 S/N AT5A11720
S770 AT5211529 &
through
AboveAT5A12499 TOLERANCES:
Printed On October 2017
csf
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT WEST FARGO, NORTH DAKOTA, USA
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
Standard Machine S/N B3BV11290 through B3BV11599

TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
UNLESS OTHERWISE SPECIFIED
TITLE
7300236
SCHEM LF MFR MAN (B)
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
DWG. NO. Sheet 1 of 17
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT
B
REV
REVISED C161 PIN ASSIGMENTS
DESCRIPTION
103427 MPS
CHG NOTICE DWN
6
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 17
7300236
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4
1400 RED/WHT
C408 SHT12/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT11/E4
FUSE RELAY CENTER
1110 RED/WHT 1440 RED/WHT
2 SHT11/G8
FUSE 11 25 A GATEWAY CTRLR
1070 RED 1120 RED/WHT 1130 RED/WHT
11A 11B 3
+12V BATTERY MEGAFUSE SP2
100.0 Amps J1B
HW11 1 1 FUSE 13 25 A SP36 1150 RED/WHT
T5 T4 13A 13B 3
1180 RED/WHT
AUX CTRLR
2
J2B
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT15/E8
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
FUSE 20 5 A SHT14/F8
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
25A 25B SHT9/H8
FUSE 26 15A
26A 26B SHT9/G8
FUSE 10 30A
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
22A 22B SHT16/F7
SP24
FUSE 24 25 A
24A 24B SHT12/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8

S770 AT5211529 &
through
csf


OR REGULATIONS.
TITLE
7300236

COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 2 / 17
7300236
FRC1 ENGINE 1525 RNG
SHT6/E4
ECU RELAY - G
1035 RED/WHT +12V PWR 30

1506 RNG/WHT
1 SWITCHED
SHT2/D1 G1 87 1540 RNG/WHT 1545 RNG/WHT SP54 1507 RNG/WHT
86 85
G4
SP73
1508 RNG/WHT
3
ENG ECU CTRLR

POWER
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/E1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT7/B7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
12A 12B SHT16/G7
1700 RNG/WHT
1520 RNG/WHT SHT11/C8
SHT13/D3 1705 RNG/WHT
SHT11/B8
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
SP11 1960 RNG/WHT
J2B SHT11/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT12/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT11/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
SP42 1565 RNG/WHT
SHT17/E4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
GND
86 85
BUS BAR
A5 A2 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT12/F8
FUSE 23 15 A
23A 23B SHT7/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
SP37
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3

S770 AT5211529 &
through
csf


OR REGULATIONS.
TITLE
7300236

X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 3 / 17
7300236
ENG ECU CTRLR
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
2003 BLK SHT10/F7 GATEWAY CTRLR
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT17/F5 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
2150 BRN
SHT7/G7
2430 BRN
SHT7/C7
2080 BLK
SHT5/D3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT11/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10
2960 BLK
SHT11/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT11/D4 16
GATEWAY CTRLR 2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/D4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
SHT11/C8 J2B SHT12/E8
2930 BLK C428
SHT11/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT16/B7 SHT16/H6 T10
SHT7/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT10/H4
2620 BLK C489 2720 BLK

SHT14/C4 MFR ACCESSORY B B
2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK AUX CTRLR
SHT7/E4
2630 BLK 2185 BRN
SHT14/B4 2405 BLK SHT17/E7 SP58 2995 BRN
SHT7/D4 2195 BRN 17 SENSOR GROUND
SHT13/G3
2455 BLK
J2B
SHT16/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
SHT6/D7
2290 BLK
SHT15/B8
2505 BLK
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2035 BLK
SHT10/G8
SP55 SP5 2000 BLK
2115 BLK 2105 BLK
SHT14/D8
2055 BLK 2520 BLK

SHT3/C1 SHT13/D3
2030 BLK 2530 BLK

SHT15/F8 SHT13/F3
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8

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OR REGULATIONS.
TITLE
7300236

X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
SHT 4 / 17
7300236
CAN BUS
(NOT IN STD CAB HARN 7303755)
RE016 RE019 C479

C408
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
GATEWAY CTRLR R3-1 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31TP-16 TP-16 TP-01 TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08 9460 PUR TP-08
9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
CAN HI 9 3 3 3 CAN HI
R3-2 TP-04
R2
J1B TP-02 TP-06
C479
C503
RH DLX PANEL
9440 PUR TP-06
4 CAN LO
9340 PUR/WHT
2 CAN HI
TP-11
C503
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
9420 PUR 9660 PUR CAN LO
AUX CTRLR 4 4 4 4
TP-11
9280 PUR
8 CAN LO
9180 PUR/WHT
9 CAN HI * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
4 4 4 4
SUSP SEAT JOYSTICK HARNESS
AUX CTRLR C426

Remote Run Tool, ACD
TP-12 9500 PUR/WHT TP-12
CAN HI 14 A A CAN HI
9600 PUR
CAN LO 20 B B CAN LO
J2B
3095 LBL
REMOTE RUN KEY 24
J2A
GATEWAY CTRLR
3090 LBL 3085 LBL REMOTE RUN KEY

REMOTE RUN KEY 21 D D
SP93
J1B
C C
1735 RNG/WHT SWITCHED POWER

SHT3/D1 E E
1165 RED/WHT UNSWITCHED POWER

SHT2/D1 F F
2710 BLK GROUND

SHT4/C6 G G

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OR REGULATIONS.
7300236
TITLE


X ± 13
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 5 / 17
7300236
ENGINE
CAN BUS
RE014
120 Ohm Terminator DOSING CONTROL UNIT
120 OHM 0.5 W RESISTOR
ENG ECU CTRLR Resistor internal to
R5-1
TP-17 TP-17 TP-18 TP-18
SP81 TP-20
SP90
TP-22 9210 PUR TP-22 SP67 TP-24 TP-24 SP71 TP-26 TP-26 SP70 TP-28 Controller TP-28
9200 PUR 9215 PUR 9415 PUR TP-20 9265 PUR 9275 PUR 9245 PUR
ENG CAN LO 47 65 ENG CAN LO
SP82 SP91 SP68 SP72 SP69

9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT 9165 PUR/WHT 9175 PUR/WHT 9145 PUR/WHT
ENG CAN HI 48 66 ENG CAN HI
R5-2
J7A C121
TP-19 TP-21 TP-23 TP-25 TP-27
9105 PUR/WHT
C163
9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
GATEWAY CTRLR 9195 PUR/WHT
4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
TP-21 9155 PUR/WHT

ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
TP-29 TP-29
CAN HI DCU DIAGNOSTIC 9720 PUR/WHT
5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC
C169
C121

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OR REGULATIONS.
7300236
SCHEM LF MFR
TITLE
MAN (B)

X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 6 / 17
7300236
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
MFR-BCT HARN CONN T21 S
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/F7
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
STARTER RELAY SIGNAL 7 1
3560 LBL T11
STARTER RELAY FEEDBACK 22
2150 BRN GND 1
SHT4/G3 B
AIR FILTER T12
3150 LBL SWITCH (NC) 2015 BLK
AIR FILTER SENDER SIGNAL 16 A SIG
SHT4/E3
C405
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12
TAILGATE FANS RELAY-C C104 LEFT TAILGATE FAN

TAILGATE FANS CONN FUSE 15 A
8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
TAILGATE FAN RELAY OUTPUT 9 C5 C2
86 85 C119
RIGHT TAILGATE FAN
J1A FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
3 3 A B A
SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113
3180 LBL 3180 LBL HAND THROTTLE

FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT12/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
MFR HARN CONN 2 (LT GRAY) C
C406 3690 LBL
3690 LBL SIG
THROTTLE PRIMARY SIGNAL 10 6 6 A
2430 BRN 2690 BRN GND
SHT4/G3 2 SHT12/D5 B
C120
T
ENGINE TEMP C114
3110 LBL
ENGINE TEMP SIGNAL 18 1 SENSOR (950-4400 OHM)
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
J1B 8020 TAN INTAKE HEATER FUSE CONTACTOR
SHT9/F8 SP74
ENG ECU CTRLR +12V PWR 150 AMPS
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN
SP77 8500 TAN 1
IGN SW ON 19 C100 T29 T26 T27 T28 30
2865 BRN GND C100 T30 T14
WATER IN FUEL RETURN 34 2 1445 RED/WHT 1 85 1
WATER IN FUEL SENSOR SHT2/D1 8505 TAN 1
T41 86 T40
(FUEL FILTER)
3865 LBL SIG
T31
WIF SENSOR 9 1
8510 TAN
PRE HEATER RELAY DRIVER 56
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT8/G3
8014 TAN
AIR INLET TEMP 35 3 3 SHT8/F3
1 3420 LBL
4 4 SHT8/H7
T42
J7A ENG-CROSSOVER

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OR REGULATIONS.
7300236
SCHEM LF MFR
TITLE
MAN (B)

X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 7 / 17
7300236
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT7/B5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
2 46 FUEL TEMP SENSOR RETURN GND
C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1
KNOCK SENSOR 1 SHIELD-01
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1
ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
3 29 ENGINE BLOCK ACCELEROMETER #2 SHIELD
INJECTOR #1
C146 FUEL INJECTOR #1 HSDA 27 1
CRANKSHAFT POSITION SENSOR SHIELD-03

SHIELD-03
1 36 CRANKSHAFT SENSOR NEG FUEL INJECTOR #1 LSD1A 26 2
2 60 CRANKSHAFT POSITION SENSOR C139
3 87 CRANKSHAFT SENSOR SHIELD
INJECTOR #2
C145 FUEL INJECTOR #2 HSDB 50 1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3

3 38 VREF 1 RAIL PRESSURE SENSOR FUEL INJECTOR #3 LSD1B 75 2
1 35 RAIL PRESSURE SENSOR C141
P
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
2 19
FUEL INJECTOR #4 HSDA 3 1
C143
FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
VREF 1 INLET METERING VALVE
1 SHT7/B5 C142
2 77 INLET METERING VALVE (PWM)
C154
J7B
J7B

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OR REGULATIONS.
TITLE
7300236

COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT Printable Version Click Here
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 8 / 17
7300236
HOSE HEATER MAIN
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2975 BLK 1 T33

DCU CASE GND
2915 BLK
DOSING CONTROL UNIT

SP62
SHT2/C1 5 HOSE RELAY MAIN SIGNAL 93
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
SHT6/D4 2 HOSE 1 HEATER
7999 WHT 8320 TAN
2870 BLK CAN JUMPER 90 2
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8340 TAN
C123
8020 TAN HOSE 1 RELAY FB SP88
SHT7/C7 22 IGNITION SIGNAL
72
2170 BRN 8330 TAN
1 75 TANK HEATER VALVE GND 30 2955 BLK
87 SP86
TANK HEATING
VALVE 8540 TAN HOSE 1 HEATER 8550 TAN
2985 BLK
4 92 94 86 85
2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET 8250 TAN
C125
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
2 9 ENV TEMP GND 8370 TAN 8360 TAN
ENVIRONMENTAL HOSE 3 RELAY FB 27 30
TEMPERATURE T SP61 87
8800 TAN
1 31 ENV TEMP SIG 8600 TAN C122
HOSE 3 HEATER 28 86 85 SUPPLY MODULE
C159
2075 BRN RL013 RL013
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 1690 RNG/WHT HEATER BATT+
T SM HEATER BATT 4 11
INLET 8530 TAN CAT TEMP DOC INLET 8650 TAN HEATER SIGNAL
1 34 SM HEATER SIGNAL 3 12
1695 RNG/WHT PUMP MOTOR BATT +
C160 +5V POWER 55 3
SM PUMP MOTOR CONTROL 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122

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OR REGULATIONS.
7300236
TITLE

X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 9 / 17
7300236
FRC1
TRACTION LOCK RELAY - D
C425 HYDRAULICS
4100 LGN
1360 RED/WHT +12V PWR B B
SHT2/F1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
86 SHT4/D6 C C B OHM 12 V TRACK 2 SPEED ADAPTER
FRC1 FRC1 (SEE ADDITIONAL OPTIONS DWG)
C308
2035 BLK WHEEL 2 SPD ADP HARNESS 7159366

SHT4/B8 TRACK 2 SPD HARNESS 7243409
GATEWAY CTRLR
TRACTION LOCK RELAY 4110 LGN

SIGNAL 8
TRACTION LOCK RELAY 3430 LBL
FEEDBACK 13
2220 BRN GND

SHT4/H3 B
HYDRAULIC TEMPERATURE SENDER
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
HYD TEMP SIGNAL 32 A
C108
3320 LBL SIG

HYD FILTER DIFF PRESS 34 A
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446
HYD LOCK VALVE SOL 2410 BRN GND

1 2
GROUND
HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
J1A
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
6
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
HYD CHARGE PRESS

SENDER SIGNAL
HYD CHARGE PRESS

SENDER POWER
HYD LOCK
SOLENOID SIGNAL
4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID (MALE)
FRONT ROD 2330 BRN SIG 3.3 OHM PWM
18 2
SOLENOID GROUND
C418
4340 LGN GND
1
GATEWAY CTRLR
FRONT BASE SOLENOID (FEMALE)
FRONT BASE 2340 BRN SIG 3.3 OHM PWM
1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

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OR REGULATIONS.
TITLE
7300236
DWG. NO.Sheet 10 of 17
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 10 / 17
7300236
1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN
C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/E1 1
2940 BLK GROUND

SHT4/F8 3
BUZZER GATEWAY CTRLR
10 C408
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4

SHT3/E1 5 C499
C500
SHT16/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2
1960 RNG/WHT J1A

SHT3/E1
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5
6
1
5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
SHT4/E8 2 1 RH DLX PANEL
C479 SHT5/G1
5 6 1590 RNG/WHT SWITCHED POWER

SHT3/D1 5
4
3 1240 RED/WHT UNSWITCHED POWER
SW1 SHT2/H1 1
SW1
C480 2250 BLK GROUND
1775 RNG/WHT SHT4/F8 3
SHT3/E1 LEFT PANEL CONN (GRAY)
3620 LBL DOOR SIGNAL

SHT12/D3 12
C503 SHT5/F1
3610 LBL PARK BRAKE OUTPUT

2
SW12
DESOX INHIBIT SWITCH(OPT KIT)
2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1700 RNG/WHT 8050 TAN
SHT3/E1 7 9 4
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 SW12
C480

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OR REGULATIONS.
TITLE
7300236
X ± 13
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 11 / 17
7300236
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT12/D1 5
4
SW4 3
SW4
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
7 7
4275 LGN
8 8
9 9
4550 LGN *
2795 BLK GND
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT16/C2
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
2690 BRN
(SEE ADDITIONAL
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 3620 LBL
SENSOR SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND SHT2/G1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR 2 2 WIPER MOTOR GROUND
C
5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B 5690 YEL

SHT7/D4
HARNESS WASHER PUMP

* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S770 AT5211529 &
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OR REGULATIONS.
7300236
TITLE

X ± 13 MAT Printable Version Click Here
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 12 / 17
7300236
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8
T20
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
TILT SPOOL LOCK 2980 BRN GND

SOLENOID GROUND 10 3
LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
HANDLE LOCK (ACS ONLY)
LIFT SPOOL LOCK 2990 BRN GND 2520 BLK

SOLENOID GROUND 2 3 SHT4/B6 E
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
7.8 OHM 12V 1520 RNG/WHT
SIG
1 SHT3/E3 A
LEFT HANDLE RIGHT
C422 4830 LGN
ROCKER DOWN 22 B
RIGHT POSTION SWITCH
4840 LGN
LEFT HANDLE RIGHT ROCKER UP 28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7
LEFT HANDLE PADDEL LEFT 12 G

TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
C410
J2A LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR

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OR REGULATIONS.
TITLE
7300236
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 13 / 17
7300236
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - RC1
C438
2760 BLK GND
1350 RED/WHT MFR HARN CONN 3 (DK GRAY) B RIGHT FRONT
SHT2/E1 30 6620 PNK SP23 6610 PNK 6610 PNK 6130 PNK WORK LIGHT
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK
FRONT WORK LIGHTS 2610 BLK GND

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
SHT2/E1 TAILGATE HARN
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK 31
REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
REAR LIGHT RELAY GND 1
28
FEEDBACK RIGHT REAR
6210 PNK
FRC1 WORK LIGHT

J1A
REAR LIGHT 6210 PNK SIG 1
RELAY - E T15 TERMINAL (+)
1320 RED/WHT T17 TERMINAL (+)

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
FRC1 FRC1 T18 TERMINAL (-)
2045 BLK
SHT4/B8

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OR REGULATIONS.
TITLE
7300236
X ± 13
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 14 / 17
7300236
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

M (NOT IN STD CAB HARN 7303755)
7440 WHT SIG
1
C610
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
C350 MAGNET CLUTCH

2290 BLK 2280 BLK (COMPRESSOR)
SHT4/C6
GND
2
C486

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OR REGULATIONS.
TITLE
7300236
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 15 / 17
7300236
C355 C428
# FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
C438 1405 RED/WHT

SHT17/D6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT 1430 RED/WHT
SP43
SHT2/C1 1 1 X T3
* FLASHER
1200 RED/WHT L
FLOAT (ACS/AHC ONLY)
3500 LBL
T3
SHT11/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
*
2970 BLK 6700 PNK
C423 6 5 SHT17/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676 C C
LEFT SPEAKER
* * RADIO CONN A A
HANDLE LOCK (ACS ONLY) 1

7820 WHT
3
LEFT
SPEAKER (+)
*
1
7830 WHT LEFT
AUX CTRLR 2 4 SPEAKER (-) 2
L010
HIGH FLOW C279 3
FLOAT (ACS/AHC ONLY) 2460 BRN AIR RIDE SEAT
SOLENOID GROUND 26 RIGHT SPEAKER 1510 RNG/WHT
SHT12/E1 4
J2A GND
B
* 7810 WHT RIGHT
PWR
PWR
RIGHT POSTION SWITCH HIGH FLOW 2 6 SPEAKER (-)

SOLENOID 2210 BLK GND
SIG 7.5 OHM 12 V 7800 WHT SHT12/E1 5
PADDLE A 1 5 RIGHT GND
SPEAKER (+) 6
HIGH FLOW
C415 C278 1885 RNG/WHT
4460 LGN C277
SOLENOID SIGNAL 26 SHT12/E1 1
J2B 2885 BLK
GATEWAY CTRLR SHT12/D1 2
C408 C676
MFR HARN CONN 1 C126
1460 RED/WHT TWO SPEED GROUND 26 2350 BRN GND
A SHT2/C1 (BLACK) HORN CONNECTOR 2
TRIGGER TWO SPEED
7210 WHT 7210 WHT SIG J1A TRACK 2 SPEED
B 13 13 A A _ SOLENOID (SEE ADDITIONAL
4350 LGN OPTIONS DWG)
C412 SIG
1 5.1 OHM 12 V
HORN
2785 BLK GND + TWO SPEED SIGNAL 26 C441
SHT4/E8 B B
J1B

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OR REGULATIONS.
7300236
TITLE

DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT Printable Version Click Here
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 16 / 17
7300236
*SW7
AUX CTRLR
3410 LBL
C438
14 14
3410 LBL
RIDE CONTROL
1 2
2890 BLK
OPTIONS 2
RIDE CONTROL SWITCH AUTO 23 SHT4/E8
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7 RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL
FRC1 FRC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428 *
SW13
REVERSING FAN
MFR HARN CONN 2 (LT GRAY)
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIG 16 7 7 3
2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIG 29 8 8 6
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
REVERSING FAN RETURN 27 2
J2A REVERSING
FAN COIL
3485 LBL
REVERSING FAN SIGNAL 25 1
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR 10 C
PRESSURE SENSOR
5105 YEL
+5V PWR 24 B
J2B
* SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

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OR REGULATIONS.
TITLE
7300236
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT Printable Version Click Here
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 17 / 17
7300236
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
9 SH09 - DOSING CONTROL UNIT LEGEND
10 SH10 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
11 SH11 - CAB DISPLAY CONNECTOR
12 SH12 - CAB BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
13 SH13 - MANUAL CONTROLS 1 1
14 SH14 - LIGHTS
15 SH15 - HVAC
PARTIAL CONNECTOR
16 SH16 - OPTIONS 1
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
17 SH17 - OPTIONS 2
1 1
HARNESS PART NUMBER LGN
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN 1 1
LF MFR MAN 7322239
DLX CAB 7329485 * CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX FUEL 7266824 SHT1/F2
WIRE BREAK
SHT1/F2
BCT ENG 7242470 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
TAILGATE DOM 7267103 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
SUSP JSTK 7163706
WHL 2 SPD ADP 7159366 ENGINE 8000 THROUGH 8999 TAN TAN
TRK 2 SPD ADP 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
DEF JUMPER 7305995
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
* CAB HARNESSES USED ON S/N AT5A12587-ABOVE

B3BV11650-ABOVE
Wiring Schematic S770 S/NWARNING

AT5A12500 & Above PROPRIETARY NOTICE TOLERANCES: ECN 106368 Printed On October 2017
csf

WEST FARGO, NORTH DAKOTA, USA
Standard Machine S/N B3BV11600 & Above 7322238
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM LF MFR MAN
Sheet 1 of 17
Click Here For Interactive PDF COPYRIGHT C
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT DWG. NO.
0
REV DESCRIPTION
106368 MMM
SHT 1 / 17
7322238
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4
1400 RED/WHT
C408 SHT12/D3
1450 RED/WHT 1450 RED/WHT SP7 1305 RED/WHT
6 6 SHT5/E7
1420 RED/WHT
SHT11/E4
FUSE RELAY CENTER
2 SHT11/G8
11A 11B 3
+12V BATTERY MEGAFUSE SP2
100.0 Amps J1B
HW11 1 1 FUSE 13 25 A SP36 1150 RED/WHT
T5 T4 13A 13B 3
1180 RED/WHT
AUX CTRLR
2
J2B
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT15/E8
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
25A 25B SHT9/H8
FUSE 26 15A
26A 26B SHT9/G8
FUSE 10 30A
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
22A 22B SHT16/F7
SP24
FUSE 24 25 A
24A 24B SHT12/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT7/H8

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DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 2 / 17
7322238
SHT6/E4
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
86 85
G4
SP73
1508 RNG/WHT
3
ENG ECU CTRLR

POWER
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/E1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT7/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
12A 12B SHT16/G7
1700 RNG/WHT
SHT11/B8
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
SP11 1960 RNG/WHT
J2B SHT11/F8
C428 1785 RNG/WHT
SHT12/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT11/F4
FRC1 SWITCHED 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
POWER RELAY - A SP42 1565 RNG/WHT
SHT17/E4
1050 RED 30 FUSE 7 25 A SP65

+12V PWR
A4 7A 7B SHT5/B8
86 85 2055 BLK
A5 A2 GND 1725 RNG/WHT
SHT6/D7
8A 8B SHT12/F8
FUSE 23 15 A
23A 23B SHT7/G8
3390 LBL
FUSE RELAY FRC1 FRC1

CENTER
2055 BLK
SHT4/B8
1200 RED 30
SHT2/B1 F1 87 1585 RNG/WHT
+12W PWR
F4
3385 LBL 86 85 2065 BLK GATEWAY CTRLR
F5 F2 GND
SHT4/C8
SP100 3450 LBL
FRC1 FRC1 21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
J1A
C428
SP37
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3

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X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 3 / 17
7322238
ENG ECU CTRLR
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
1 2155 BLK 2190 BRN
SHT17/F5 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
2150 BRN
SHT7/G7
2605 BLK 2430 BRN
SHT5/E7 SHT7/C7
2080 BLK
SHT5/D3
2070 BLK
SHT5/E3
2920 BLK C408

SHT11/G8
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10
2960 BLK
SHT11/E4
T6
2250 BLK 2510 BLK SP3 2110 BLK 1 BATT GND
SHT11/D4 16
GATEWAY CTRLR 2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/D4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
2930 BLK C428
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT7/F3
2015 BLK 1
ALTERNATOR
2200 BLK
SHT10/H4 GROUND
2620 BLK C489 2720 BLK

2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK AUX CTRLR
SHT7/E4
2630 BLK 2185 BRN
SHT14/B4 2405 BLK SHT17/E7 SP58 2995 BRN
SHT7/D4 2195 BRN 17 SENSOR GROUND
SHT13/G3
2455 BLK
J2B
SHT16/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
SHT6/D7
2065 BLK
SHT3/C6 2290 BLK
2505 BLK SHT15/B8
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2035 BLK
SHT10/G8
SP55 SP5 2000 BLK
2115 BLK 2105 BLK
SHT14/D8
2055 BLK 2520 BLK

SHT3/C1 SHT13/D3
2030 BLK 2530 BLK

SHT15/F8 SHT13/F3
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8

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Sheet 4 of 17
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 4 / 17
7322238
CAN BUS
C479
Z3 C408
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) Z4 LEFT PANEL
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR (BLACK)
SP31 SP39 SP35
9260 PUR 9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
CAN LO 8 4 4 4
SP30 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
J1B C479
C503
AUX CTRLR RH DLX PANEL
9280 PUR 9440 PUR
8 CAN LO 4 CAN LO
9180 PUR/WHT 9340 PUR/WHT

9 CAN HI 2 CAN HI
J2B
C503
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK RIGHT JOYSTICK
SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
TELEMATICS 9320 PUR/WHT 9560 PUR/WHT CAN HI
3 3 3 3
1305 RED/WHT 9420 PUR 9660 PUR CAN LO
PWR 10 SHT2/G1 4 4 4 4
2605 BLK
GND 11 SHT4/G8
C448
Z5 MFR HARN CONN 4 (BLACK)
120 OHM 0.5 W RESISTOR SP104
CAN HI 3
9500 PUR/WHT
9510 PUR/WHT
7 7 * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
9 9 1840 RNG/WHT 1840 RNG/WHT +12V PWR
9610 PUR SHT3/B1 1 1 1 1
9615 PUR 9605 PUR 10 10 2080 BLK 2080 BLK GND
CAN LO 4 9600 PUR SHT4/G8 2 2 2 2
8 8 9300 PUR/WHT 9540 PUR/WHT CAN HI
C481 SP103 3 3 3 3
4 4 4 4
AUX CTRLR C426

9600 PUR 9610 PUR

J2B
3615 LBL CAN SELECT
CAN SELECT 25 C C
3095 LBL
REMOTE KEY 24
J2A
GATEWAY CTRLR
3090 LBL 3085 LBL REMOTE KEY

SP93
J1B
SHT3/D1 E E

SHT2/D1 F F
2710 BLK GROUND

SHT4/C6 G G

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Sheet 5 of 17
X ± 13 MAT
0
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SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 5 / 17
7322238
ENGINE
CAN BUS
ENG ECU CTRLR Resistor internal to
Z1
Controller
9200 PUR 9215 PUR 9415 PUR 9210 PUR 9265 PUR 9275 PUR 9245 PUR
47 65

J7A C121
C163
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR
3
4
2870 BLK 2875 BLK
9205 PUR SHT9/F8 5
20 ENG CAN LO SP78
C163
9105 PUR/WHT
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
4 4 1
ENGINE CAN 9225 PUR 9225 PUR
1 1 4 ENG CAN LO
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
CAN HI DCU DIAGNOSTIC 9720 PUR/WHT

5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
C169
C121

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SCHEM LF MFR MAN
Sheet 6 of 17
X ± 13 MAT
0
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SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 6 / 17
7322238
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/F7
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
3560 LBL T11
STARTER RELAY FEEDBACK 22
2150 BRN GND 1
SHT4/G3 B
AIR FILTER T12
3150 LBL SWITCH (NC) 2015 BLK
SHT4/E3
C405
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25
3100 LBL

8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
TAILGATE FAN RELAY OUTPUT 9 C5 C2
86 85 C119
RIGHT TAILGATE FAN
J1A FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
3 3 A B A
SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113

FUEL SENDER F
(30 - 270 OHM) SHT12/B8 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
C406 3690 LBL
3690 LBL SIG
C120
T
ENGINE TEMP C114
3110 LBL
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
SHT9/F8 SP74
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN SP77 8500 TAN 1
IGN SW ON 19 C100 T29 T26 T27 T28 30
2865 BRN GND C100 T30 T14
T41 86 T40
(FUEL FILTER)
3865 LBL SIG T31
WIF SENSOR 9 1
8510 TAN
ENG-CROSSOVER
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
8014 TAN
3420 LBL
4 4 SHT8/H7
1
J7A
T42

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Sheet 7 of 17
X ± 13 MAT
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SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 7 / 17
7322238
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK

EGR VALVE DC MOTOR
1 64 VREF 3 EGR
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148
KNOCK SENSOR 1 BOOST PRESSURE AND TEMP SENSOR

SHIELD-01 SHIELD-01
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN BOOST TEMP SIGNAL 94 2
2 31 ENGINE BLOCK ACCELEROMETER #1 BOOST PRESSURE PWR 61 3
T
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD BOOST PRESSURE SIGNAL 12 4 P
C147 BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 C150

SHIELD-02 SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
INJECTOR #3

P
INJECTOR #4
2 19
C143

1 SHT7/B5 C142
C154
J7B
J7B

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SCHEM LF MFR MAN
Sheet 8 of 17
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SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 8 / 17
7322238
HOSE HEATER MAIN
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2975 BLK 1 T33

DCU CASE GND
2915 BLK
DOSING CONTROL UNIT

SP62
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
7999 WHT 8320 TAN
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8020 TAN 8340 TAN
C123
HOSE 1 RELAY FB SP88
72
2170 BRN 8330 TAN
87 SP86
TANK HEATING
2985 BLK
4 92 94 86 85
2965 BLK
C155 RL011 RL011
Shield Shield C124
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET C125
8250 TAN
T 87 8350 TAN
INLET 2
8900 TAN
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
8800 TAN
C159
2075 BRN RL013 RL013
INLET 8530 TAN CAT TEMP DOC INLET 8650 TAN HEATER SIGNAL
1 34 SM HEATER SIGNAL 3 12
C160 +5V POWER 55 3
76 2
SIGNAL
C121 C121 C122

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Here LF MFR MAN
Sheet 9 of 17
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 9 / 17
7322238
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/F1 D1 87 4200 LGN 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308

GATEWAY CTRLR
TRACTION LOCK RELAY 4110 LGN

SIGNAL 8
TRACTION LOCK RELAY 3430 LBL
FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
HYD LOCK VALVE SOL 2410 BRN GND

1 2
GROUND
1
J1A
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT12/C8 B
C105
4200 LGN
J1B
19
13
6
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
HYD CHARGE PRESS

SENDER SIGNAL
HYD LOCK
SOLENOID SIGNAL
4330 LGN GND

AUX CTRLR 1
18 2
SOLENOID GROUND
C418
4340 LGN GND
1
GATEWAY CTRLR
1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

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SCHEM LF MFR MAN
Sheet 10 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Printable Version Click Here
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 10 / 17
7322238
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
10 C408
SHT2/G1 1 PTOL LED 19 12 12 4

SHT3/E1 5 C499
C500
SHT16/F4
3400 LBL
1960 RNG/WHT J1A

SHT3/E1
SW9

SHT3/D1 5
6
1
5 4 SHT2/G1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SHT2/H1 1
SW1

SHT12/D3 12
C503 SHT5/F1

2
SW12

SHT4/E8 2 4 9
SHT3/E1 7 9 4
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 SW12
C480

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SCHEM LF MFR MAN
Sheet 11 of 17
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 11 / 17
7322238
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT12/D1 5
4
SW4 3
SW4
C438
4235 LGN
7 7
4275 LGN
8 8
9 9
4550 LGN *
2795 BLK GND
SHT3/F1 2 2 C212
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT16/C2
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
SHT4/E3
2790 BLK
14 14
2690 BRN
(SEE ADDITIONAL
2370 BRN 2370 BRN 2375 BRN
SP56 3620 LBL
SENSOR SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND SHT2/G1 5 5 DOOR UNSW PWR
A
+5V PWR 2 2 WIPER MOTOR GROUND
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
HARNESS WASHER PUMP
SHT10/D7
5190 YEL * C252
7253378
2845 BLK GND
B B 2
5690 YEL WASHER
SHT7/D4
MOTOR
7310 WHT PWR
A A 1
C253

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SCHEM LF MFR MAN
Sheet 12 of 17
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 12 / 17
7322238
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
SHT4/D8
T20
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR

LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421

4990 LGN
SIG
1 SHT3/E3 A
LEFT HANDLE RIGHT
C422 4830 LGN
ROCKER DOWN 22 B RIGHT POSTION SWITCH
4840 LGN
LEFT HANDLE RIGHT ROCKER UP 28 C
4810 LGN
J1B
4820 LGN
7

TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
C410
TRIGGER
GATEWAY CTRLR

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SCHEM LF MFR MAN
Sheet 13 of 17
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REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 13 / 17
7322238
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK 31

2620 BLK
3440 LBL SHT4/D8
REAR LIGHT RELAY GND 1
28
FEEDBACK RIGHT REAR
6210 PNK
FRC1 WORK LIGHT

J1A

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8

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SCHEM LF MFR MAN
Sheet 14 of 17
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 14 / 17
7322238
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
7015 WHT
SW11
1
3
C
SP40 * THERMOSTAT
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
D4
C350 MAGNET CLUTCH

SHT4/C6 GND
2
C486

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SCHEM LF MFR MAN
Sheet 15 of 17
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 15 / 17
7322238
C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT17/D6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT 1430 RED/WHT
SP43 X
SHT2/C1 1 1 T3
* FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT11/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
6010 PNK 3400 LBL
6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
D
A
E E 1
TRIGGER
(SEE ADDITIONAL
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT17/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/D4 D D
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676
LEFT SPEAKER
* * RADIO CONN
7820 WHT LEFT

HANDLE LOCK (ACS ONLY) 1 3 SPEAKER (+)
7830 WHT LEFT

AUX CTRLR 2 4 SPEAKER (-)
FLOAT (ACS/AHC ONLY) HIGH FLOW 2460 BRN

C279 * L010
HEATED SEAT
SOLENOID GROUND 26 RIGHT SPEAKER 1510 RNG/WHT
SHT12/E1 4
J2A GND
B
* 7810 WHT RIGHT
PWR PWR
RIGHT POSTION SWITCH HIGH FLOW 2 6 SPEAKER (-)

SOLENOID 2210 BLK GND GND
SIG 7.5 OHM 12 V 7800 WHT SHT12/E1 5
PADDLE A 1 5 RIGHT
SPEAKER (+) C277
HIGH FLOW
C415 C278 1885 RNG/WHT
4460 LGN
SOLENOID SIGNAL 26 SHT12/E1 1 SEE OPTION PAGES FOR HARNESSES
J2B 2885 BLK
GATEWAY CTRLR SHT12/D1 2
C408 C676
1460 RED/WHT TWO SPEED GROUND 26 2350 BRN GND
A SHT2/C1 (BLACK) HORN CONNECTOR 2
TRIGGER TWO SPEED
7210 WHT 7210 WHT SIG J1A TRACK 2 SPEED
B 13 13 A A SOLENOID (SEE ADDITIONAL
+ 4350 LGN OPTIONS DWG)
C412 SIG
1 5.1 OHM 12 V
HORN
2785 BLK GND
_ TWO SPEED SIGNAL 26 C441
SHT4/E8 B B
J1B

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SCHEM LF MFR MAN
Sheet 16 of 17
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 16 / 17
7322238
*SW7
AUX CTRLR
3410 LBL
C438
14 14
3410 LBL
RIDE CONTROL
1 2
2890 BLK
OPTIONS 2
RIDE CONTROL SWITCH AUTO 23 SHT4/E8
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7
FRC1 SWITCHED
POWER RELAY - L
1575 RNG/WHT
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
FRC1 FRC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428 *
SW13
REVERSING FAN
MFR HARN CONN 2 (LT GRAY)
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIG 16 7 7 3
2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
J2A REVERSING
FAN COIL
3485 LBL
C442
2185 BRN
SHT4/C3 A
RIDE CONTROL PRESSURE SENSOR 10 C
PRESSURE SENSOR
5105 YEL
+5V PWR 24 B
J2B
* SW8 C672
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

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SCHEM LF MFR MAN
Sheet 17 of 17
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 17 / 17
7322238
NUM NUM NUM NUM
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW10 BLOWER SWITCH 5 16
C103 TAILGATE HARNESS 8 6,14,15,17 C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW11 AC SWITCH 3 16
C104 TAILGATE FANS 4 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW12 DPF SWITCH 10 12
C105 HYD CHARGE PRESSURE 3 11 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 T1 BATT GROUND 1 6
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 T2 BUZZER GROUND 1
12
C111 MFR-BCT ENG HARN CONN 3 9 C350 AC EVAPORATOR SWITCH 2 16 C492 ACS/SJC/AWS-MFR 8 5,7,13 T3 FLASHER 2 17
C112 HYD OIL FILTER SWITCH 2 11 C355 FUEL HARNESS 6 9,17 C493 ACS/SJC/AWS-MFR 4 4,6 T4 MEGAFUSE 1 4
C113 RIGHT TAILGATE FAN CONN 2 9 C404 BACK UP ALARM 2 5,14 C497 SJC HORN/BLINKER 3 17 T6 BATT GROUND 1 6
C114 HAND THROTTLE 6 9 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 T8 BATT GROUND 1 6
C115 FOOT THROTTLE 6 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 T10 ENGINE SYSTEM GROUND 1 6
C116 FOOT THROTTLE INTMD 3 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C503 RH DLX PANEL 6 7,12 T13 BUZZER POWER 1 12
15,17
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C602 LEFT REAR TAIL LIGHT 2 15 T14 PRE HEATER 1 9
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C603 RIGHT REAR TAIL LIGHT 2 15 T15 RIGHT REAR WORK LIGHT(+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C606 POWER BOBTACH OPEN 2 17 T16 RIGHT REAR WORK LIGHT(-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C607 POWER BOBTACH CLOSE 2 17 T17 LEFT REAR WORK LIGHT (+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C610 HVAC DUCT FAN 2 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C611 BLOWER MOTOR 4 16 T19 BACKUP ALARM 1 14
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C630 THERMOSTAT 3 16 T20 BACKUP ALARM (GND) 1 14
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C635 HEATER VALVE 6 16 T26 FUSE 150 AMP 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C667 DOOR HARNESS 6 13 T27 PRE HEATER CONTACTOR PWR 1 9
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 C670 EXTERIOR BEACON HARNESS 6 17 T29 BATTERY 1 9
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 C676 RADIO 6 17
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15,
T31 PREHEATER 1 9
VALVE 16
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J1A GATEWAY CONTROLLER 34 5,9,11,12, T33 DCU CASE GND 1 10
14,15,16,17
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 1 13
T37 DOME LIGHT +
12,14,13,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J2A AUX CONTROLLER 34 11,14,17 1 13
T38 DOME LIGHT -
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 9
T42 PREHEATER FDBK
14,17
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW2 BEACON SWITCH 6 17
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW3 HAZARD SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW5 POWER BOBTACH SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW6 BUCKET POSITION SWITCH 6 17
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW9 TRAVEL CONTROL SWITCH 6 12
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 1 of 20

J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 LH PADDLE RIGHT B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 RH PADDLE LEFT B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 RH RIGHT ROCKER UP B-13 FRONT AUX (F) (BASE)
A-13 TRACTION PULL FDBK RELAY- D B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17 RH PWM LO
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 FLOAT B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21 RH TRIGGER RETURN
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HI
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25 TWO SPEED MAKEUP
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27 TWO SPEED MAKE-UP RETURN
A-28 LH RIGHT ROCKER UP
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30 RH LEFT ROCKER UP
A-30 HVAC FDBK RELAY - B
A-31 RH LEFT ROCKER DOWN
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1
WIRING SCHEMATIC
HARNESS PART NUMBER
LF MFR CTRL 7267009 (ACS/SJC MACHINE)
DLX CAB 7253375
DLX FUEL 7266824 S770 (S/N AT5A11001 - AT5A11533)
BCT ENG 7242470
TAILGATE DOM 7267103 S770 (S/N B3BV11001 - B3BV11242)
SUSP JSTK 7163706
BRAKE ADAPTER 7234968 Sheet 2 of 20
WHL 2 SPD ADP 7159366
TRK 2 SPD 7243409
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
ENGINE CONTROLLER
CONNECTOR J7 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
3 SW POWER
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CONTROLS PAGE14 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 15 (TWO WIRE BREAKS
6 GND
OPTIONS PAGE 17 SHEET #
SIGNAL
13
14
15
19 ECU RUN SIGNAL

21
24
25
26
SENSOR FREQUENCY
29
33
GROUND
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL
WIRING SCHEMATIC
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 3 of 20

(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
SP7 SHEET 12
FUSE 11 25 A J1B
SHEET 12
SP2 C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
C493
T4
ACS/SJC/AWS-MFR HARN
FUSE 17 25 A (4 PIN)
1280 RED 1235 RED/WHT 2
SHEET 9
STARTER
FUSE 4 25 A
SHEET 16
SHEET 15
1340 RED SHEET 15
SP26 1330 RED/WHT FRC1 FRONT LIGHT RELAY
SHEET 15

1325 RED FUSE 16 25 A
SHEET 5
SHEET 9
1095 RED 1100 RED/WHT HEATER HOSE RELAY Printable Version Click Here
SHEET 10

SHEET 10
WIRING SCHEMATIC
1045 RED 10 1105 RED/WHT 10 SHEET 9 1460 RED/WHT (ACS/SJC MACHINE)
SHEET 17
1040 RED FUSE 22 25 A
1490 RED/WHT
C412 LH HANDLE HORN
1410 RED/WHT
SHEET 17
S770 (S/N AT5A11001 - AT5A11533)
SP60 SP24 C408 CAB-MFR CONN
1055 RED 1290 RED
FUSE 24 25 A
1370 RED/WHT
SHEET 13
(OPTIONS) S770 (S/N B3BV11001 - B3BV11242)
C408 CAB-MFR CONN
1050 RED
(ACCESSORIES) Sheet 4 of 20
SHEET 5
1030 RED
FRC1 STARTER RELAY
FRC1
ENGINE ECU
1525 RNG
SCR INTERCONNECT
+12V RELAY - G
PWR 1506 RNG/WHT 1

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A SP50 C489

FUSE 6 25 A
SHEET 13 C408 CAB-MFR CONN (FR WIPER)
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
1950 RNG/WHT
1765 RNG/WHT SP25 1795 RNG/WHT FUSE 7 25 A
1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
1580 RNG/WHT Printable Version Click Here
+12V SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR
30
SHEET 4
1050 RED
87 1815 RNG/WHT
FUSE 23 15 A
1800 RNG/WHT
WIRING SCHEMATIC
GND 85 86
SHEET 6
2055 BLK
(ACS/SJC MACHINE)
3450 LBL 21
C428
3380 LBL 4
J1A
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
S770 (S/N AT5A11001 - AT5A11533)
C449 LH JOYSTICK
S770 (S/N B3BV11001 - B3BV11242)
C492
1740 RNG/WHT 6 ACS/SJC/AWS-MFR HARN
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 20
(8 PIN)
Printed In U.S.A. (PRINTED DECEMBER 2016)

7226988 (B)
2320 BRN
SHEET 11
GROUND
2370 BRN J1B
SHEET 13 GWY CTRLR
2220 BRN SP12 2230 BRN 17
SHEET 11
2190 BRN
2 2001 BLK SHEET 11
J7A SHEET 9
2150 BRN
SHEET 9
T32 2004 BLK
SHEET 10 2695 BRN
SHEET 9
C120 SCR-MFR CONN C115 FOOT THROTTLE
2430 BRN 18
2080 BLK C493 3 2235 BLK SHEET 9
SHEET 7 ACS/SJC/AWS-MFR HARN ENGINE TEMP GND
C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 7 C408 BATT GND
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 15
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SHEET 16
2960 BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
2250 BLK GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 17
2700 BLK 2770 BLK
SHEET 12 SHEET 17
2785 BLK 2200 BLK
SHEET 17 SHEET 11
2620 BLK
SHEET 15 C103 C489
SHEET 14 2650 BLK
SP51 2600 BLK 2390 BLK 10
T20 BU ALARM B 2600 BLK T1 2015 BLK T10
SP6
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
2455 BLK
2630 BLK SHEET 17
T18 LH REAR LIGHT
2710 BLK 2300 BLK
SHEET 7
2715 BLK
SHEET 8
C169 ENGINE CAN
SHEET 16
2290 BLK WIRING SCHEMATIC
SHEET 15 2045 BLK D4 COMPRESSOR DIODE
SHEET 11 2035 BLK SHEET 9
2295 BLK 18 (ACS/SJC MACHINE)
FRC1 TRACTION LOCK RELAY TAILGATE FANS RELAY GND
SHEET 15
2115 BLK SP55 2105 BLK SP5 2000 BLK S770 (S/N AT5A11001 - AT5A11533)
2520 BLK
SHEET 14
SHEET 5 2055 BLK
C410 LEFT HANDLE
2530 BLK
S770 (S/N B3BV11001 - B3BV11242)
SHEET 14
SHEET 16
FRC1 HVAC RELAY
2030 BLK C409 RIGHT HANDLE Sheet 6 of 20
SHEET 9 2005 BLK
FRC1 STARTER RELAY
SHEET 15
2120 BLK (PRINTED DECEMBER 2016)
Printed In U.S.A. FRC1 FRONT LIGHT RELAY 7226988 (B)
J1B
GWY CTRLR
C408
(BLACK)
CAN BUS
CAB-MFR HARN CONN 1
8 9250 PUR 9220 PUR 9220 PUR SP18 SP39 9430 PUR SP35 9450 PUR 9460 PUR
9260 PUR 9230 PUR SP31 SP79 9270 PUR SP19 4 9410 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP80 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR C492 RESISTOR
(8 PIN) 9440 PUR 4
C503
9290 PUR 7
9190 PUR/WHT 8
1830 RNG/WHT 1
SHEET 5 C450
9240 PUR 1 2070 BLK 2
9140 PUR/WHT 4 9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
2080 BLK 2
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
J1B WIRING SCHEMATIC

GWY CTRLR
21 3090 LBL D
(ACS/SJC MACHINE)
REMOTE RUN KEY
SHEET 5
1735 RNG/WHT
C
E
S770 (S/N AT5A11001 - AT5A11533)
SWITCHED POWER
1165 RED/WHT F
SHEET 4
SHEET 6
2710 BLK G UNSWITCHED POWER
GROUND
S770 (S/N B3BV11001 - B3BV11242)
Sheet 7 of 20
Printed In U.S.A.
7226988 (B)
J7A
ECU CNTRLR
ENGINE CAN BUS SP81 SP90
C121
DOSING CONTROL UNIT
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR
NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
SHEET 10 2870 BLK

NOx POST TREATMENT
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
C169
1640 RNG/WHT 4
ENGINE CAN
9225 PUR 1
1 1725 RNG/WHT 9125 PUR/WHT 2
SHEET 5
2 2715 BLK 2825 BLK 3
SHEET 6 SHEET 10
3 9155 PUR/WHT
4 9255 PUR C121 Printable Version Click Here
DOSING CONTROL UNIT
5 9720 PUR/WHT 82 CAN HI WIRING SCHEMATIC

6 9820 PUR 60
CAN LO
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 8 of 20

1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M ENGINE C111
MFR-BCT HARN CONN
STARTER
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
FUSE 12
SHEET 5
7 8210 TAN B
22 C115 FOOT ALTERNATOR G
3560 LBL C405 1800 RNG/WHT
AIR FOOT THROTTLE THROTTLE
2150 BRN B GND ADAPTER EXCITATION
SHEET 6 FILTER D
16 3150 LBL A SIG SWITCH HARNESS 2015 BLK
(NC) E 7217683 SHEET 6
C116
F ENGINE GROUND TERMINAL
FOOT THROTTLE INTDM
5695 YEL C 5695 YEL C +5V PWR
J1A SHEET 13
GWY CTRLR 33 3695 LBL A 3695 LBL A
SIG
2695 BRN B 2695 BRN B GND
SHEET 6
FRC1
TAILGATE FANS
25 3105 LBL 18 RELAY - C FUSE 15 A
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 1 A
30 LEFT 8110 TAN 14 8110 TAN 14 8125 TAN 14
SHEET 4 2 B
TAILGATE 2400 BLK 14 2400 BLK 14
TAILGATE FANS RELAY GND 2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 4 2405 BLK 14
TAILGATE SHEET 6 FUSE 15 A
C113
J1B C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN C172
C406 A B FAN CONN
12 3180 LBL C 3180 LBL A SIG 8135 TAN 14 A
FUEL SENDER
2180 BRN D 2180 BRN B GND B
10 3690 LBL SHEET 6 (30 - 270 OHM)

2430 BRN 18 TEMP CAB-MFR HARN CONN 2 PWR FUSE 150 A
SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 8515 TAN SP77 8500 TAN
(950-4400 OHM) T14
T26 T27
3690 LBL 6 3690 LBL A 8510 TAN 85 86 1445 RED/WHT
SIG
8007 TAN
SHEET 6 8505 TAN T31
D
E
J7A F
ENG ECU CTRLR 8020 TAN SP74 Printable Version Click Here
SHEET 10
19 8008 TAN
WIRING SCHEMATIC
C100
9 3865 LBL 1
(ACS/SJC MACHINE)
34 2865 BRN 2 (FUEL FILTER)
56
GND
S770 (S/N AT5A11001 - AT5A11533)
C118
ENG-CROSSOVER
S770 (S/N B3BV11001 - B3BV11242)
28 8013 TAN
35 8014 TAN SHEET 5 1511 RNG/WHT

8013 TAN
1
2 FREQ
TO C154 - Pin 1
See Sheet 18 of 20
TO MAF - Pin 1
Sheet 9 of 20
See Sheet 18 of 20
8014 TAN 3 TEMP TO MAF - Pin 4
See Sheet 18 of 20
4
T42 3420 LBL TO GLOW PLUG - ECU Pin 179
See Sheet 18 of 20
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
DCU CASE GND
85 86
2915 BLK
C121
DOSING CONTROL UNIT
SP62
71 C123
1255 RED/WHT 73 67 HOSE 1 HEATER
2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
2945 BLK 7 SP88 8330 TAN 30
8140 TAN
SHEET 8 72 8340 TAN
2870 BLK 2855 BLK 29
C124
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 2135 BRN SP85
C155
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 8260 TAN 8250 TAN 30
SP89 87 2965 BLK
C156 C125
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
2 61 85 86
28 8600 TAN
C158
1 8520 TAN 62
CATALYST TEMPERATURE Printable Version Click Here
2 84 C122
SCR OUTLET 2160 BRN
SUPPLY MODULE
C159
4 1690 RNG/WHT 11 WIRING SCHEMATIC
1 8800 TAN 31 HEATER BATT+
2 2050 BRN 9
3 8650 TAN 12
HEATER SIGNAL (ACS/SJC MACHINE)
55 1695 RNG/WHT 3
C160 76 8700 TAN 2
PUMP MOTOR BATT +
S770 (S/N AT5A11001 - AT5A11533)
1 PUMP MOTOR CONTROL SIGNAL
8530 TAN 18 TXL 34
54 2095 BRN 4
PUMP MOTOR GND S770 (S/N B3BV11001 - B3BV11242)
77 5
1680 RNG/WHT
78 8750 TAN 6
PURGING PUMP BATT +
Sheet 10 of 20
PURGING PUMP SIGNAL
17 1685 RNG/WHT 10
PRESSURE SENSOR BATT+
39 3000 LBL 9 (PRINTED DECEMBER 2016)
PRESSURE SENSOR SIGNAL
Printed In U.S.A.
40 2085 BRN 8
PRESSURE SENSOR GND 7226988 (B)
PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
C425
B C308
BRAKE
1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
SHEET 4 87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
GND 85 86 12 V
2035 BLK OPTIONS DWG)
SHEET 6 WHEEL 2 SPD ADP HARNESS 7159366
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG
HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR Printable Version Click Here
J2A
C418 WIRING SCHEMATIC
18 2330 BRN 2 GND FRONT ROD
AUX CTRLR
4330 LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
(ACS/SJC MACHINE)
1 2340 BRN
C419
2 GND FRONT BASE
S770 (S/N AT5A11001 - AT5A11533)
3.3 OHM PWM S770 (S/N B3BV11001 - B3BV11242)
Sheet 11 of 20
19 13
J2B
CAB DISPLAY
T13
BUZZER (+)
1940 RNG/WHT
SHEET 5
LEFT PANEL C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12 7 C503
DESOX INHIBIT SWITCH (OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 4 8070 TAN
1 SHEET 6 GROUND
1 6
3 8060 TAN
WIRING SCHEMATIC
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 12 of 20

SW4
*
HAND/FOOT
SHEET 5
1785 RNG/WHT
2060 BLK
(ACS)
H/ISO
(SJC, AWS)
SWITCH
2 1
5
3
6
CAB
C492
SHEET 14 4230 LGN
C438
(DK GRAY)
SHEET 13
4 * DLX CAB HARN 7253375 ONLY
(8 PIN) CAB-MFR HARN CONN 3
5
SHEET 14 4240 LGN
4220 LGN 4235 LGN 7 4235 LGN
3 4275 LGN SP29 8 4275 LGN
9
2 4550 LGN
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
* T37
DOME LIGHT (+)
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR WIRING SCHEMATIC
SHEET 9 5690 YEL
HARNESS WASHER PUMP
7253378
(ACS/SJC MACHINE)
SHEET 9 5695 YEL
S770 (S/N AT5A11001 - AT5A11533)
* C252
A
C253
1
PWR S770 (S/N B3BV11001 - B3BV11242)
7310 WHT WASHER
2845 BLK B 2845 BLK 2 GND

MOTOR
Sheet 13 of 20

MANUAL CONTROLS J2A SHEET 6
2530 BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
K
AUX CTRLR SHEET 13 4230 LGN G
C404 A
BU ALARM-MFR HARN
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
SIG
2 7.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
SIG SHEET 5
7.8 OHM 12V J
2
4240 LGN H
SHEET 13
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 14 of 20

C434-1
LIGHTS
C408
(BLACK)
C434-2
SHEET 6 LEFT FRONT
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
FRC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - J C435-2
(DK GRAY)
6130 PNK A SIG
1350 RED/WHT 30
SHEET 4 87 6610 PNK 13 50.00 Watts
6610 PNK
2120 BLK 85 86 SP64

SHEET 6
6630 PNK
FRC1
FRONT WORK
LIGHTS RELAY - K C103
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
+12V RELAY - E
1320 RED/WHT
GND 85 2630 BLK GND WORK LIGHT
2045 BLK 86 SHEET 6
SHEET 6 T18 TERMINAL (-)
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 15 of 20

HVAC * C610
2440 BLK 2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK
* C483
C BLK
POTENTIOMETER
* DLX CAB HARN 7253375 ONLY 7420 WHT
7425 WHT
A
B
DBL
WHT
(TEMP CONTROL
SWITCH)
(NOT IN STD CAB HARN) C635
* D SIG
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10

PWR 30 OFF
1140 RED/WHT
1
2030 BLK GND 85 86 4
SHEET 6 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

SWITCH B 7023 WHT 7020 WHT 1 Printable Version Click Here
A 7024 WHT
C486
WIRING SCHEMATIC
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
(ACS/SJC MACHINE)
2290 BLK 2280 BLK
SHEET 6
D4 S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 16 of 20

C355
C428
(LT GRAY)
OPTIONS
# C607
FUEL HARN CAB-MFR HARN CONN 2 #
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB
CLOSE GND 2 2470 BLK 2770 BLK B 2770 BLK
SHEET 6 4480 LGN (NOT IN STD FUEL HARN 7149219)
*POWER
SW5
2 1
# C606 BOBTACH
SWITCH 5
3
4
GND 2 2480 BLK 6
POWER BOB
OPEN SIG 1 4480 LGN F 4480 LGN 10 (NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
4
2 * SW6
OPTIONS DWG)
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
C497
SJC RIGHT
*-
C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1885 RNG/WHT 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 13 SHEET 13
3 6520 PNK B OPTIONS DWG) 2 6
J2A 2885 BLK
SHEET 13
AUX CTRLR
C415
4460 LGN A SIG
SOLENOID
7.5 OHM 12 V
J2B
AUX CTRLR
26
(ACS/SJC MACHINE)
C441
TRACK 2 SPEED
S770 (S/N AT5A11001 - AT5A11533)
J1A 26 2350 BRN 2 GND TWO SPEED
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL S770 (S/N B3BV11001 - B3BV11242)
OPTIONS DWG)
J1B
GWY CTRLR
26
Sheet 17 of 20

SUPPLIED ENGINE HARNESS
TO C118 - Pin 4
See Sheet 9 of 20 PRE HEATER 179 J7B
ENG ECU CTRLR
(DOOSAN HARNESS)
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4
EGR VALVE INTAKE
DC MOTOR 3 POSITION RETURN 172 169 SENSOR RETURN 4 MANIFOLD TEMP
6 H BRIDGE POS 192
2 H BRIDGE NEG 193
C149 TO C118 - Pin 33

1 COOLANT TEMP SENSOR 109 See Sheet 9 of 20
COOLANT TEMP 4 INTAKE
C148 137 POSITION SENSOR GRD 3
1 FUEL TEMP SENSOR 110 TO C118 - Pin 2 2
FUEL TEMP
SENSOR 2 FUEL RETURN 146 See Sheet 9 of 20
C136
ENGINE BLOCK SENSOR SIGNAL 111 OIL TEMPERATURE SENSOR TEMPERATURE
RETURN GRD
SHIELD 128
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK
ACCELEROMETER 2 2 SENSOR RETURN 133
SHIELD 129
C145
CRANKSHAFT CRANK POSITION SENSOR 160
POSITION 136
CRANK SENSOR NEG
SENSOR
C144
C138
1 SENSOR RETURN 147
CAM SHAFT 2 POS SENSOR 159 Printable Version Click Here
SENSOR 112 INTAKE PRESSURE SENSOR A
3 VREF1 CAM TO C118 - Pin 1 INLET TEMP
167 INTAKE PRESSURE RETURN D PRESSURE
C143
See Sheet 9 of 20 SENSOR WIRING SCHEMATIC
1 RAIL PRESS URE SENSOR 135
RAIL PRESSURE
SENSOR
2 SENSOR RETURN 119 (ACS/SJC MACHINE)
3 138 C139
VREF 1 SENSOR 127 FUEL INJECTOR HSDA
CYL 1
S770 (S/N AT5A11001 - AT5A11533)
C141 126 FUEL INJECTOR LSD1A
CYL 3
FUEL INJECTOR HSDB
FUEL INJECTOR LSD1B
151
175 C140
S770 (S/N B3BV11001 - B3BV11242)
150 FUEL INJECTOR HSDB
C142 174 FUEL INJECTOR LSD2B CYL 2 Sheet 18 of 20
CYL 4 125 C154
FUEL INJECTOR LSD2A
177 PWM 2
INLET METERING (PRINTED DECEMBER 2016)
TO C118 - Pin 1 1 VALVE
Printed In U.S.A. See Sheet 9 of 20 7226988 (B)
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS 7164144
K TILT PEDAL K TILT MOTOR 2
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A PWM
+5V
5970 YEL 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A HALL SENSOR 2980 BRN 1 GND
+5V PWR
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GND
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H
E
3980 LBL
3990 LBL
(ACS/SJC MACHINE)
S770 (S/N AT5A11001 - AT5A11533)
S770 (S/N B3BV11001 - B3BV11242)
Sheet 19 of 20

ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
SJC PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN

A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
6 ISO LITE
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
SJC 7234953 LIFT 14 RF ANGLE
C429 ACTUATOR
A22 PUMP 7198705 15 LR ANGLE
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
2980 BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
C428 23 R QUAD A DRIVE
34 TILT ACTUATOR
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
6 27 GROUND
23 2990 BRN 1 GND
24 28 GROUND
4290 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN BRN 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1710 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4270 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A
C474 1 1830 RNG/WHT 1 +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493

28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2
48 1260 RED/WHT 1170 RED/WHT 1
2240 BLK 4
(ACS/SJC MACHINE)
1760 RNG/WHT S770 (S/N AT5A11001 - AT5A11533)
2280 BLK
2270 BLK
2260 BLK
S770 (S/N B3BV11001 - B3BV11242)
1180 RED/WHT
1190 RED/WHT
Sheet 20 of 20
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED DECEMBER 2016)
HARNESS)

CONN DESCRIPTION NUM SHEET CONN DESCRIPTION NUM SHEET CONN DESCRIPTION NUM SHEET CONN DESCRIPTION NUM SHEET
OF OF OF OF
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW6 BUCKET POSITION SWITCH 6 17
C103 TAILGATE HARNESS 8 6,14,15,17 C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW9 TRAVEL CONTROL SWITCH 6 12
C104 TAILGATE FANS 4 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW10 BLOWER SWITCH 5 16
C105 HYD CHARGE PRESSURE 3 11 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 SW11 AC SWITCH 3 16
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 SW12 DPF SWITCH 10 12
C111 MFR-BCT ENG HARN CONN 3 9 C350 AC EVAPORATOR SWITCH 2 16 C492 ACS/SJC/AWS-MFR 8 5,7,13 T1 BATT GROUND 1 6
C112 HYD OIL FILTER SWITCH 2 11 C355 FUEL HARNESS 6 9,17 C493 ACS/SJC/AWS-MFR 4 4,6 T2 BUZZER GROUND 1 12
C113 RIGHT TAILGATE FAN CONN 2 9 C404 BACK UP ALARM 2 5,14 C497 SJC HORN/BLINKER 3 17 T3 FLASHER 2 17
C114 HAND THROTTLE 6 9 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 T4 MEGAFUSE 1 4
C115 FOOT THROTTLE 6 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 T6 BATT GROUND 1 6
C116 FOOT THROTTLE INTMD 3 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C503 RH DLX PANEL 6 7,12 T8 BATT GROUND 1 6
15,17
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C603 RIGHT REAR TAIL LIGHT 2 15 T13 BUZZER POWER 1 12
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C606 POWER BOBTACH OPEN 2 17 T14 PRE HEATER 1 9
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C610 HVAC DUCT FAN 2 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 C676 RADIO 6 17 T27 PRE HEATER CONTACTOR PWR 1 9
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15, T29 BATTERY 1 9
VALVE 16
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J1A GATEWAY CONTROLLER 34 5,9,11,12, T31 PREHEATER 1 9
14,15,16,17
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 T32 ECU CASE GND 1 6
12,13,14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J2A AUX CONTROLLER 34 11,14,17 T33 DCU CASE GND 1 10
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 J2B AUX CONTROLLER 26 4,5,6,7,11, T37 DOME LIGHT + 1 13
14,17
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9 T38 DOME LIGHT - 1 13
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 RC1 FRONT WORK-LIGHTS RELAY 4 15 T42 PREHEATER FDBK 1 9
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 RC2 FRONT WORK-LIGHTS RELAY 4 15
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW1 BRAKE SWITCH 6 12
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW2 BEACON SWITCH 6 17
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW3 HAZARD SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW5 POWER BOBTACH SWITCH 6 17
(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 1 of 20
Printed In U.S.A. 7281506 (A)
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 LH PADDLE RIGHT B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 RH PADDLE LEFT B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 RH RIGHT ROCKER UP B-13 FRONT AUX (F) (BASE)
A-13 TRACTION PULL FDBK RELAY- D B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17 RH PWM LO
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 FLOAT B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21 RH TRIGGER RETURN
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HI
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25 TWO SPEED MAKEUP
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27 TWO SPEED MAKE-UP RETURN
A-28 LH RIGHT ROCKER UP
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30 RH LEFT ROCKER UP
A-30 HVAC FDBK RELAY - B
A-31 RH LEFT ROCKER DOWN
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1
HARNESS PART NUMBER WIRING SCHEMATIC Printable Version Click Here
LF MFR CTRL 7281508

DLX CAB 7253375 (ACS/SJC MACHINE)
DLX FUEL 7266824
BCT ENG 7242470 S770 (S/N AT5A11534 - AT5A11719)
SUSP JSTK 7163706 S770 (S/N B3BV11243 - B3BV11289)
BRAKE ADAPTER 7234968
WHL 2 SPD ADP 7159366
Sheet 2 of 20
TRK 2 SPD 7243409

LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
ENGINE CONTROLLER
CONNECTOR J7 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
3 SW POWER
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CONTROLS PAGE14 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 15 (TWO WIRE BREAKS
6 GND
OPTIONS PAGE 17 SHEET #
SIGNAL
19 ECU RUN SIGNAL
SENSOR FREQUENCY
GROUND
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL
WIRING SCHEMATIC
(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 3 of 20

(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
SP7 SHEET 12
FUSE 11 25 A J1B
SHEET 12
SP2 C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
C493
T4
FUSE 17 25 A (4 PIN)
1280 RED 1235 RED/WHT 2
SHEET 9
STARTER
FUSE 4 25 A
SHEET 16
SHEET 15
1350 RED/WHT FRC1 REAR LIGHT RELAY
FUSE 2 20 A SHEET 15
SP26 SHEET 15 FRC1 FRONT LIGHT RELAY

1325 RED FUSE 16 25 A
SHEET 5
SHEET 9

SHEET 10
SHEET 10
WIRING SCHEMATIC
1045 RED 10 1105 RED/WHT 10 SHEET 9 1460 RED/WHT
1040 RED FUSE 22 25 A

SHEET 17
C412 LH HANDLE HORN (ACS/SJC MACHINE)
SHEET 17
1055 RED
SP60
1290 RED
FUSE 24 25 A
1370 RED/WHT
SP24 C408 CAB-MFR CONN
(OPTIONS)
S770 (S/N AT5A11534 - AT5A11719)
SHEET 13
C408 CAB-MFR CONN
(ACCESSORIES)
S770 (S/N B3BV11243 - B3BV11289)
1050 RED
SHEET 5
Sheet 4 of 20
1030 RED
FRC1 STARTER RELAY
FRC1
ENGINE ECU
1525 RNG
SCR INTERCONNECT
+12V RELAY - G
PWR 1506 RNG/WHT 1

85 86
8005 TAN 45

FUSE 21 15 A
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A SP50 C489


1760 RNG/WHT SHEET 13 C408 CAB-MFR CONN (FR WIPER)
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
1950 RNG/WHT
1765 RNG/WHT SP25 1795 RNG/WHT FUSE 7 25 A
1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
1580 RNG/WHT
+12V SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR 30
SHEET 4 1050 RED
87 1815 RNG/WHT
WIRING SCHEMATIC
GND 85 86
SHEET 6 2055 BLK
(ACS/SJC MACHINE)
3450 LBL 21
C428
3380 LBL 4
J1A
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
S770 (S/N AT5A11534 - AT5A11719)
C449 LH JOYSTICK
S770 (S/N B3BV11243 - B3BV11289)
C492
1740 RNG/WHT 6 ACS/SJC/AWS-MFR HARN
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 20
(8 PIN)

GROUND SHEET 11
SHEET 13
2320 BRN
2370 BRN
2220 BRN SP12 2230 BRN
J1B
GWY CTRLR
17
SHEET 11
2190 BRN
2 SHEET 11
2001 BLK C105 HYD CHG PRESSURE SENDER
J7A SHEET 9
2150 BRN
SHEET 9
T32 2004 BLK
SHEET 10 2695 BRN
SHEET 9
C120 SCR-MFR CONN C115 FOOT THROTTLE
2430 BRN 18
2080 BLK C493 3 2235 BLK SHEET 9
SHEET 7 ACS/SJC/AWS-MFR HARN ENGINE TEMP GND
C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 7 C408 BATT GND
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 15
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
2745 BLK
C499 PTOL SHEET 16
2960 BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 17
2700 BLK 2770 BLK
SHEET 12 SHEET 17
2785 BLK 2200 BLK
SHEET 17 SHEET 11
2620 BLK
SHEET 15 C103 C489
SHEET 14 2650 BLK
SP51 2600 BLK 2390 BLK 10
T20 BU ALARM B 2600 BLK T1
2015 BLK T10
SHEET 15 SP6
2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
2455 BLK
2630 BLK SHEET 17
T18 LH REAR LIGHT
2710 BLK 2300 BLK
SHEET 7
2715 BLK
SHEET 8
C169 ENGINE CAN
SHEET 16
2290 BLK WIRING SCHEMATIC
SHEET 15 2045 BLK D4 COMPRESSOR DIODE
SHEET 11 2035 BLK SHEET 9 2295 BLK 18 (ACS/SJC MACHINE)
SHEET 15 2115 BLK SP55 2105 BLK SP5 2000 BLK S770 (S/N AT5A11534 - AT5A11719)
FRC1 FRONT LIGHT RELAY 2520 BLK
SHEET 14
SHEET 5
2055 BLK
C410 LEFT HANDLE
2530 BLK
S770 (S/N B3BV11243 - B3BV11289)
SHEET 14
SHEET 16
FRC1 HVAC RELAY
2030 BLK C409 RIGHT HANDLE Sheet 6 of 20
SHEET 9 2005 BLK
FRC1 STARTER RELAY
SHEET 15
2120 BLK (PRINTED DECEMBER 2016)
Printed In U.S.A. FRC1 FRONT LIGHT RELAY
7281506 (A)
J1B
C408
(BLACK)
CAN BUS
GWY CTRLR CAB-MFR HARN CONN 1
8 9250 PUR 9220 PUR 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR
9260 PUR 9230 PUR SP31 SP79 9270 PUR SP19 4 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP80 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR C492 RESISTOR
(8 PIN) 9440 PUR 4
C503
9290 PUR 7
9190 PUR/WHT 8
1830 RNG/WHT 1
SHEET 5 C450
9240 PUR 1 2070 BLK 2
9140 PUR/WHT 4 9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
2080 BLK 2
9280 PUR 8 9300 PUR/WHT 3
J2B C426 SHEET 14
9180 PUR/WHT 9 9400 PUR 4
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
J1B
21 3090 LBL D
C
REMOTE RUN KEY WIRING SCHEMATIC
1735 RNG/WHT E
SHEET 5
SHEET 4
1165 RED/WHT F
SWITCHED POWER
UNSWITCHED POWER
(ACS/SJC MACHINE)
2710 BLK G
SHEET 6 GROUND
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 7 of 20
Printed In U.S.A.
7281506 (A)
ENGINE CAN BUS C121
J7A
ECU CNTRLR DOSING CONTROL UNIT
SP81 SP90
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
SHEET 10 2870 BLK

NOx POST TREATMENT
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
C169
1640 RNG/WHT 4
ENGINE CAN
9225 PUR 1
1 1725 RNG/WHT 2
2 2715 BLK 2825 BLK 3
SHEET 6 SHEET 10
3 9155 PUR/WHT
4 9255 PUR C121
DOSING CONTROL UNIT
5 9720 PUR/WHT 82 CAN HI WIRING SCHEMATIC Printable Version Click Here

6 9820 PUR 60
CAN LO
(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 8 of 20

1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M C111
MFR-BCT HARN CONN
STARTER
ENGINE
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
FUSE 12
SHEET 5
7 8210 TAN B
22 C115 FOOT ALTERNATOR G
3560 LBL C405 1800 RNG/WHT
AIR FOOT THROTTLE THROTTLE
2150 BRN B GND ADAPTER EXCITATION
SHEET 6 FILTER D
16 3150 LBL A SIG SWITCH HARNESS 2015 BLK
(NC) E 7217683 SHEET 6
C116
F ENGINE GROUND TERMINAL
FOOT THROTTLE INTDM
5695 YEL C 5695 YEL C +5V PWR
J1A SHEET 13
GWY CTRLR 33 3695 LBL A 3695 LBL A
SIG
2695 BRN B 2695 BRN B GND
SHEET 6
FRC1
TAILGATE FANS
25 3105 LBL 18 RELAY - C FUSE 15 A
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 1 A
30 LEFT 8110 TAN 14 8110 TAN 14 8125 TAN 14
SHEET 4 2 B
TAILGATE 2400 BLK 14 2400 BLK 14
TAILGATE FANS RELAY GND 2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 4 2405 BLK 14
TAILGATE SHEET 6 FUSE 15 A
C113
J1B C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN C172
C406 A B FAN CONN
12 3180 LBL C 3180 LBL A SIG 8135 TAN 14 A
FUEL SENDER
10 2180 BRN D 2180 BRN B GND (30 - 270 OHM) B
3690 LBL SHEET 6

2430 BRN 18 TEMP CAB-MFR HARN CONN 2 PWR FUSE 150 A
SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 8515 TAN SP77 8500 TAN
(950-4400 OHM) T14
T26 T27
3690 LBL 6 3690 LBL A 8510 TAN 85 86 1445 RED/WHT
SIG
8007 TAN
8505 TAN T31
SHEET 6 D
E
J7A F
8020 TAN SP74
ENG ECU CTRLR SHEET 10 Printable Version Click Here
19 8008 TAN
WIRING SCHEMATIC
C100
9 3865 LBL 1
(ACS/SJC MACHINE)
34 2865 BRN 2 (FUEL FILTER)
56
GND
S770 (S/N AT5A11534 - AT5A11719)
C118
ENG-CROSSOVER
S770 (S/N B3BV11243 - B3BV11289)
28 8013 TAN
35 8014 TAN SHEET 5 1511 RNG/WHT

8013 TAN
1
2
Sheet 9 of 20
FREQ
8014 TAN 3 TEMP
4
T42 3420 LBL (PRINTED DECEMBER 2016)
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
85 86
DCU CASE GND
2915 BLK
C121
DOSING CONTROL UNIT
SP62
71 C123
1255 RED/WHT 73 67 HOSE 1 HEATER
2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
7 SP88 8330 TAN 30
8140 TAN
SHEET 8 2945 BLK 72 8340 TAN
2870 BLK 2855 BLK 29
C124
22 2145 BRN
8020 TAN
94 1
SHEET 9 8550 TAN
8240 TAN 2
53 2135 BRN SP85
C155
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 8260 TAN 8250 TAN 30
SP89 87 2965 BLK
C156 C125
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
2165 BLK 2
8350 TAN
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
2 61 85 86
28 8600 TAN
C158
1 8520 TAN 62
CATALYST TEMPERATURE Printable Version Click Here
2 84 C122
SCR OUTLET 2160 BRN SUPPLY MODULE
C159
4 1690 RNG/WHT 11 WIRING SCHEMATIC
1 8800 TAN 31 HEATER BATT+
2 2050 BRN 9
3 8650 TAN
12
HEATER SIGNAL (ACS/SJC MACHINE)
55 1695 RNG/WHT 3
C160 76 8700 TAN
2
PUMP MOTOR BATT +
S770 (S/N AT5A11534 - AT5A11719)
1 34 PUMP MOTOR CONTROL SIGNAL
8530 TAN 18 TXL
54 2095 BRN 4
PUMP MOTOR GND S770 (S/N B3BV11243 - B3BV11289)
77 1680 RNG/WHT 5
78 8750 TAN 6
PURGING PUMP BATT +
Sheet 10 of 20
PURGING PUMP SIGNAL
17 10
39 3000 LBL
9 (PRINTED DECEMBER 2016)
PRESSURE SENSOR SIGNAL
Printed In U.S.A.
40 2085 BRN 8
PRESSURE SENSOR GND 7281506 (A)
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS C425
B C308
4100 LGN BRAKE
1360 RED/WHT PWR 30
SHEET 4 4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
8 4110 LGN
13 3430 LBL
C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
J2A
C418 WIRING SCHEMATIC
18 2330 BRN 2 GND FRONT ROD
AUX CTRLR
4330 LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
(ACS/SJC MACHINE)
1 2340 BRN
C419
2 GND FRONT BASE
S770 (S/N AT5A11534 - AT5A11719)
3.3 OHM PWM S770 (S/N B3BV11243 - B3BV11289)
Sheet 11 of 20
19 13
J2B
T13
CAB DISPLAY
BUZZER (+)
1940 RNG/WHT
SHEET 5
LEFT PANEL C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12 7 C503
DESOX INHIBIT SWITCH (OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 4 8070 TAN
1 SHEET 6 GROUND
1 6
3 8060 TAN

(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 12 of 20
*SW4
CAB
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C492 C438 SHEET 13 2060 BLK 5 6 * DLX CAB HARN 7253375 ONLY
ACS/SJC/AWS-MFR HARN 4230 LGN (DK GRAY) 4
(8 PIN) SHEET 14
SHEET 14 4240 LGN
CAB-MFR HARN CONN 3
5 4220 LGN 4235 LGN 7 4235 LGN
3 4275 LGN SP29 8 4275 LGN
2 4550 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
*POWER
C212
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
* DOME
T37
LIGHT (+)
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * DOME
T38
LIGHT (-)
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1 WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR WIRING SCHEMATIC
SHEET 9 5690 YEL
HARNESS WASHER PUMP
7253378
(ACS/SJC MACHINE)
SHEET 9 5695 YEL
S770 (S/N AT5A11534 - AT5A11719)
* C252 A C253
1
PWR S770 (S/N B3BV11243 - B3BV11289)
7310 WHT WASHER
2845 BLK B 2845 BLK 2 GND

MOTOR
Sheet 13 of 20

MANUAL CONTROLS
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 6
AUX CTRLR SHEET 13 4230 LGN G
C404 A
BU ALARM-MFR HARN
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK 20 4640 LGN D
2 7.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 2990 BRN 3 11 4810 LGN F SIDE SHIFT
GND
SIG SHEET 5
7.8 OHM 12V J
2
4240 LGN H
SHEET 13
2520 BLK E
SHEET 6
7 5 Printable Version Click Here

J1B
GWY CTRLR WIRING SCHEMATIC
(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 14 of 20

C434-1
C408
(BLACK)
LIGHTS
C434-2
SHEET 6 LEFT FRONT
50.00 Watts
C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
RC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - 1 C435-2
(DK GRAY)
6130 PNK A SIG
6620 PNK SP23 2705 BLK B GND WORK LIGHT
87 6610 PNK 13 6610 PNK 50.00 Watts
2120 BLK 85 86 SP64

SHEET 6
6630 PNK
6000 PNK
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
+12V RELAY - E
1320 RED/WHT
GND 85 86 SHEET 6
SHEET 6 2045 BLK
T18 TERMINAL (-)
(ACS/SJC MACHINE)
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 15 of 20
HVAC 2440 BLK
7440 WHT
* C610
2
1
GND
SIG
HVAC DUCT
FAN
2560 BLK * C483

C BLK
7420 WHT A DBL POTENTIOMETER
7425 WHT B (TEMP CONTROL
* DLX CAB HARN 7253375 ONLY WHT SWITCH)
C635
(NOT IN STD CAB HARN) * D SIG
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10

PWR 30 OFF
1140 RED/WHT
1
2030 BLK GND 85 86 4
SHEET 6 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT Printable Version Click Here
C486
7025 WHT 1 SIG WIRING SCHEMATIC
2 MAGNET CLUTCH
GND
SHEET 6
2290 BLK 2280 BLK
(COMPRESSOR)
(ACS/SJC MACHINE)
D4
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Sheet 16 of 20
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
#
OPTIONS
# C607
POWER BOB
SIG
GND
1
2
4470 LGN
2470 BLK 2770 BLK
E
B
4470 LGN
2770 BLK
11 4470 LGN (NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 6 4480 LGN
SW5
*POWER 2 1
# C606 BOBTACH 3
SWITCH 5 4
POWER BOB
GND
SIG
2
1
2480 BLK
4480 LGN F 4480 LGN 10
6 (NOT IN STD CAB HARN)
OPEN
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
C411
B
SHEET 4
L
* FLASHER
T3
LEFT HANDLE CONN

C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
4
2 * SW6
OPTIONS DWG)
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
C497
SJC RIGHT
*- C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1885 RNG/WHT 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 13 SHEET 13
J2A 3 6520 PNK B OPTIONS DWG) 2885 BLK 2 6
SHEET 13
AUX CTRLR
C415
7.5 OHM 12 V
J2B
AUX CTRLR
26
(ACS/SJC MACHINE)
C441
TRACK 2 SPEED
S770 (S/N AT5A11534 - AT5A11719)
J1A 26 2350 BRN 2 GND TWO SPEED
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL S770 (S/N B3BV11243 - B3BV11289)
OPTIONS DWG)
J1B
GWY CTRLR
26
Sheet 17 of 20

ENGINE
T14 PRE HEATER 179 J7B
PRE HEATER C130
ENG ECU CTRLR 105 TEMP SENSOR 1
C153 EXHAUST GAS
(DOOSAN HARNESS)
1 122 TEMP SENSOR
SENSOR RETURN 1
WASTE GATE BEFORE DPF
2 186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 POSITION SENSOR 161 TEMP SENSOR
SUPPLIED
123 SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
2 POSITION FEEDBACK 113
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR
SENSOR RETURN
TEMP SENSOR
AIR RETURN 171
C135
C149 184 5
H BRIDGE POS
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
RETURN GND
SHIELD 128
C146
132 C137
1 SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
129 157 VM 2
SHIELD & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147 Printable Version Click Here
CAM SHAFT 2 159
POS SENSOR 112 A
SENSOR
3 VREF1 CAM 140
167
INTAKE PRESS SENSOR
INTAKE PRESS RETURN D
INLET TEMP
PRESSURE
WIRING SCHEMATIC
SENSOR
C143
1 RAIL PRESSURE SENSOR 135
134
168
INTAKE AIR TEMP SENSOR
INTAKE AIR TEMP RETURN
C
?
(ACS/SJC MACHINE)
RAIL PRESSURE
SENSOR
2
3
SENSOR RETURN
VREF 1 SENSOR
119
138 C139
S770 (S/N AT5A11534 - AT5A11719)
127 FUEL INJECTOR HSDA
C141
151
126 FUEL INJECTOR LSD1A CYL 1 S770 (S/N B3BV11243 - B3BV11289)
FUEL INJECTOR HSDB
CYL 3
150 FUEL INJECTOR HSDB
C140
Sheet 18 of 20
C142 174 CYL 2
FUEL INJECTOR LSD2B
CYL 4
FUEL INJECTOR LSD2A 125 C154 (PRINTED DECEMBER 2016)
177 PWM 2
Printed In U.S.A. INLET METERING
7281506 (A)
1 VALVE
ACS CONTROLLER
ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION HARNESS PART NUMBER
ACS 7164144 EXMF, LF
ACS 7190593 MF
F F LIFT HANDLE F LIFT MOTOR 1
CONTROLS
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
MAINFRAME HARNESS 1170 RED/WHT C409 C466
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A PWM
+5V
5970 YEL 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GND LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 4660 LGN 3 SIG K 4645 LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL Printable Version Click Here
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
3990 LBL 2 SIG
5750 YEL
5650 YEL 5980 YEL WIRING SCHEMATIC
5970 YEL 5990 YEL
(ACS/SJC MACHINE)
H
E
3980 LBL
3990 LBL
S770 (S/N AT5A11534 - AT5A11719)
S770 (S/N B3BV11243 - B3BV11289)
Printed In U.S.A. Sheet 19 of 20

ACS CONTROLLER
J5 DRIVE CONTROLLER
SJC
PIN FUNCTION
1 SAFETY IN
2 TWO SPEED SWITCH
3 SPARE DIGITAL INPUT 2
4 H PAT SWITCH
5 ISO PAT SWITCH
CONTROLS
6 ISO LITE
7 L SWASH PLATE ANGLE
8 R SWASH PLATE ANGLE
9 SPARE ANALOG 4
# 10 SPARE ANALOG 5
HARNESSES 7159325, 7159458 ONLY K TILT PEDAL K TILT MOTOR 2
11 L FWD RETURN
12 CAN HIGH
LIFT
C429 ACTUATOR 13 LF ANGLE
4600 LGN 5 14 RF ANGLE
J5 - DRIVE 4610 LGN
6
8
15 LR ANGLE
16 H PAT LITE
CONTROLLER 2980 BRN 1
4
GND
17 RR ANGLE
# C454 3980 LBL 2 SIG 18 L JOYSTICK X
29 2890 BRN 2880 BRN 3 GND
7 19 L JOYSTICK Y
5880 YEL 1 +5V PWR 5980 YEL 3 +5V PWR 20 R JOYSTICK X
LEFT SPEED
33 3880 LBL 2 SIG SENSOR 21 L FWD DRIVE
34 3885 LBL 4 SIG C428 TILT ACTUATOR 22 CAN LOW
5990 YEL 3 +5V PWR
40 5890 YEL # C453 4 23 R QUAD A DRIVE
+5V
5970 YEL
5870 YEL 1 +5V PWR 3990 LBL 2 24 R QUAD B DRIVE
SIG
2870 BRN 3 GND 6 25 TWO SPEED 1
23 3870 LBL 2 RIGHT SPEED
SIG 2990 BRN 1 GND 26 BRAKE LIGHT OUTPUT
SENSOR
24 3875 LBL 4 SIG 4640 LGN 5 27 GROUND
7
C536 28 GROUND
2970 BRN
5810 YEL 2 C543 A22 PUMP HARNESS 4650 LGN 8
29 SENSOR GROUND
2810 BRN 4 2810 BRN 1 GND
RIGHT
30 SENSOR SUPPLY 2 +5V
8 3810 LBL 3 3810 LBL 3 SIG
1710 RNG/WHT 1 1710 RNG/WHT 2 SWASHPLATE K 31 L REV DRIVE
+12V PWR
J 32 CAN SHIELD
J2-ACS
C537
E 33 L QUAD A DRIVE
5860 YEL 2 C542
H 34 L QUAD B DRIVE
2860 BRN 4 2860 BRN 1 GND
LEFT F 35 SAFETY OUT
7 3860 LBL 3 3860 LBL 3 SIG SWASHPLATE G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 36 BACKUP ALARM
C
37 R JOYSTICK Y
C501 C546 D
43 4260 LGN 1 4260 LGN 1 B 38 SPARE ANALOG 1
RIGHT FORWARD DRIVE
39 SPARE PWM COIL 7
ACS CONTROLLER
42 2660 BRN 2 2660 BRN 2 A
40 SENSOR SUPPLY 1 +5V
C547 41 L REV RETURN
44 4250 LGN 3 4250 LGN 1 A
RIGHT REVERSE DRIVE +5V 42 R FWD RETURN
45 2650 BRN 4 2650 BRN 2 G
43 R FWD DRIVE
J1-ACS
F
C545
44 R REV DRIVE
9240 PUR E
31 4280 LGN 5 4280 LGN 1 D 45 R REV RETURN
9140 PUR/WHT
41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE 46 TWO SPEED 2
1760 RNG/WHT B
2280 BLK H 47 UNSWITCHED BATTERY
C544 C 48 UNSWITCHED BATTERY
21 4270 LGN 7 4270 LGN 1
LEFT FORWARD DRIVE 49 SPARE PWN COIL 6
11 2670 BRN 8 2670 BRN 2
50 SWITCHED BATTERY
K
TO SJC BRAKE A
C474
HARNESS D
26 4210 LGN A
J3-ACS
(SEE ADDITIONAL OPTIONS F
SHEET) SUSP SEAT JOYSTICK HARNESS
2270 BLK H
2260 BLK J
C492
1180 RED/WHT C C460
12 9190 PUR/WHT 8 1 1830 RNG/WHT 1
1190 RED/WHT B +12V PWR
22 9290 PUR 7 C450 2 2
E 2070 BLK GND
4 4550 LGN 2
G RIGHT JOYSTICK 4 9660 PUR 4 CAN LO RIGHT
6 4220 LGN 5 (TO DLX CAB HARNESS) JOYSTICK
16 4275 LGN 3 3 3
9560 PUR/WHT CAN HI
9140 PUR/WHT 4
9240 PUR 1
50 1750 RNG/WHT 1740 RNG/WHT 6
MAINFRAME C459
HARNESS 1 1840 RNG/WHT 1 +12V PWR
27 2470 BLK C493 C449 2 2080 BLK 2 GND
28 2490 BLK 2235 BLK 3 LEFT JOYSTICK LEFT
(TO DLX CAB HARNESS) 4 9640 PUR 4 CAN LO
47 1250 RED/WHT 1235 RED/WHT 2 JOYSTICK
48 1260 RED/WHT 1170 RED/WHT 1 3 9540 PUR/WHT 3 CAN HI
2240 BLK 4
1760 RNG/WHT WIRING SCHEMATIC

2280 BLK
2270 BLK (ACS/SJC MACHINE)
2260 BLK
1180 RED/WHT
1190 RED/WHT
S770 (S/N AT5A11534 - AT5A11719)
36 7100 WHT
C404
A (CONNECTS TO BACKUP
S770 (S/N B3BV11243 - B3BV11289)
B ALARM C404 ON MFR
HARNESS) Sheet 20 of 20
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281506 (A)
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
LEGEND
9 SH09 - DOSING CONTROL UNIT
10 SH10 - HYDRAULICS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CONNECTOR
11 SH11 - CAB DISPLAY
12 SH12 - CAB BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 1 1
13 SH13 - MANUAL CONTROLS
14 SH14 - LIGHTS
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
15 SH15 - HVAC
16 SH16 - OPTIONS 1
17 SH17 - OPTIONS 2 MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
1 1
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN

1 1
CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
HARNESS PART NUMBER WIRE BREAK
LF MFR CTRL 7295962 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
DLX CAB 7301237 * SHT1/F2
WIRE BREAK
SHT1/F2
DLX FUEL 7266824 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
BCT ENG 7242470 ENGINE 8000 THROUGH 8999 TAN TAN
SUSP JSTK 7163706 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
WHL 2 SPD ADP 7159366 COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
TRK 2 SPD 7243409
DEF JUMPER 7305995
* CAB HARNESSES USED ON S/N AT5A11720-AT5A12586

B3BV11290-B3BV11649

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
PROPRIETARY NOTICE TOLERANCES: ECN 102537 Printed On October 2017
csf

ACS / SJC Machine S/N B3BV11290 through B3BV11599 7295961 (B)
SCHEM ELEC LF CTRL
Sheet 1 of 19
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
B
REV
REVISED C161 PIN ASSIGNMENTS
DESCRIPTION
103427 MPS
CHG NOTICE DWN
6
SHEET
SHT 1 / 17
7295961
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4
1400 RED/WHT
C408 SHT12/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT11/E4
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT SHT11/G8
2
11A 11B 3
SP2
FUSE 13 25 A SP36 J1B
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
+12V BATTERY MEGAFUSE
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT15/E8
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
25A 25B SHT9/H8
FUSE 26 15A
26A 26B SHT9/G8
FUSE 10 30A
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
22A 22B SHT16/F7
SP24
FUSE 24 25 A
24A 24B SHT12/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 2 of 19
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 2 / 17
7295961
SHT6/E4
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
86 85
G4
SP73
1508 RNG/WHT
3
POWER
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT7/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
12A 12B SHT16/G7
1700 RNG/WHT
SHT10/B8
SHT12/G3 SHT10/G8
1940 RNG/WHT
SHT10/H8
1930 RNG/WHT
SP11 1960 RNG/WHT
J2B SHT10/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT11/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT10/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT10/E4
SP42 1565 RNG/WHT
SHT16/E4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
A4 7A 7B SHT5/B8
GND
86 85
BUS BAR
A5 A2 1725 RNG/WHT
SHT6/D7
1580 RNG/WHT
8A 8B SHT12/F8
FUSE 23 15 A
23A 23B SHT7/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
J1A
C428
SP37
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3
C492
1740 RNG/WHT
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 3 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 3 / 17
7295961
ENG ECU CTRLR
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
6 2370 BRN
SHT11/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
1 2155 BLK 2190 BRN
SHT16/F4 SHT9/D7
J1B
2880 BLK 2180 BRN
SHT8/F8 SHT7/D7
C493
2150 BRN
ACS/SJC/AWS CONN 2 SHT7/G7
2235 BLK 2695 BRN
2080 BLK 3 3 SHT7/F7
SHT5/D3 2430 BRN
2240 BLK SHT7/C7
2070 BLK 4 4
SHT5/E3
C493 T6
2920 BLK 1 BATT GND
SHT10/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT10/G4 10 10
2960 BLK
SHT10/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT10/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
SHT13/H8
J1B
2745 BLK
SHT14/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT11/D8
2860 BLK 16
SHT16/C4
AUX CTRLR SHT15/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT16/H4 15
2065 BLK SP28 2730 BLK
2930 BLK C428
2830 BLK 2900 BLK 2900 BLK
SHT15/D5 1 1
2700 BLK SP47
SHT10/F8
2785 BLK 2770 BLK
SHT7/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT9/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT12/F8 C103
TAILGATE HARN T1
SHT13/C4 B B
SP51
2610 BLK
SHT13/E4 2400 BLK
SHT7/E4 AUX CTRLR
2630 BLK
SHT13/B4 2405 BLK 2195 BRN
SHT7/D4 SHT12/G3 SP58 2995 BRN
2185 BRN 17 SENSOR GROUND
SHT16/D7
2455 BLK
SHT15/D6 J2B
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
SHT6/D7
2505 BLK 2290 BLK

SHT16/G4 SHT14/B8
2045 BLK
SHT13/B8 2295 BLK
2035 BLK SHT7/D7
SHT9/G8
SP55 SP5 2000 BLK

2115 BLK 2105 BLK
SHT13/D8
2055 BLK 2520 BLK

SHT3/C1 SHT12/D3
2030 BLK 2530 BLK

SHT14/F8 SHT12/F3
2005 BLK
SHT7/G7
2120 BLK
SHT13/E8

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 4 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 4 / 17
7295961
CAN BUS
RE016 RE019 C479

C408
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
GATEWAY CTRLR R3-1 SP18 (BLACK)
SP79 SP19 SP39 SP35 TP-07 R1
TP-09 9260 PUR TP-09 TP-10
9230 PUR TP-10 SP31 TP-12 9250 PUR
TP-12 TP-14 9270 PUR TP-14 TP-16 9220 PUR TP-16 TP-01 9220 PUR TP-01 TP-03 9410 PUR TP-03 TP-05 9430 PUR TP-05 9450 PUR
TP-07 TP-08 9460 PUR TP-08
CAN LO 8 4 4 4 CAN LO

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
R3-2 SP20 TP-04
R2
J1B TP-02 TP-06
C479
C503
TP-15 RH DLX PANEL
9440 PUR TP-06
C492 4 CAN LO
ACS/SJC/AWS-MFR HARN (8 PIN)
9340 PUR/WHT
9290 PUR TP-15 2 CAN HI
TP-11 TP-13 7 7 CAN LO
9190 PUR/WHT C503

8 8 CAN HI
9240 PUR TP-13

1 1 CAN LO *
C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK
C450
RIGHT JOYSTICK
9140 PUR/WHT 1830 RNG/WHT 1830 RNG/WHT +12V PWR
4 4 CAN HI SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
AUX CTRLR 4 4 4 4
TP-11
9280 PUR
8 CAN LO
9180 PUR/WHT
9 CAN HI * C449 C459 C449
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 4 4
SHT4/G8 2 2 3 3
3 3 2 2
4 4 1 1
C426
AUX CTRLR
TP-30 9500 PUR/WHT TP-30
9600 PUR
J2B
3095 LBL
REMOTE RUN KEY 24
J2A
GATEWAY CTRLR
3090 LBL 3085 LBL REMOTE RUN KEY

SP93
J1B
C C

SHT3/D1 E E

SHT2/D1 F F
2710 BLK GROUND

SHT4/C6 G G

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 5 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 5 / 17
7295961
ENGINE
CAN BUS
RE014
R5-1 Resistor internal to
ENG ECU CTRLR SP90
TP-17 TP-17 TP-18 TP-18
SP81 TP-20 TP-22 9210 PUR TP-22 SP67 TP-24 TP-24 SP71 TP-26 TP-26 SP70 TP-28 Controller TP-28
9200 PUR 9215 PUR 9415 PUR TP-20 9265 PUR 9275 PUR 9245 PUR
ENG CAN LO 47 65 ENG CAN LO

R5-2
J7A C121
TP-19 TP-21 TP-23 TP-25 TP-27
9105 PUR/WHT
C163
9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
TP-21 9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
TP-29 TP-29
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
C169
C121

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 6 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 6 / 17
7295961
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
1030 RED
SHT2/A1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1
1800 RNG/WHT
SHT2/F7
1800 RNG/WHT
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
3560 LBL FOOT THROTTLE T11
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN GND FOOT THROTTLE 1
SHT4/G3 B HARNESS
AIR FILTER 7217683 T12
3150 LBL SWITCH (NC) C116 D 2015 BLK
E SHT4/E3
FOOT THROTTLE INTDM F
C405 5695 YEL
5695 YEL +5V PWR
SHT12/C8 C C C
THROTTLE SECONDARY SIGNAL 33 A A A
SHT4/G3 B B B
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25 C115
3100 LBL

8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
C5 C2
86 85 C119
RIGHT TAILGATE FAN
FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
TAILGATE FAN RELAY OUTPUT 9 3 3 A B A
J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113

FUEL SENDER F
(30 - 270 OHM) SHT12/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
C406 3690 LBL
3690 LBL SIG
C120
T
ENGINE TEMP C114
3110 LBL
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
SHT9/F8 SP74
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN SP77 8500 TAN
IGN SW ON 19 C100 T29 T26 T27 T28 30 1
2865 BRN GND C100 T30 T14
WATER IN FUEL SENSOR SHT2/D1 8505 TAN
T41 86 T40 1
(FUEL FILTER)
3865 LBL SIG
T31
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
8014 TAN
1 3420 LBL
4 4 SHT8/H7
T42
J7A ENG-CROSSOVER

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 7 of 19
COPYRIGHT C
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 7 / 17
7295961
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK

EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1
KNOCK SENSOR 1 SHIELD-01
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
C150
ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
INJECTOR #3

P
INJECTOR #4
2 19
C143

1 SHT7/B5 C142
C154
J7B
J7B

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 8 of 19
X ± 13
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR MAT DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 8 / 17
7295961
HOSE HEATER MAIN
SHT2/C1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2975 BLK 1 T33

DCU CASE GND
2915 BLK
DOSING CONTROL UNIT

SP62
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
7999 WHT 8320 TAN
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8020 TAN 8340 TAN
C123
72
2170 BRN 8330 TAN
87 SP86
TANK HEATING
2985 BLK
4 92 94 86 85
2965 BLK
C155 RL011 RL011
Shield Shield C124
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 RED AGENT SHIELD
49 HOSE 2 HEATER
HOSE 2 RELAY FB SP89 C124
2025 BRN
8250 TAN
T 87 8350 TAN
INLET 2
8900 TAN
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
8800 TAN
C159
2075 BRN RL013 RL013
INLET 8530 TAN 8650 TAN
CAT TEMP DOC INLET HEATER SIGNAL
1 34 SM HEATER SIGNAL
3 12
C160 +5V POWER 55 3
76 2
SIGNAL
C121 C121 C122

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf


Here ELEC LF CTRL
Sheet 9 of 19
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 9 / 17
7295961
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308

GATEWAY CTRLR
TRACTION LOCK 4110 LGN

RELAY SIGNAL 8
3430 LBL
TRACTION LOCK 13
RELAY FEEDBACK
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

HYD LOCK VALVE 1 2
SOL GROUND
1
J1A
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
6
HYD LOCK
SOLENOID SIGNAL
TRACTION
SOLENOID OUTPUT
HYD CHARGE PRESS
SENDER SIGNAL
HYDRAULIC
FAN SIGNAL
HYD CHARGE PRESS

SENDER POWER
4330 LGN GND

AUX CTRLR 1
18 2
SOLENOID GROUND
C418
4340 LGN GND
1
GATEWAY CTRLR
1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 10 of 19
X ± 13
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR MAT DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 10 / 17
7295961
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
10 C408
SHT2/G1 1 PTOL LED 19 12 12 4

SHT3/E1 5 C499
C500
SHT15/F4
3400 LBL
1960 RNG/WHT J1A

SHT3/E1
SW9

SHT3/D1 5
6
1
5 4 SHT2/G1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SHT2/H1 1
SW1

SHT11/D3 12
C503 SHT5/F1

2
SW12

SHT4/E8 2 4 9
SHT3/E1 7 9 4
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 1
C480
SW12

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 11 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 11 / 17
7295961
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT11/D1 5
4230 LGN 4
SHT12/F3
4240 LGN SW4 3
SHT12/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
3 3 8 8
2 2
4550 LGN
9 9
4550 LGN *
2795 BLK GND
SHT3/F1 2 2 C212
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT15/C2
1885 RNG/WHT
SHT15/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT15/C2
2885 BLK
SHT15/B3
2060 BLK
SHT11/H8
C428
SHT4/E3
2790 BLK
14 14
(SEE ADDITIONAL
2690 BRN
2370 BRN 2370 BRN 2375 BRN
SP56 SENSOR 3620 LBL
SHT10/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
6 6
+5V PWR
2 2 WIPER MOTOR GROUND
C
SP13 SP52
5100 YEL 5370 YEL 5370 YEL 5375 YEL 7310 WHT
5V CTRLR PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B 5690 YEL

5695 YEL SHT7/D4
SHT7/F7
HARNESS WASHER PUMP
* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 12 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 12 / 17
7295961
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
RIGHT HANDLE LEFT
SHT3/E3 A
ROCKER DOWN 4930 LGN
31 J
RIGHT HANDLE 4940 LGN
30 H LEFT POSITION SWITCH
LEFT ROCKER UP
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN RIGHT ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
SHT4/D8 4230 LGN
T20 SHT11/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR

LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V LIFT (ACS/AHC ONLY)
4980 LGN SIG AUX CTRLR
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT11/G8 H
4990 LGN
SIG
1 LEFT HANDLE RIGHT
SHT3/E3 A
C422 ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
LEFT HANDLE RIGHT 4840 LGN
ROCKER UP 28 C
4810 LGN
J1B
4820 LGN
7

TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
C410
TRIGGER
GATEWAY CTRLR

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 13 of 19
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 13 / 17
7295961
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - FC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

FC1 FC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK

SHT4/D8 2
RELAY - FC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
FC2 FC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
MRKR LIGHT PWR
SHT4/D8 2
5
RELAY SIGNAL C602
RELAY FEEDBACK 31

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
6210 PNK
FRC1 WORK LIGHT

J1A

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 14 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 14 / 17
7295961
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
SP40 * THERMOSTAT
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
D4
C350 MAGNET CLUTCH

SHT4/C6
GND
2
C486

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 15 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 15 / 17
7295961
C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT16/C6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
SHT2/B1 1 1 X T3
* FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT10/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT10/G8 1
6415 PNK SW3 2
C103
D
A
E E 1
TRIGGER
(SEE ADDITIONAL
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT16/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT16/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT16/C4 D D
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
AUX CTRLR B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY C497 OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) 7200 WHT C676 C C
HORN SIGNAL 5 C C
SJC HORN/BLINKER
LEFT SPEAKER
* * RADIO CONN A A
6420 PNK (SEE ADDITIONAL
RIGHT BLINKER SIGNAL 4 A A
OPTIONS DWG) 1
7820 WHT
3 LEFT
SPEAKER (+)
*
6520 PNK 1
LEFT BLINKER SIGNAL 3 B B 7830 WHT LEFT
2 4 2
SPEAKER (-)
HIGH FLOW 2460 BRN L010
26 C279 3
SOLENOID GROUND AIR RIDE SEAT
RIGHT SPEAKER 1510 RNG/WHT
J2A SHT11/E1 4
GND
B
HIGH FLOW * 7810 WHT
PWR
PWR
RIGHT POSTION SWITCH RIGHT

SOLENOID 2 6
SPEAKER (-)
2210 BLK GND
SIG
A 7.5 OHM 12 V SHT11/E1 5
7800 WHT RIGHT
PADDLE 1 5 GND
C415 SPEAKER (+) 6
HIGH FLOW 4460 LGN C278
26 1885 RNG/WHT
SOLENOID SIGNAL SHT11/E1 1 C277
J2B
2885 BLK
SHT11/D1 2
C408 GATEWAY CTRLR
C676
1460 RED/WHT
A SHT2/B1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
_
C412 SOLENOID (SEE ADDITIONAL
HORN 4350 LGN OPTIONS DWG)
SIG
1 5.1 OHM 12 V
2785 BLK GND +
SHT4/E8 B B TWO SPEED SIGNAL 26 C441
J1B

S770 AT5211529 &
through
AboveAT5A12499 WARNING PROPRIETARY NOTICE TOLERANCES: ECN 102537 Printed On October 2017
csf

SCHEM ELEC LF CTRL
Sheet 16 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
SHT 16 / 17
7295961
*SW7 OPTIONS 2
AUX CTRLR C438 RIDE CONTROL
3410 LBL 3410 LBL 2890 BLK
RIDE CONTROL SW AUTO 23 14 14 1 2 SHT4/E8 (NOT IN STD CAB HARN 7303755)
SW7 SW7
3480 LBL
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
1575 RNG/WHT
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
COIL COIL FRC1 FRC1
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428
* SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIG 16 7 7 3
2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
J2A REVERSING FAN
COIL
3485 LBL
C442
2185 BRN
SHT4/C3 A
RIDE CONTROL PRESSURE SENSOR 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 5V SUPPLY 24 B
J2B
SW8 C672
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

S770 AT5211529 &
AT5A11720 through
AboveAT5A12499
csf

SCHEM ELEC LF CTRL
Sheet 17 of 19
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
SHT 17 / 17
7295961
ACS CONTROLLER
HARNESS PART NUMBER

J1-ACS
CONTROLLER
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
5750/YEL 3990/LBL 2 SIG
5650/YEL 5980/YEL
5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL

S770 AT5211529 &
through
AboveAT5A12499 Printed On October 2017
Printable Version Click Here Sheet 18 of 19
S770 AT5211529 &
through
AboveAT5A12499 Printed On October 2017
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
LEGEND
9 SH09 - DOSING CONTROL UNIT
10 SH10 - HYDRAULICS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CONNECTOR
11 SH11 - CAB DISPLAY
12 SH12 - CAB BATTERY GROUND 2000 THROUGH 2999 BLACK BLK 1 1
13 SH13 - MANUAL CONTROLS
14 SH14 - LIGHTS
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
15 SH15 - HVAC
16 SH16 - OPTIONS 1
17 SH17 - OPTIONS 2 MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
1 1

1 1
CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
HARNESS PART NUMBER WIRE BREAK
LF MFR CTRL 7322241 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
DLX CAB 7329485 * SHT1/F2
WIRE BREAK
SHT1/F2
DLX FUEL 7266824 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
BCT ENG 7242470 ENGINE 8000 THROUGH 8999 TAN TAN
SUSP JSTK 7163706 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
WHL 2 SPD ADP 7159366 COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
TRK 2 SPD 7243409
DEF JUMPER 7305995
* CAB HARNESSES USED ON S/N AT5A12587-ABOVE

B3BV11650-ABOVE

csf

ACS / SJC Machine S/N B3BV11600 & Above 7322240
SCHEM ELEC LF CTRL
Sheet 1 of 19
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT Printable Version Click Here
0
REV DESCRIPTION
106368 MMM
SHT 1 / 17
7322240
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4
1400 RED/WHT
C408 SHT12/D3
1450 RED/WHT 1450 RED/WHT SP7 1305 RED/WHT
FUSE RELAY CENTER 6 6 SHT5/E7
1420 RED/WHT
1110 RED/WHT SHT11/E4
2 1440 RED/WHT
FUSE 11 25 A SHT11/G8
GATEWAY CTRLR
11A 11B 3
SP2
FUSE 13 25 A SP36 J1B
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
+12V BATTERY MEGAFUSE
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT15/E8
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
25A 25B SHT9/H8
FUSE 26 15A
26A 26B SHT9/G8
FUSE 10 30A
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
22A 22B SHT16/F7
SP24
FUSE 24 25 A
24A 24B SHT12/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT7/H8

csf

SCHEM ELEC LF CTRL
Sheet 2 of 19
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 2 / 17
7322240
SHT6/E4
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
86 85
G4
SP73
1508 RNG/WHT
3
POWER
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
J7A
SHT2/E1
1345 RED/WHT FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT7/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
12A 12B SHT16/G7
1700 RNG/WHT
SHT11/B8
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
SP11 1960 RNG/WHT
J2B SHT11/F8
C428 1785 RNG/WHT
SHT12/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT11/F4
FRC1 SWITCHED 2 2 SHT11/E4
POWER RELAY - A SP42 1565 RNG/WHT
SHT17/E4
1050 RED 30 FUSE 7 25 A SP65

+12V PWR
A4 7A 7B SHT5/B8
86 85 GND 2055 BLK

A5 A2 1725 RNG/WHT
SHT6/D7
8A 8B SHT12/F8
FUSE 23 15 A
23A 23B SHT7/G8
3390 LBL
FRC1 FRC1
FRC1 SWITCHED
POWER RELAY - F 2055 BLK
SHT4/B8
1200 RED 30
SHT2/B1
+12V PWR
F1 87 F4 1585 RNG/WHT
3385 LBL 86 85 GND 2065 BLK GATEWAY CTRLR

F5 F2 SHT4/C8
SP100 3450 LBL
FRC1 FRC1 21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
J1A
C428
SP37
9 9 SHT5/D3
C492 1830 RNG/WHT

1740 RNG/WHT SHT5/E3
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)

csf

SCHEM ELEC LF CTRL
Sheet 3 of 19
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 3 / 17
7322240
ENG ECU CTRLR
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
1 2155 BLK 2190 BRN
SHT17/F4 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
C493
2150 BRN
2605 BLK ACS/SJC/AWS CONN 2 SHT7/G7
SHT5/E7 2235 BLK 2695 BRN
2080 BLK 3 3 SHT7/F7
SHT5/D3 2430 BRN
2240 BLK SHT7/C7
2070 BLK 4 4
SHT5/E3
C493 T6
2920 BLK 1 BATT GND
SHT11/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10
2960 BLK
SHT11/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT11/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/C4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
2930 BLK C428
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT7/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT10/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK
SHT7/E4 AUX CTRLR
2630 BLK
SHT14/B4 2405 BLK 2195 BRN
SHT7/D4 SHT13/G3 SP58 2995 BRN
2185 BRN 17 SENSOR GROUND
SHT17/D7
2455 BLK
SHT16/D6 J2B
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
2065 BLK SHT6/D7
SHT3/C6
2505 BLK 2290 BLK
SHT17/G4 SHT15/B8
2045 BLK
SHT14/B8 2295 BLK
2035 BLK SHT7/D7
SHT10/G8
SP55 SP5 2000 BLK

2115 BLK 2105 BLK
SHT14/D8
2055 BLK 2520 BLK

SHT3/C1 SHT13/D3
2030 BLK 2530 BLK

SHT15/F8 SHT13/F3
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8

csf

SCHEM ELEC LF CTRL
Sheet 4 of 19
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 4 / 17
7322240
CAN BUS
C479
Z3 C408
GATEWAY CTRLR Z4 LEFT PANEL
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK)
SP79 SP19 SP18 SP39 SP35 120 OHM 0.5 W RESISTOR (BLACK)
9260 PUR 9230 PUR
SP31 9250 PUR 9270 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
CAN LO 8 4 4 4

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
SP20
J1B C479
C492
9290 PUR RH DLX PANEL
7 7 CAN LO
9440 PUR
9190 PUR/WHT 4 CAN LO
8 8 CAN HI
9340 PUR/WHT
9240 PUR 2 CAN HI
1 1 CAN LO
9140 PUR/WHT C503

4 4 CAN HI
AUX CTRLR
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK
C450
RIGHT JOYSTICK
9280 PUR SHT3/B1 1 1 1 1
8 CAN LO 2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9180 PUR/WHT 9320 PUR/WHT 9560 PUR/WHT CAN HI
9 CAN HI 3 3 3 3
J2B 4 4 4 4
TELEMATICS
1305 RED/WHT
PWR 10
2605 BLK
SHT2/H1
* C449 C459 C449
LEFT JOYSTICK
GND 11 SHT4/G8 LEFT JOYSTICK CONN LEFT JOYSTICK
C448 1840 RNG/WHT 1840 RNG/WHT +12V PWR
Z5 MFR HARN CONN 4 (BLACK) SHT3/B1 1 1 4 4
120 OHM 0.5 W RESISTOR SP104 9500 PUR/WHT 2080 BLK 2080 BLK GND
9515 PUR/WHT 9505 PUR/WHT 7 7 SHT4/G8 2 2 3 3
CAN HI 3 9510 PUR/WHT 9300 PUR/WHT 9540 PUR/WHT CAN HI
9 9 3 3 2 2
9610 PUR 9400 PUR 9640 PUR CAN LO
9615 PUR 9605 PUR 10 10 4 4 1 1
CAN LO 4 9600 PUR
8 8 SUSP SEAT JOYSTICK HARNESS
C481 SP103
C426
AUX CTRLR
9600 PUR 9610 PUR

J2B
3615 LBL CAN SELECT
CAN SELECT 25 C C
3095 LBL
REMOTE KEY 24
J2A
GATEWAY CTRLR
3090 LBL 3085 LBL REMOTE KEY

SP93
J1B
SHT3/D1 E E

SHT2/D1 F F
2710 BLK GROUND

SHT4/C6 G G

csf

SCHEM
Here ELEC LF CTRL
Sheet 5 of 19
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED Printable Version Click
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 5 / 17
7322240
ENGINE
CAN BUS
Resistor internal to
ENG ECU CTRLR Z1
Controller
9200 PUR 9215 PUR 9415 PUR 9210 PUR 9265 PUR 9275 PUR 9245 PUR
47 65

J7A C121
C163
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR
3
4
2870 BLK 2875 BLK
9205 PUR SHT9/F8 5
20 ENG CAN LO SP78
C163
9105 PUR/WHT
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
4 4 1
ENGINE CAN 9225 PUR 9225 PUR
1 1 4 ENG CAN LO
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
C169
C121

csf

SCHEM ELEC LF CTRL
Sheet 6 of 19
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 6 / 17
7322240
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
1030 RED
SHT2/A1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1
1800 RNG/WHT
SHT2/F6
1800 RNG/WHT
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
3560 LBL FOOT THROTTLE T11
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN GND FOOT THROTTLE 1
SHT4/G3 B HARNESS
AIR FILTER 7217683 T12
3150 LBL SWITCH (NC) C116 D 2015 BLK
E SHT4/E3
FOOT THROTTLE INTDM F
C405 5695 YEL
5695 YEL +5V PWR
SHT12/C8 C C C
THROTTLE SECONDARY SIGNAL 33 A A A
SHT4/G3 B B B
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25 C115
3100 LBL

8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
C5 C2
86 85 C119
RIGHT TAILGATE FAN
FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
TAILGATE FAN RELAY OUTPUT 9 3 3 A B A
J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113

FUEL SENDER F
(30 - 270 OHM) SHT12/B8 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
C406 3690 LBL
3690 LBL SIG
C120
T
ENGINE TEMP C114
3110 LBL
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
SHT9/F8 SP74
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN SP77 8500 TAN 1
IGN SW ON 19 C100 T29 T26 T27 T28 30
2865 BRN GND C100 T30 T14
T41 86 T40
(FUEL FILTER)
3865 LBL SIG T31
WIF SENSOR 9 1
8510 TAN
ENG-CROSSOVER
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
8014 TAN
3420 LBL
4 4 SHT8/H7
1
J7A
T42

csf

SCHEM ELEC LF CTRL
Sheet 7 of 19
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 7 / 17
7322240
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK

EGR VALVE DC MOTOR
1 64 VREF 3 EGR
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148
KNOCK SENSOR 1 BOOST PRESSURE AND TEMP SENSOR

SHIELD-01 SHIELD-01
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN BOOST TEMP SIGNAL 94 2
2 31 ENGINE BLOCK ACCELEROMETER #1 BOOST PRESSURE PWR 61 3
T
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD BOOST PRESSURE SIGNAL 12 4 P
C147 BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 C150

SHIELD-02 SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
INJECTOR #3

P
INJECTOR #4
2 19
C143

1 SHT7/B5 C142
C154
J7B
J7B

csf

SCHEM ELEC LF CTRL
Sheet 8 of 19
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 8 / 17
7322240
HOSE HEATER MAIN
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2975 BLK 1 T33

DCU CASE GND
2915 BLK
DOSING CONTROL UNIT

SP62
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
7999 WHT 8320 TAN
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8020 TAN 8340 TAN
C123
72
2170 BRN 8330 TAN
87 SP86
TANK HEATING
2985 BLK
4 92 94 86 85
2965 BLK
C155 RL011 RL011
Shield Shield C124
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 RED AGENT SHIELD
49 HOSE 2 HEATER
HOSE 2 RELAY FB SP89 C124
2025 BRN
8250 TAN
T 87 8350 TAN
INLET 2
8900 TAN
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
8800 TAN
C159
2075 BRN RL013 RL013
INLET 8530 TAN 8650 TAN
CAT TEMP DOC INLET HEATER SIGNAL
1 34 SM HEATER SIGNAL
3 12
C160 +5V POWER 55 3
76 2
SIGNAL
C121 C121 C122

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SCHEM ELEC LF CTRL
Sheet 9 of 19
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 9 / 17
7322240
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/F1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308

GATEWAY CTRLR
TRACTION LOCK 4110 LGN

RELAY SIGNAL 8
3430 LBL
TRACTION LOCK 13
RELAY FEEDBACK
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

HYD LOCK VALVE 1 2
SOL GROUND
1
J1A
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT12/C8 B
C105
4200 LGN
J1B
19
13
6
HYD LOCK
SOLENOID SIGNAL
TRACTION
SOLENOID OUTPUT
HYD CHARGE PRESS
SENDER SIGNAL
HYDRAULIC
FAN SIGNAL
4330 LGN GND

AUX CTRLR 1
18 2
SOLENOID GROUND
C418
4340 LGN GND
1
GATEWAY CTRLR
1 2
SOLENOID GROUND
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

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SCHEM ELEC LF CTRL
Sheet 10 of 19
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 10 / 17
7322240
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
10 C408
SHT2/G1 1 PTOL LED 19 12 12 4

SHT3/E1 5 C499
C500
SHT16/F4
3400 LBL
1960 RNG/WHT J1A

SHT3/E1
SW9

SHT3/D1 5

5 4 SHT2/H1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT12/D3 12
C503 SHT5/F1

2
SW12

SHT4/E8 2 4 9
SHT3/E1 7 9 4
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 SW12
C480

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SCHEM ELEC LF CTRL
Sheet 11 of 19
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 11 / 17
7322240
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT12/D1 5
4230 LGN 4
SHT13/F3
4240 LGN SW4 3
SHT13/D3
SW4
C492
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
3 3 8 8
2 2
4550 LGN
9 9
4550 LGN *
2795 BLK GND
SHT3/F1 2 2 C212
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT16/C2
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
SHT4/E3
2790 BLK
14 14
(SEE ADDITIONAL
2690 BRN
2370 BRN 2370 BRN 2375 BRN
SP56 SENSOR 3620 LBL
SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
6 6
+5V PWR
2 2 WIPER MOTOR GROUND
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V CTRLR PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5695 YEL
SHT7/F7
HARNESS WASHER PUMP
SHT10/D7
5190 YEL * C252
7253378
2845 BLK GND
5690 YEL B B 2
SHT7/D4 WASHER
MOTOR
7310 WHT PWR
A A 1
C253

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SCHEM ELEC LF CTRL
Sheet 12 of 19
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 12 / 17
7322240
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
RIGHT HANDLE LEFT
SHT3/E3 A
ROCKER DOWN 4930 LGN
31 J
RIGHT HANDLE 4940 LGN
30 H LEFT POSITION SWITCH
LEFT ROCKER UP
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN RIGHT ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
SHT4/D8 4230 LGN
T20 SHT12/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR

LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V LIFT (ACS/AHC ONLY)
4980 LGN SIG AUX CTRLR
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT12/G8 H
4990 LGN
SIG
1 LEFT HANDLE RIGHT
SHT3/E3 A
C422 ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
LEFT HANDLE RIGHT 4840 LGN
ROCKER UP 28 C
4810 LGN
J1B
4820 LGN
7

TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
C410
TRIGGER
GATEWAY CTRLR

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SCHEM ELEC LF CTRL
Sheet 13 of 19
COPYRIGHT C
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 13 / 17
7322240
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - FC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

FC1 FC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK

SHT4/D8 2
RELAY - FC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
FC2 FC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
MRKR LIGHT PWR
SHT4/D8 2
5
RELAY SIGNAL C602
RELAY FEEDBACK 31

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
6210 PNK
FRC1 WORK LIGHT

J1A

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8

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SCHEM ELEC LF CTRL
Sheet 14 of 19
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 14 / 17
7322240
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
SP40 * THERMOSTAT
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
D4
C350 MAGNET CLUTCH

SHT4/C6 GND
2
C486

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SCHEM ELEC LF CTRL
Sheet 15 of 19
X ± 13 MAT Printable Version Click Here
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 15 / 17
7322240
C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT17/C6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
SHT2/B1 1 1 X T3
* FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT11/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
D
A
E E 1
TRIGGER
(SEE ADDITIONAL
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT17/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/C4 D D
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
AUX CTRLR B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY C497 OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) 7200 WHT C676
HORN SIGNAL 5 C C
SJC HORN/BLINKER
LEFT SPEAKER
* * RADIO CONN
6420 PNK (SEE ADDITIONAL
RIGHT BLINKER SIGNAL 4 A A 7820 WHT LEFT
HANDLE LOCK (ACS ONLY) OPTIONS DWG) 1 3
SPEAKER (+)
6520 PNK
LEFT BLINKER SIGNAL 3 B B 7830 WHT LEFT
2 4
SPEAKER (-) L010
HIGH FLOW
SOLENOID GROUND
26
2460 BRN C279
1510 RNG/WHT
* HEATED SEAT
RIGHT SPEAKER SHT12/E1 4
J2A GND
B
HIGH FLOW * 7810 WHT
PWR PWR
RIGHT POSTION SWITCH RIGHT

SOLENOID 2 6
SPEAKER (-) GND
2210 BLK GND
SIG
A 7.5 OHM 12 V SHT12/E1 5
7800 WHT RIGHT
PADDLE 1 5
C415 SPEAKER (+)
C277
HIGH FLOW 4460 LGN C278
26 1885 RNG/WHT
SOLENOID SIGNAL SHT12/E1 1 SEE OPTION PAGES FOR HARNESSES
J2B
2885 BLK
SHT12/D1 2
C408 GATEWAY CTRLR
C676
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
+ SOLENOID (SEE ADDITIONAL
C412 4350 LGN OPTIONS DWG)
HORN SIG
1 5.1 OHM 12 V
GND
_
2785 BLK
SHT4/E8 B B TWO SPEED SIGNAL 26 C441
J1B
Wiring Schematic S770 S/N AT5A12500 & Above WARNING PROPRIETARY NOTICE TOLERANCES: ECN 106368 Printed On October 2017
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SCHEM ELEC LF CTRL
Sheet 16 of 19
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368
CHG NOTICE DWN
MMM
SHEET
SHT 16 / 17
7322240
*SW7 OPTIONS 2
AUX CTRLR C438 RIDE CONTROL
3410 LBL 3410 LBL 2890 BLK
RIDE CONTROL SW AUTO 23 14 14 1 2 SHT4/E8 (NOT IN STD CAB HARN 7303755)
SW7 SW7
3480 LBL
FRC1 SWITCHED
POWER RELAY - L
1575 RNG/WHT
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
COIL COIL FRC1 FRC1
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428
* SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIG 16 7 7 3
2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
J2A REVERSING FAN
COIL
3485 LBL
C442
2185 BRN
SHT4/C3 A
RIDE CONTROL PRESSURE SENSOR 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 5V SUPPLY 24 B
J2B
SW8 C672
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

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SCHEM ELEC LF CTRL
Sheet 17 of 19
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
106368 MMM
SHT 17 / 17
7322240
ACS CONTROLLER
HARNESS PART NUMBER

J1-ACS
CONTROLLER
H 2280/BLK
ACS 7190593 MF
SEE MANUAL CONTROL
2280/BLK
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
6
2980/BRN
2990/BRN
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL
Wiring Schematic S770 S/N AT5A12500 & Above Printed On October 2017
Wiring Schematic S770 S/N AT5A12500 & Above Printed On October 2017
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CONNECTOR C426 To Mainframe
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN SSL 7-PIN
CAN CONNECTOR D F C E A B G
Harness

9800
1160
9700
1710
9500
9600
2710
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
WIRE BREAK KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
(TWO WIRE BREAKS UNSW POWER F 1160 RED/WHT 2720 H GROUND

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
JOIN ONE WIRE) SW POWER E 1730 RNG 9 1720 B SW POWER ACD
ENGINE 8000 THROUGH 8999 TAN TAN 9 Machine
SHEET # CAN LOW B 9620 PUR 9610 E CAN LOW
Connector to
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR CAN HIGH A 9520 PUR 14 9510 D CAN HIGH Engine
GROUND G 2730 BLK 13 C OPEN Compartment
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT Connector 7-PIN A
C666 ATTACHMENT
OPEN
on Loader G OPEN
CONNECTOR
SSL 7-PIN Boom
CAN CONNECTOR J
BOOM-MOUNTED
N ACD CONNECTORS
KEY "RUN" D 9800 D SW POWER K 1740
UNSW POWER 2 1160 F

GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
CAN SHIELD C 9700 C F OUTPUT F 5350 5350 H F OUTPUT
SW POWER 1 1710 E G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
CAN LOW B 9600 A Output
C OUTPUT C 5300 5300 G C OUTPUT
CAN HIGH A 9500 B Connector to
D OUTPUT D 5150 5150 D D OUTPUT
Engine
GROUND 3 2700 G A OUTPUT A 5250 5250 F A OUTPUT Compartment
7-PIN M E
Connector M OUTPUT 5200 5200 B OUTPUT
on Loader C666 C426

ATTACHMENT
CONNECTOR
ID (K TO L)
ID (K TO P)
L
P
5910
12
5000 A
K
J OUTPUT
Boom 5510 5450 K OUTPUT

11
CONTROL HARNESS - 7175321 Connector
C506 14-PIN
ATTACHMENT
CONNECTOR
C704 J3 - 10-PIN GRAY
on Loader 5900 J ID #1
Boom 5500 A ID #2
B ID #3
ACD
C ID #4 Input
D ID #0 Connector to
C667 SW7 DELUXE ATTACHMENT E OPEN
Engine
Compartment
DOOR HARN C250 SENSOR SHOWN REAR CONTROL HARNESS -
F OPEN
G OPEN
4 3630/LBL 1 SIG WITH DOOR OPEN C129 WIPER 6732730 H OPEN
5 1400/RED/WHT 2 PWR DOOR SENSOR A SWITCH K OPEN
TO CAB B
TO DLX CAB 6 1865/RNG/WHT 1 2
HARNESS
HARNESS 1 C 2820/BLK 3
3 4 5 7230/WHT T6 1
6 REAR
2 WIPER
MOTOR C667
7170531 SPECIAL APPS DOOR HARNESS DOOR HARN C250 SENSOR SHOWN
4 3630/LBL 1 SIG WITH DOOR OPEN
7180207 REAR WIPER HARNESS 5 1400/RED/WHT 2 PWR DOOR SENSOR
C251
6 7330/WHT C PARK
R2
CAB 1570/RNG/WHT
C667 750 OHM RESISTOR E
DOOR HARN C250 HARNESS
1W 5%
5 1400/RED/WHT 1 1400/RED/WHT 1 1850/RNG/WHT 3 7300/WHT A LOW
1 WIPER
1410/RED/WHT
2
3 7310/WHT 6 1860/RNG/WHT D SW PWR MOTOR
4 5
R1
300 OHM RESISTOR SW8
0.5W 5% C251 FRONT WIPER
SENSOR SHOWN SWITCH
4 3630/LBL 2 3630/LBL 3635/LBL 2 SIG WITH DOOR OPEN 2 2840/BLK B GND
2860/BLK 3 2860/BLK 1 GND DOOR SENSOR

6
7155024 DOOR HARNESS
7195485 DOOR SENSOR HARNESS
TO DLX
CAB HARNESS Printable Version Click Here
C251
7330/WHT C PARK WIRING SCHEMATIC
SW8 1570/RNG/WHT
1850/RNG/WHT
FRONT WIPER
SWITCH
E
(KIT AND OPTION HARNESS)
1 3 7300/WHT A LOW
3 7310/WHT
1
6
2
1860/RNG/WHT D SW PWR
WIPER
MOTOR ALL MODELS
4 5
2 2840/BLK 2850/BLK B GND Sheet 1 of 6
7171105 FORESTRY DOOR HARNESS
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7195572 (E)

C425
C489-B B C427
TO BRAKE
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE 1510/RNG 1 MAINFRAME A 1
4200/LGN SOLENOID
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE 2210/BLK 2 HARNESS C 2
2200/BLK 9.8 OHM
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED 12 V
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT C220 C489-A
C437 C428
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT A 1520/RNG 1 TO
1500/RNG 2 2360/BRN 2 GND TWO SPEED
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK C 2 MAINFRAME MAKEUP SOLENOID
2230/BLK 2220/BLK 1 4360/LGN 1 SIG
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HARNESS 8.8 OHM 12V
B 6500/PNK
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C441 C429
TO
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C103-A C103-B 2 2350/BRN 2 GND TWO SPEED
MAINFRAME
LIGHTS 6000 THROUGH 6999 PINK PNK G 6501/PNK 6502/PNK G HARNESS 1 4350/LGN 1 SIG SOLENOID
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT 5.1 OHM 12 V
ENGINE 8000 THROUGH 8999 TAN TAN H 6200/PNK H
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B 2600/BLK B
EXMF, LF: 7177692 2 SPD TRACK ADAPTER
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT D 6510/PNK D EXLF: 7190709 2 SPD TRACK ADAPTER
E 6410/PNK E
F F
7110/WHT
A 6310/PNK A
BACK-UP ALARM
C 7100/WHT C SWITCHES
C404
TO A 7100/WHT
MAINFRAME B 1720/RNG/WHT
7219294 - HARNESS NEUTRAL LIGHT HARNESS
LEGEND
7175017 BACK-UP ALARM HARNESS
PARTIAL CONNECTOR
C362 C414
A 4440/LGN 1 SIG
REAR BASE (M) C411 TO
B 2440/BLK 2 GND 7.5 OHM 12V MAINFRAME
CONNECTOR WHITE TIE STRAP A C E B D HARNESS
C413 (5 WAY LH)
C 4430/LGN 1 SIG
6000/PNK
REAR ROD (F)
D 2430/BLK 2 GND 7.5 OHM 12V
WIRE BREAK C497 6510/PNK
TO BROWN TIE STRAP
(TWO WIRE BREAKS
MAINFRAME
C416 B 6415/PNK 2780/BLK
JOIN ONE WIRE)
HARNESS E 4450/LGN 1 SIG REAR ROD LOCK 86 85
SHEET # 6410/PNK
F 2450/BLK 2 GND 7.5 OHM 30
87
12 V TO A 6515/PNK 2790/BLK
YELLOW TIE STRAP MAINFRAME
C417 86 85
HARNESS
G 4480/LGN 1 SIG 30 6010/PNK 6020/PNK
REAR BASE LOCK 87
H 2480/BLK 2 GND
9.8 OHM
GREEN TIE STRAP 12 V C 7200/WHT 2770/BLK
86 85
7173271 REAR AUX HARNESS C412 30
TO 87
B 2785/BLK
MAINFRAME
HARNESS A 1420/RED/WHT
(2 WAY LH)
TO C489-1 C489-2
ADDITIONAL
MAINFRAME B B
2720/BLK 2740/BLK ACCESSORY
HARNESS
C414 A 1720/RNG A POWER
(ACCESSORY
4440/LGN 1 SIG CONNECTOR
REAR BASE POWER)
AUX CTRLR J2B PIN 5
2440/BRN 2 GND 7.5 OHM 12V
AUX CTRLR J2A PIN 2 7151940 SJC/AWS/SCPA HRN/BLINKER HARNESS
WHITE TIE STRAP
C413
AUX CTRLR 4430/LGN 1 SIG
J2B PIN 7 REAR ROD
2430/BRN 2 GND 7.5 OHM 12V Printable Version Click Here
AUX CTRLR J2A PIN 10
BROWN TIE STRAP
TO C489-1
J2B PIN 4
4450/LGN
C416
1 SIG
WIRING SCHEMATIC
MAINFRAME REAR ROD LOCK
B 2720/BLK 2450/BLK 2 GND
HARNESS 7.5 OHM
(ACCESSORY A 1780/RNG/WHT 2725/BLK YELLOW TIE STRAP 12 V
POWER) C417
ADDITIONAL
C489-2
A
4480/LGN 1 SIG
REAR BASE LOCK
ALL MODELS
ACCESSORY 2480/BLK 2 GND
POWER
CONNECTOR
B J2B PIN 6
GREEN TIE STRAP
9.8 OHM
12 V Sheet 2 of 6
7191339 or 7201414 REAR AUX HARNESS (PRINTED OCTOBER 2017)

LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C129
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB ACCESSORY
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK POWER CONN
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS A 1410/RED/WHT 1200/RED/WHT
JOIN ONE WIRE)
SHEET # 1430/RED/WHT X T3
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B FLASHER CONN
TO STANDARD SW2
CAB HARNESS L
BEACON
SWITCH
C 2780/BLK
2725/BLK 6
SW3 5
4
4 WAY FLASHER 1 2
SWITCH
3
6570/PNK 1
C670 C609 2 2780/BLK
3 C670
E 6700/PNK 1 C669 (PINS 3 & 6 4
STD CAB: STROBE 5 2850/BLK 6700/PNK E
D 2780/BLK 2775/BLK 2 INTERNALLY
TO ACC HARNESS BEACON 1 6440/PNK RIGHT 6 D
C INSULATED) 2420/BLK
FLASHER TO EXTERIOR
A 2785/BLK 2 2785/BLK 2795/BLK C
DLX CAB: LIGHT CAB HARNESS
TO DLX CAB HARNESS F 6440/PNK 2790/BLK A
B 3 LEFT 6440/PNK F
6540/PNK 6540/PNK
FLASHER 6540/PNK B
7169130 ACC HARNESS
LIGHT
(STD CAB HARNESS ONLY)
6718872 EXTERIOR CAB HARNESS
7169753 4 WAY FLASHER HARNESS
C800
C667
6340/PNK A 6340/PNK REGISTRATION DOOR HARN C250 SENSOR SHOWN
2670/BLK B 2670/BLK (LICENSE PLATE) WITH DOOR OPEN
4 3620/LBL 1 SIG
LAMP
5 1400/RED/WHT 2 PWR DOOR SENSOR
7153090 HARNESS LICENSE LIGHT
6 C251
TO EURO 3 C PARK
7310/WHT
TAILGATE C603 HT
HARNESS Taillight Right CAB 3 30/W
E 1 1570 7
7104670 HARNESS 5
6 A LOW
C103 F 1850/RNG/WHT
D A 3 HT
6510/PNK 6510/PNK BLU
1 7 300/W E HIGH WIPER
C407-A C407-B 6610/PNK C RED 2814 MOTOR
2 2840/BLK 4
2 7305/WHT
H 6200/PNK 6320/PNK A A 6430/PNK B YEL
B 2600/BLK 2610/BLK D BLK 1860/RNG/WHT D SW PWR
BREAK CONNECTION INTERMITTENT WIPER
FOR ROADLIGHT KIT 2620/BLK SWITCH
-
2842/BLK B GND
6210/PNK +
Backup Alarm
7231771 INTERMITTENT WIPER DOOR HARNESS
6660294
NOTE: SPLICE ADDED BEFORE
WITH ROADLIGHT KIT: C 2650/BLK CONNECTOR INSTEAD OF AT PIN.
7100/WHT
TO ROADLIGHT KIT + -
C602
HARNESS G 6600/PNK Taillight Left Printable Version Click Here
E Taillight Left
F 7104671
7104671
WITHOUT ROADLIGHT
KIT: TO MAINFRAME
E 6410/PNK 6410/PNK
6620/PNK
A
C
BLU
RED
WIRING SCHEMATIC
HARNESS 6330/PNK B YEL
6210/PNK
F D BLK
2640/BLK
2630/BLK
6210/PNK
-
-
ALL MODELS
+
6310/PNK 6250/PNK
Sheet 3 of 6
+
A 6310/PNK 6310/PNK
SP24
7217483 - HARNESS EUR TAILGATE
7175287 - HARNESS EUR TAILGATE (HARNESS SAME AS 7175287
EXCEPT AS SHOWN ABOVE) (PRINTED OCTOBER 2017)

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT F 1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK E 3
7210/WHT A 6330/WHT 2
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN 2310/BLK B 2120/BLK 6
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C 5 Front Turn Light
7230/WHT 6120/LGN
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
7270/WHT D 6340/RED 4
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
Position Light
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
C407-B
TO EURO
6430/PNK
TAILGATE F F
HARNESS Relay1
6420/PNK A 7210/WHT E
Right Side Lights
87 6410/PNK 6440/PNK D 7250/WHT 7260/WHT B
1020/RED 1410/RED/WHT
6510/PNK E C Brake Light
10.0 Amps 30 7200/WHT 7200/WHT
6400/PNK 6220/PNK C 7220/WHT 7240/WHT A
85 86 2020/BLK
2110/BLK B 2300/BLK 2320/BLK D Rear Turn Light
T01
Relay2
Left Side Lights
87 6310/PNK
1010/RED 1400/RED/WHT
10.0 Amps 30
T02
6300/PNK 85 86 2030/BLK
2120/BLK B 2300/BLK E
ADDITIONAL
1510/RNG A
ACCESSORY 6330/PNK A 7210/WHT F
2210/BLK B POWER
6120/PNK C 7220/WHT 7240/WHT A
CONNECTOR
6340/PNK D 7250/WHT 7260/WHT B Rear Position Light
1730/RNG A 1520/RNG 1500/RNG A 6520/PNK E 7200/WHT C
C 2200/BLK B HARNESS F D Brake Light
2730/BLK 2230/BLK 2320/BLK
87
6600/PNK B 6500/PNK
30
87A
85 86
TO
SJC/AWS/SCPA A 6330/WHT 2
4210/LGN 1 7210/WHT
CONTROLS HARNESS
(1 PIN CONN) 7270/WHT D 6340/RED 4 Position Light
7175581 - SJC BRAKE HARNESS

E 3
(ONLY FOR SJC OPTION) 7230/WHT C 6120/LGN 5
2310/BLK B 2120/BLK 6
F 1
H 6010/PNK 6320/PNK H
6530/PNK G
B 2000/BLK 2010/BLK B
D
E
6210/PNK
6110/PNK
6230/PNK
6130/PNK
D
E HARNESS WIRING SCHEMATIC Printable Version Click Here
HARNESS F
G
F
A 6000/PNK 6000/PNK A ALL MODELS
C 7100/WHT 7100/WHT C
Sheet 4 of 6

LEGEND
PARTIAL CONNECTOR
** HARNESS STVB 04
1
2
CONNECTOR
** HARNESS HEIGHT ADJUSTMENT
STVB A
STVB 02 STVB 92 L4/RD
WIRE BREAK
1 L1/BK
COMPRESSOR (TWO WIRE BREAKS
2 (SUSPENSION) JOIN ONE WIRE)
STVB B
3 SHEET #
S1
(MOMENTARY)
L2/RD 1 4
2
C277
HEATING MAT SEAT
1 L6/BK L3/RD YEL
2
** HARNESS STVB 03 STVB xx
3
L5/RD
1
HARNESS 4 L1/RD 2
5 L3/BK L4/BK
L12/BLK
60°C / 50°C
L13/BRN
6 L2/VT
BRN
STVB H2 HEATING SWITCH

L10/RED
S2
STVB 03 STVB H1 STVB H3

1
L7/BK 2
L14/BRN
YEL HEATING MAT BACK
STVB H5 STVB xx
L11/BLK 1
2
60°C / 50°C
BRN

7308952 HEATED SEAT
WIRING SCHEMATIC
ALL MODELS
Sheet 5 of 6
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
C001
CALAMP TELEMATICS CONN
C678
1
MACHINE CONN
2
3 9502/PUR/WHT/18 4 CAN HI
4 9602/PUR/18 3
CAN LO
5
6
7
8
9
10 1167/RED/WHT/18 1
UNSWITCHED POWER 7335305 & 7335295 NON-TELEMATIC JUMPER
11 2712/BLK/18 2
CAN GROUND
12

7300058 CALAMP ADP TELEMATICS HARNESS
WIRING SCHEMATIC
ALL MODELS
Sheet 6 of 6

ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6
DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710 SPLICE (•) - Used to show when

3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at
high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.

Standard Cab Harness Connectors
NA9085

Deluxe Cab Harness Connectors
NA9584

Mainframe Manual Harness Connectors
NA9586

Mainframe SJC, AHC, ACS Harness Connectors
NA9587

Engine Harness Connectors
NA9665

Description
Figure 60-10-1
P100958A P121167
The loader has a 12 volt, negative ground, alternator

charging system.
The electrical system is protected by fuses located in the

operator cab and a 100 ampere master fuse (Inset)
[Figure 60-10-1] located above the battery in the engine
compartment.
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Inspect the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-4
Fuse And Relay Location / Identification 1
Figure 60-10-2
1
P109659
1
Line up the clips on the back of the fuse panel cover with
P100414A
the slots (Item 1) [Figure 60-10-4] in the fuse panel and
push the cover into position when finished.
The fuse and relay panel is located behind an access Line up the clips on the access panel with the slots
panel near the left foot pedal or footrest. Pull the panel at provided and push the panel into position [Figure 60-10-
each end (Item 1) [Figure 60-10-2] to remove. 2]. A locating pin helps align the panel during installation.
Figure 60-10-3 A table is provided with details on amperage ratings and

the circuits affected by each fuse and relay. [Figure 60-
10-5 on Page 60-10-12] or [Figure 60-10-6 on Page 60-
10-13] or [Figure 60-10-7 on Page 60-10-14] or [Figure
60-10-8 on Page 60-10-15].
1
P107513B
The electrical system is protected from overload by fuses

located under the fuse panel cover (Item 1) [Figure 60-
10-3]. Remove the fuse panel cover by pulling at each
end.
A decal located on the fuse panel cover indicates fuse

and relay location and fuse amperage ratings.

ELECTRICAL SYSTEM (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
Figure 60-10-5
NA3313
The table below is for earlier models with decal part number 7251372. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-5]. Relays are identified by the letter “R” in the AMP column.
ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP
Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power
F2 Front Lights 20 F15 ACS Controller 25 B Heater / HVAC R
F3 Traction 30 F16 Engine Controller 25 C Fan R
Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm
Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm
F6 Wiper / Washer 25 F19 Not Used -- F Not Used --
F7 Switched Power 25 F20 Engine Controller 5 G Engine Controller R
Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power
Accessories and
F9 Not Used -- F22 25 J Front Lights R
Front Horn
F10 Fan 30 F23 Alternator 15 K Front Lights R
Cab Accessories
F11 Bobcat Controller 25 F24 25 L Not Used --
Power Port
F12 Bucket Position 15 F25 Hose 10 M Starter R
Auxiliary
F13 25 F26 Dosing Controller 15
Controller

Figure 60-10-6
NA3314
The table below is for later models with decal part number 7280029. Fuse location and amperage ratings are shown
Cab Switched
Power
Drive Controller
Back-up Alarm
Switched Power
Back-up Alarm
Cab Switched
Power
Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn
F10 Fan 30 F23 Alternator 15 K Not Used --
Cab Accessories
Power Port
Auxiliary
Controller

Figure 60-10-7
NA3328
The table below is for later models with decal part number 7300261. Fuse location and amperage ratings are shown
Cab Switched
Power
Drive Controller
Back-up Alarm
Switched Power
Back-up Alarm
Cab Switched
Power
Accessories and
Front Horn
Cab Accessories
Power Port
Auxiliary
Controller

Figure 60-10-8
NA3346
The table below is for models with decal part number 7323430. Fuse location and amperage ratings are shown in the
table below and on the decal [Figure 60-10-8]. Relays are identified by the letter “R” in the AMP column.
Cab Switched
Power
Drive Controller
Back-up Alarm
Switched Power
Back-up Alarm
F6 Wiper / Washer 25 F19 Not Used -- F Heated Seat R
Cab Switched
Power
Accessories and
Front Horn
Cab Accessories Automatic Ride

F11 Bobcat Controller 25 F24 25 L R
Power Port Control
Auxiliary
Controller

ELECTRICAL SYSTEM (CONT’D) Figure 60-10-11
Figure 60-10-9
P121159
(Earlier models with decal part number 7251372) -

1 Four additional relays (Item 1) [Figure 60-10-11] for the
P121166
DEF / AdBlue® tank heater system are located under the
operator cab on the left side of the loader. Stop the
Two 15 ampere inline fuses (Item 1) [Figure 60-10-9] for engine and raise the operator cab to access the relays.
the rear door fans are located on the inside of the rear (See Raising on Page 10-30-2.)
door.
Figure 60-10-12
Figure 60-10-10
P121159A
P100958B P121621A
(Later models with decal part number 7280029) - Six

The air intake heater is protected by a 150 ampere inline additional relays are located under the operator cab on
fuse (Inset) located just above the battery inside a two- the left side of the loader. Four relays (Item 1) are for the
piece rubber boot (Item 1) [Figure 60-10-10]. Slide the DEF / AdBlue® tank heater system. Two relays (Item 2)
rubber boot apart to access the fuse holder. [Figure 60-10-12] are for the front lights. Stop the engine
and raise the operator cab to access the relays. (See
Raising on Page 10-30-2.)

Solenoid Testing
Figure 60-10-13
P9175

for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15 P127797A P100960
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery into the loader, do not touch
W-2065-0807
any metal parts with the battery terminals.
Stop the engine and open the rear door. Adjust battery wrap for proper fit.
When removing the battery from the loader, do not touch Connect the negative (-) cable last to prevent sparks.
any metal parts with the battery terminals.
Installation: Tighten battery cables to 5 - 6 N•m (4 - 5 ft-
Figure 60-20-1 lb) torque.
Connect and tighten the battery cables.

2
Install and tighten the battery hold-down clamp.
Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
1 Close the rear door.
4
WARNING
P121168
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Disconnect the negative (-) cable (Item 1) [Figure 60-20- Keep arcs, sparks, flames and lighted tobacco away
1]. from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Remove the battery hold-down clamp (Item 3) [Figure
60-20-1]. Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before
Disconnect the positive (+) cable (Item 2) [Figure 60-20- connecting to a charger. Unplug charger before
1] from the battery. connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Remove the battery wrap (Item 4) [Figure 60-20-1] and W-2066-0910
the battery from the loader.

BATTERY (CONT’D)
Servicing WARNING
interval. (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
The Bobcat brand battery supplied with your machine is contact. Wear goggles, protective clothing and
sealed and does not require watering. Proper charging rubber gloves to keep acid off body.
and storage are important to maximize the life of all
batteries. In case of acid contact, wash immediately with water.
Figure 60-20-3 and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
Maintaining Battery Charge Level
All batteries will self-discharge over time. This machine

has features that require battery power even when the
machine is not being used. Use of a quality battery
maintainer is highly recommended to ensure that your
machine is ready to start when you need it and avoid
P127797A P100960 costly battery replacement.
Battery Maintainers
Simple steps for reliability and long battery life:
Use a good quality battery maintainer to keep the battery
• Keep battery posts and terminals clean [Figure 60- above 12.4 volts for machines that are not frequently
20-3]. used. Batteries below 12.4 volts must first be charged
using a battery charger. Solar maintainers should have a
• Keep terminals tight. minimum capacity of 10 watts to be effective.
• Remove corrosion from battery and terminals with Battery Service During Machine Storage
sodium bicarbonate (baking soda) and water solution.
Remove the battery if storing the machine for an
• Put Bobcat Battery Saver or grease on the battery extended period of time. Fully charge the battery. Store
terminals and cable ends to prevent corrosion. the battery in a cool dry place above freezing and boost
charge periodically. If battery removal is not desired, a
• Operate the machine for at least 15 minutes to good quality battery maintainer must be used to
recover from the battery drain caused by engine compensate for battery self-discharge and parasitic loads
startup whenever practical. from machine controllers, accessories, and features such
as connected machine intelligence.
• Maintain the battery charge level. This is a key factor
for long battery life.
• Charge a severely discharged battery with a battery

charger instead of relying on the machine charging
system. (See Battery Charging on Page 60-20-3.)
• Check the battery state of charge every 30 days on

machines that are not frequently used. (See Battery
Testing on Page 60-20-3.)

BATTERY (CONT’D) Battery Charging
Battery Testing A battery charger designed for 12 volt charging systems

is recommended. Follow the battery charger
Figure 60-20-4 manufacturer’s instructions to charge the battery to 12.6
volts (100% charge). Batteries should be charged at
room temperature to avoid an undercharge or overcharge
condition. Never attempt to charge a frozen battery.
The following table can be used to identify the

approximate amount of time required to charge a
1
discharged battery. Allow at least 60 minutes after
operating the machine or charging the battery to get an
accurate reading.
STATE CHARGER MAXIMUM RATE

BATTERY
OF
VOLTAGE
CHARGE 30 Amps 20 Amps 10 Amps
P-30836 12.6 V 100% READY TO USE
12.4 V 75% 0.9 hr. 1.3 hr. 2.5 hr.
The simplest and most common check to determine 12.2 V 50% 1.9 hr. 2.7 hr. 5.1hr.
battery state of charge is to use a digital multimeter or
voltmeter (Item 1) [Figure 60-20-4]. 12.0 V 25% 2.9 hr. 4.3 hr. 7.8 hr.
11.8 V 0% 4.0 hr. 5.7 hr. 10.7 hr.
A battery found below 12.4 volts must be charged to
100% charge per the battery charger’s recommendation. NOTE: Use a good quality automatic charger to avoid
Allow at least 60 minutes after operating the machine battery damage from overcharging.
or charging the battery to get an accurate reading.
If the reading is less than 12.4 volts after the battery has
been charged for several hours, see your Bobcat dealer
to have a more thorough battery test performed. WARNING
The freezing point of battery electrolyte is dependent on
the battery state of charge. Keeping the battery voltage
above 12.4 volts will help prevent batteries from freezing,
Keep arcs, sparks, flames and lighted tobacco away
even at extremely low temperatures.
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
If the battery freezes, the internal grid may be damaged
and the case will be distorted or cracked. If this happens,
Do not jump start or charge a frozen or damaged
dispose of the battery according to local regulations.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
W-2066-0910

BATTERY (CONT’D) Figure 60-20-5
Using A Booster Battery (Jump Starting)

2
If the engine will not start without using a booster battery,
BE CAREFUL! There must be one person in the 4
operator’s seat and one person to connect and
disconnect the battery cables.
The key switch must be in the STOP position. The

booster battery must be 12 volt.
3 1
WARNING P121189A

SERIOUS INJURY OR DEATH Connect the end of the first cable (Item 1) to the positive
Keep arcs, sparks, flames and lighted tobacco away (+) terminal of the booster battery. Connect the other end
from batteries. When jumping from booster battery of the same cable (Item 2) [Figure 60-20-5] to the
make final connection (negative) at machine frame. positive (+) terminal on the engine starter.
Do not jump start or charge a frozen or damaged Connect the end of the second cable (Item 3) to the
battery. Warm battery to 16°C (60°F) before negative (-) terminal of the booster battery. Connect the
connecting to a charger. Unplug charger before other end of the same cable (Item 4) [Figure 60-20-5] to
connecting or disconnecting cables to battery. Never the engine.
W-2066-0910 Keep cables away from moving parts. Start the engine.
After the engine has started, remove the negative (-)

Open the rear door.
cable (Item 4) first. Remove the cable from the positive
(+) terminal (Item 2) [Figure 60-20-5].
Remove the cables from the booster battery.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR Move the alternator toward the engine fully and remove
the belt from the pulleys.
Belt Adjustment
Inspect the pulleys for wear.
The alternator belt is a special maintenance free type that
is pretensioned over the pulleys. This belt eliminates the Install new belt.
need for a tensioning device and does not require
periodic adjustment. Figure 60-30-3
Belt Replacement
Figure 60-30-1 1
1 2
P121088A
Use a pry bar (Item 1) [Figure 60-30-3] in the location

shown to move the alternator until the bottom alternator
mounting bolt (Item 2) [Figure 60-30-2] can be installed.
P121090A
Tighten the top alternator mounting bolt and the bottom
alternator mounting bolt [Figure 60-30-2].
Remove the alternator belt shield mounting nuts and
bolts (Item 1) [Figure 60-30-1]. Install the alternator belt shield, mounting bolts, and nuts
[Figure 60-30-1].
Remove the alternator belt shield (Item 2) [Figure 60-30-
1]. Close the rear door.
Figure 60-30-2
P121089A
Remove the bottom alternator mounting bolt (Item 2).

Loosen the top alternator mounting bolt (Item 1) [Figure
60-30-2].

ALTERNATOR (CONT’D) Figure 60-30-4
Charging System Inspection
WARNING 1 1

contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

P122381
and wash eye with clean, cool water for at least 15
minutes.
If the charging system malfunctions inspect the following:
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get Inspect the condition and tension of the alternator belt.
prompt medical attention. Replace belt if worn or deteriorated.
W-2065-0807
Inspect the alternator wiring harness and connectors
(Item 1) [Figure 60-30-4] at alternator. Harness and
connectors must be clean and tight.
WARNING Inspect the fuse for the alternator in the fuse panel. If
fuse is burned, find the cause and repair / replace. If fuse
is in doubt, remove it and test for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
Keep arcs, sparks, flames and lighted tobacco away
batteries.)
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. Verify the charge of the battery. Make sure battery is fully
charged.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before Disconnect the battery cables (negative first, then
connecting to a charger. Unplug charger before positive). Inspect the cable clamps and battery posts for
connecting or disconnecting cables to battery. Never corrosion. Remove acid or corrosion from the battery and
lean over battery while boosting, testing or charging. cables with a sodium bicarbonate and water solution. Put
W-2066-0910 grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.

lb) torque.
IMPORTANT
disconnected.
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-6
Figure 60-30-5
P122381
P122446
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.
TOOL KIT - MEL1563 on Page 10-60-1.) or (See Figure 60-30-7
7217666 on Page 10-61-1.)
Turn the engine on with the Remote Start Tool and run at
idle. With a voltmeter, test the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21,1°C (70° F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the 1

following high voltage test. 2
If the voltage is lower than 13.5 volts, run the engine at

high idle and retest voltage. If voltage is still below 13.5 P122447
volts, proceed with the following low voltage test.
Test the voltage across the “L” terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, inspect wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-8
1
2
P122448
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-6] from the alternator.
Test the continuity between the “S” terminal (Item 1)

[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21,1°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair.

ALTERNATOR (CONT’D) Figure 60-30-10
Remove the air conditioning belt. (See Belt Replacement

on Page 80-20-2.) (If Equipped).
1
IMPORTANT
disconnected.
P122382
• Extra battery cables (booster cables) are Disconnect the red wire (Item 1) [Figure 60-30-10] from
connected wrong. the alternator which comes from the battery.
I-2023-1285
Figure 60-30-11
Figure 60-30-9
1
1 2
P122384
P122381
Remove the belt shield mounting nuts and bolts (Item 1)

Disconnect the negative (-) cable from the battery. and remove the belt shield (Item 2) [Figure 60-30-11].

lb) torque.
Disconnect the wiring harness connector (Item 1)

[Figure 60-30-9] from the alternator.

ALTERNATOR (CONT'D)
Figure 60-30-12
P122386
Remove the bottom alternator bolt / ground cable (Item 1)

[Figure 60-30-12].
Figure 60-30-13
1
P122385
Remove the belt and alternator from the loader.

ALTERNATOR (CONT’D)
1. Nut
2. Pulley
3. Spacer
4. Front Case
5. Bearing
6. Cover, Bearing
7. Bolt
8. Rotor
9. Stator
10. Seal 8
11. Rectifier
12. Stud 7
6
13. Holder, Brush
14. Guide, Slip Ring 5
15. Rear Case 4
12
3
2
1
15
14
12
11
9 10
7
6
5
16 7
13
NA6697S

STARTER Removal And Installation
Testing Open the rear door.
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
The battery must be at full charge. Installation: Tighten battery cables to 5 - 6 N•m (4 - 5 ft-
lb) torque.
The cable connections on the battery must be clean and
tight.
Figure 60-40-3
Figure 60-40-1
3
Bat
S 1
2
M
Cranking
Motor 3
P122383
A-1992
Disconnect the wires (Item 1) and positive (+) cable (Item

2) [Figure 60-40-3] from the starter solenoid.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -
If the starter turns but does not turn the engine, the 12.3 ft-lb) torque.
starter drive has a defect.
Remove the three bolts (Item 3) [Figure 60-40-3].
Figure 60-40-2
Remove the starter from the engine.
Bat
S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT'D)
1. Bolt 12 13. Washer

2. O-ring 14. Nut
3. Bracket 15. Shaft
4. Snapring 16. Ball
5. Stop 17. Armature
6. Gear 14 18. Bearing
13
7. Spring 19. Boot
8. Holder 11 20. Yoke
9. Lever 21. Holder
10. Plate 3
11. Lever 8 10
12. Switch 7
7
2
1 9
17
3
2 18
7
6
6 16
4 5
15
4
1
13
6
1
15
2
19
13 3
2 21
20
B-19824

INSTRUMENT PANELS
Left Panel
Figure 60-50-1
2 3 12
13
1 7
4 14 18
6 8 9 10 11 16
17
5 15
19 22
20 21
23 24
25
P-90726K
The left panel [Figure 60-50-1] is the same for all machines regardless of options and accessories.
ITEM DESCRIPTION FUNCTION / OPERATION

1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light is on when the seat bar is UP.
10 LIFT AND TILT VALVE The light is on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light is on when the loader cannot be driven.

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)

12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
DIESEL EXHAUST FLUID (DEF) / Diesel exhaust fluid (DEF) / AdBlue® level low. (See DIESEL EXHAUST
13
AdBlue® MALFUNCTION FLUID (DEF) / ADBLUE® SYSTEM in this manual.)
Instructs operator to fasten shoulder belt when operating in high range.
14 SHOULDER BELT (Option)
Remains lit while in high range.
HYDRAULIC SYSTEM
15 Hydraulic system malfunction or failure. (See Service Codes*)
MALFUNCTION
16 FUEL Fuel level low or sensor error.
DIESEL EXHAUST FLUID (DEF) / Shows the amount of diesel exhaust fluid (DEF) / AdBlue® in the tank. (See
17
AdBlue® LEVEL SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM in this manual.)
18 FUEL GAUGE Shows the amount of fuel in the tank.
Press once for REAR taillights. (Right green LED will light.) Press a second
time to turn FRONT and REAR work lights ON. REAR taillights will turn
LIGHTS without road option
OFF. (Left green LED will light.) Press a third time to turn all lights off. (Left
and right green LEDs will be off.)
Press once for FRONT boom light, license plate light and REAR taillights.
19
(Right green LED will light.) Press a second time to turn FRONT and REAR
LIGHTS with road option work lights ON. FRONT boom light, license plate light and REAR taillights
will turn OFF. (Left green LED will light.) Press a third time to turn all lights
off. (Left and right green LEDs will be off.)
Press and hold 5 seconds to show software version in display screen.
Press once to engage auto idle. (Left green LED lights.) Press a second
AUTO IDLE (Option)
time to disengage. (See AUTO IDLE in this manual.)
20
Move cursor to the left inside the DISPLAY SCREEN when using certain
INFORMATION button menus.
AUXILIARY HYDRAULICS without Press once to activate the auxiliary hydraulic system. (Left green LED
high-flow option lights.) Press a second time to deactivate the system.
Press once to activate the auxiliary hydraulic system. (Left green LED
AUXILIARY HYDRAULICS with lights.) Press a second time to engage the HIGH-FLOW auxiliary
21
high-flow option hydraulics. (Left and right green LEDs light.) Press a third time to deactivate
auxiliary hydraulics. (Left and right green LEDs off.)
Move cursor to the right inside the DISPLAY SCREEN when using certain
INFORMATION button menus.
Cycles through (after each button press):
• Hourmeter (On startup)
• Engine rpm
• Battery voltage
22 INFORMATION
• Drive response menu
• Steering drift compensation menu
• Maintenance clock
• Service codes*
Functions only when the seat bar is raised and the engine is running. Press
once to unlock the brakes. Allows you to use the steering levers or
23 TRACTION LOCK OVERRIDE joystick(s) to move the loader forward or backward when using the backhoe
attachment. (See TRACTION LOCK OVERRIDE in this manual.) Press a
second time to lock the brakes.
Press to activate the BICS™ when the seat bar is down and operator is
24 PRESS TO OPERATE LOADER
seated in operating position. Button will light.
PARKING BRAKE (Standard on all Press the top to engage the Parking Brake. Press the bottom to disengage.
25
loaders) (See PARKING BRAKE in this manual.)
* This manual contains a table with Service Code descriptions. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

Display Screen
The display screen can display the following information:
• Operating hours
• Engine rpm
• Battery voltage
• Drive response setting
• Steering drift compensation setting
• Maintenance clock countdown
• Service codes
• Engine preheat countdown
• Speed management setting
• Lift and tilt compensation setting
Figure 60-50-2
3 4 5 6 7
NA3071
The display screen is shown in [Figure 60-50-2]. The

data display will show operating hours upon startup.
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine RPM
6. Battery / Charging Voltage
7. Service

Right Panel (Standard Key Panel)

FUNCTION /
ITEM DESCRIPTION
OPERATION
Figure 60-50-3
Press the top to

ADVANCED
select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
select Foot Controls.
Press the top to

SELECTABLE
select ‘ISO’ Control
JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
select ‘H’ Control
(Option)
Pattern.
FOUR-WAY Press the top to turn

FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING BEACON
P-85285 (Option) Press the top to turn
OR light ON; bottom to
STROBE LIGHT turn OFF.
This machine may be equipped with a Standard Key
(Option)
Panel [Figure 60-50-3].
The Standard Key Panel has a key switch (Item 1)

[Figure 60-50-3] used to turn the loaders electrical
system on and off, and to start and stop the engine.
The switch location (Item 2) [Figure 60-50-3] can have

different functions depending on machine configuration.
See the following table for more information.

INSTRUMENT PANELS (CONT’D) The switch location (Item 5) [Figure 60-50-4] can have
different functions depending on machine configuration.
Right Panel (Keyless Start Panel) See the following table for more information.
Figure 60-50-4
FUNCTION /
ITEM DESCRIPTION
OPERATION
Press the top to

ADVANCED
1 select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
2 3
Press the top to
SELECTABLE
JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
(Option)
Pattern.
4

5 (Option) turn OFF.
P-90819H
ROTATING BEACON
(Option) Press the top to turn
This machine may be equipped with a Keyless Start
(Option)
1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
2. LOCK Key: Used to lock keypad. The lock key will

display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. Key Switch: Used to turn the loaders electrical


INSTRUMENT PANELS (CONT’D) 5. Key Switch: Used to turn the loaders electrical
Right Panel (Deluxe Instrumentation Panel)
The switch location (Item 6) [Figure 60-50-5] can have
Figure 60-50-5 different functions depending on machine configuration.
See the following table for more information.
1 FUNCTION /
ITEM DESCRIPTION
OPERATION
2
Press the top to
3 ADVANCED
select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
Press the top to

SELECTABLE
5 JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
(Option)
Pattern.
6
(Option) turn OFF.
P-90212J
This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].
ROTATING BEACON
(Option) Press the top to turn
1. Keypad (keys 1 through 0): The keypad has two
functions:
(Option)
- To enter a number code (password) to allow starting
the engine.
- To enter a number as directed for further use of the

display screen.
2. Display Screen: The display screen is where all

system setup, monitoring, and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen

choices.
4. ENTER Button: Used to make selections on the

display screen.

INSTRUMENT PANELS (CONT’D) Change Language:
Right Panel (Deluxe Instrumentation Panel) (Cont’d) Press the left or right scroll button to cycle through the
languages. The language that is stopped on becomes
Figure 60-50-6 the default language used for the Deluxe Instrumentation
The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-180-1.)
Enter The Password:
Use the numbers on the keypad to enter the password,

then press the [ENTER] button. A symbol will appear on
the display screen for each number entered. The left
scroll button can be used to backspace if an incorrect
number is entered.
If the correct password is not entered, [INVALID

NA3187 PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
The first screen you will see on your new loader is shown See CONTROL PANEL SETUP for further description of
in [Figure 60-50-6]. screens to set up the system for your use. (See Right
Panel Setup (Deluxe Instrumentation Panel) on Page 60-
When this screen is on the display you can enter the 180-1.)
password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See Changing The Owner
Password on Page 60-190-1.) Keep your
password in a safe location for future needs.

INSTRUMENT PANELS (CONT’D) Right Switch Panel
Left Switch Panel
Figure 60-50-7
1 1
2 2
3 3
NA3323
This machine may be equipped with a left switch panel NOTE: Earlier models did not have switch locations
[Figure 60-50-7]. four and five on the left switch panel.

FOUR-WAY
Press the top to turn lights ITEM DESCRIPTION FUNCTION / OPERATION
1 FLASHER
ON; bottom to turn OFF.
LIGHTS (Option) Press and hold the up arrow
ROTATING to disengage the Bob-Tach
BEACON (Option) POWER wedges. Press and hold the
Press the top to turn light ON; 1 BOB-TACH down arrow to engage the
2 OR
bottom to turn OFF. (Option) Bob-Tach wedges into the
STROBE LIGHT
(Option) attachment mounting frame
holes.
HYDRAULIC
Press the top to engage 2 NOT USED –––
BUCKET
3 Hydraulic Bucket Positioning;
POSITIONING Automatic Operation - middle
bottom to disengage.
(Option) REVERSING FAN position; Manual Operation -
3
AUTOMATIC Press the top to engage (Option) press top momentarily; press
4 RIDE CONTROL Automatic Ride Control; bottom to disengage.
(Option) bottom to disengage. Press the bottom to inhibit
Press the top to turn lights DeSOX. See SELECTIVE
DESOX INHIBIT
ON; bottom to turn OFF. 4 CATALYTIC REDUCTION
SIDE LIGHTING (Option)
5 NOTE: Turn side lighting (SCR) SYSTEM in this
(Option) manual.
OFF when driving
on public roads.

INSTRUMENT PANELS (CONT’D) Right Side Lower Panel
Left Side Lower Panel Figure 60-50-9
Figure 60-50-8 1
2
3
1 2 4
P-85267D
P-85282
This machine may be equipped with a right side lower
panel [Figure 60-50-9].
This machine may be equipped with a left side lower
panel [Figure 60-50-8].
ITEM DESCRIPTION FUNCTION / OPERATION Provides a 12 volt receptacle

1 POWER PORT
for accessories.
Turn clockwise to increase fan
2 RADIO (Option) See Radio in this manual.
FAN MOTOR speed; counterclockwise to
1 Used to connect headphones
(Option) decrease. There are four
positions; OFF-1-2-3. HEADPHONE to the optional radio output.
3
JACK (Option) Automatically silences
Press top of switch to start;
AIR speakers when used.
bottom to stop. Switch will
CONDITIONING / SPEAKER Right speaker used with
2 light when started. Fan Motor 4
DEFROST (Option) optional radio.
(Item 1) must be ON for air
SWITCH (Option)
conditioning to operate.
Turn clockwise to increase the
TEMPERATURE
temperature;
3 CONTROL
counterclockwise to
(Option)
decrease.
SPEAKER Left speaker used with
4
(Option) optional radio.

INSTRUMENT PANELS (CONT’D) Right Panel (Standard Key Panel) Removal And
Installation
Left Panel Removal And Installation
Figure 60-50-12
Figure 60-50-10
1 1
1 1 2
2
P-85929
P-85928
Remove the two mounting bolts (Item 1) and the fastener

Remove the two mounting bolts (Item 1) and the fastener (Item 2) [Figure 60-50-12].
(Item 2) [Figure 60-50-10].
Installation: Be careful to not overtighten the instrument
Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded
panel mounting bolts to prevent stripping of the threaded holes in the panels. Tighten the panel screws to 3 - 4
holes in the panels. Tighten the panel screws to 3 - 4 N•m (25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
NOTE: Inspect and replace the seal as needed (Item 3) [Figure 60-50-12].
3) [Figure 60-50-10].
Figure 60-50-13
Figure 60-50-11
1 P-85931
P-85930
Pull the right instrument panel down and disconnect the

Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-13].
wire harness connectors (Item 1) [Figure 60-50-11] from
the panel. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Right Panel (Deluxe Instrumentation Panel) Removal
And Installation
Right Panel (Keyless Start Panel) Removal And
Installation Figure 60-50-16
Figure 60-50-14
3
3
1
1 1
1
2
2 P-90527
P-90819A
(Item 2) [Figure 60-50-16].
(Item 2) [Figure 60-50-14]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 3 - 4
panel mounting bolts to prevent stripping of the threaded N•m (25 - 35 in-lb) torque.
holes in the panels. Tighten the panel screws to 3 - 4
N•m (25 - 35 in-lb) torque. NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-16].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-14]. Figure 60-50-17
Figure 60-50-15
P-90530
P-90818A
wire harness connector (Item 1) [Figure 60-50-17].
wire harness connector (Item 1) [Figure 60-50-15]. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Alarm Disassembly And Assembly
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-19
Disconnect the key switch wiring harness.
Figure 60-50-18
2
P-85947
Remove the left side instrument panel.

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-19] from
the loader alarm.
Remove the key (Item 1) from the switch. Remove the
ignition switch retaining nut (Item 2) [Figure 60-50-18] Remove the alarm from the loader instrument panel.
from the switch.
Remove the ignition switch from the control panel.

INSTRUMENT PANELS (CONT'D) Right Switch Panel Removal And Installation
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) Removal And Installation on Page 60-50-10.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-10.) Figure 60-50-22
Figure 60-50-20
1
1
P107695
1
P-85945
Remove the fastener (Item 1) and screw (Item 2) [Figure
60-50-22].
Remove the two fasteners (Item 1) [Figure 60-50-20].
Figure 60-50-23
Figure 60-50-21
1 1
2
1 2
P-85944A
P-85946
Remove the two screws (Item 1) and the right side panel
Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-23].
(Item 2) [Figure 60-50-21].

LIGHTS Figure 60-60-3
Front Removal And Installation 1
Disconnect the negative(-) cable from the battery. (See


lb) torque.
1
Figure 60-60-1
1
P-85436
Figure 60-60-4
1 1
P-85433
Installation: Tighten the two bolts to 4 - 5 N•m (35 - 45

in-lb) torque.
Figure 60-60-2 P-85435
Remove the two bulbs (Item 1) [Figure 60-60-3] and

[Figure 60-60-4] from the housing by turning bulb a 1/4
turn.
1
NOTE: Two different light bulbs are used, take note
1 when removing to assure correct installation.
Reverse the above procedure to install the bulb.
P-85434
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness connectors.

LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-7
Figure 60-60-5
1 2
P-85586C
P-85438
Pry the cab light (Item 1) free from the headliner (Item 2)
[Figure 60-60-7].
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light too far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.
P-85437 P115307
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Reverse this procedure for installation.

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)
Description
The Gateway controller is the main controller, it provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
The Gateway and Auxiliary controller are located behind

the access panel near the operator’s left foot.

BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2680 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL PULL RELAY SIGNAL
4 3380 LBL SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION PULL RELAY SIGNAL
9 OPEN NA NA
10 2670 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7021 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 3430 LBL TRACTION PULL RELAY FEEDBACK
14 3420 LBL GLOW PLUG RELAY FEEDBACK
15 3160 LBL ENGINE SPEED SENSOR SIGNAL
16 3150 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 2380 BRN PTOL LED
20 3030 LBL PTOL SWITCH
21 3450 LBL SWITCHED POWER RELAY FEEDBACK
22 3560 LBL STARTER RELAY FEEDBACK
23 OPEN NA NA
24 8130 TAN START ENGINE
25 3140 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO-SPEED GROUND
27 2360 BLACK TWO-SPEED MAKEUP GROUND
28 3440 LBL REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 3410 LBL FUEL RELAY FEEDBACK
31 3460 LBL MRKR LIGHT PWR RELAY FEEDBACK
32 3220 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3220 LBL HYD FILTER DIFF PRESS

J1B
WIRE
NUMBER
1 3190 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4680 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4670 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9200 PUR/WHT CAN LO 0
9 9100 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3370 LBL SEATBAR SENSOR SIGNAL
12 3180 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 2230 BRN SENSOR GROUND
18 3170 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 3090 LBL REMOTE ATTACHMENT SIGNAL
22 3040 LBL RUN / ENTER
23 5190 YEL HYDRAULIC CHARGE PRESSURE
24 5100 YEL +5V SUPPLY
25 4360 LGN TWO-SPEED MAKEUP
26 4350 LGN TWO-SPEED SIGNAL

Auxiliary Controller
1 1
34 26
J2A J2B
Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BRN JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 3130 BRN JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLERS (GATEWAY AND NOTE: The connectors are keyed and will only plug
AUXILIARY) (CONT’D) in one way.


1.)
1 1
Remove the left inside access panel. (See Removal And

Installation (Left) on Page 50-130-1.)
Figure 60-70-1
P101568
Remove the controller mounting bolts (Item 1) [Figure

60-70-3] from the left fender.
Installation: Tighten the controller mounting bolts to 17 -

1
Remove the Gateway and Auxiliary controllers from the
loader.
P122387
Unplug the two harness connectors (Item 1) [Figure 60-

70-1] from the Auxiliary controller.
Figure 60-70-2
P122388
Unplug the two harness connectors (Item 1) [Figure 60-

70-2] from the Gateway controller.

BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS

or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.

BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-2

1
1.)
Figure 60-71-1
1 P-85902

from the controller.
Remove the controller from the loader.
1 NOTE: The calibration procedure must be followed

when replacing a controller. (See Lift And Tilt
Calibration (ACS) on Page 60-160-11.)
P-85903
NOTE: Before unplugging any controller the key

switch must be off.
Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.
NOTE: The connectors are keyed and will only plug

in one way.

BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same as those used on
drive functions. the ACS system.
The drive controller is located underneath the operator’s The hydrostatic drive pump has two electromagnetic coils
cab attached to the control panel. on each of the two pumps to control the drive of the
loader. The coils will direct the forward and reverse
The drive controller monitors the position of the joysticks, outputs of the pump to the drive motors. The hydrostatic
pump swash plate angles and position of the ISO and H drive pump is equipped with position sensors mounted to
pattern switch. the bottom of the swash plates to provide feedback to the
controllers to sense uncommanded swash plate
The drive controller works along with the ACS controller movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
ACS
CONTROL
RIGHT DRIVE HYDRAULIC
HAND CONTROL MOTOR
PANEL
LIFT / TILT
ISO ACTUATORS
SWITCH
ENGINE
INTERNAL CAN BUS
RIGHT
JOYSTICK
FWD / REV
SWASH PLATE
LEFT SENSORS
JOYSTICK
AUXILIARY DRIVE
LEFT CONTROL PUMP
HAND
PANEL
HYDRAULIC
ACD
MOTOR
EXTERNAL CONTROL
GATEWAY CAN BUS
CONTROL NA5677

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification
P-64295

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4
Remove the three bolts (Item 1) [Figure 60-72-1] that

secure the controller.

Figure 60-72-2
J S
P-64325
Remove the drive controller [Figure 60-72-4].

1
P-64324
Remove the screw and wire harness (Item 1) [Figure 60-

72-2].
Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

DOSING CONTROL UNIT (DCU) Removal And installation
Description DCU removal and installation. (See Dosing Control Unit

(DCU) Removal And Installation on Page 70-30-11.)
The dosing control unit (DCU) is used for overall control
of the SCR system.

ENGINE CONTROL UNIT (ECU) Figure 60-80-1
Description
1
The engine ECU controls the amount, timing, mixture
and pressure of fuel that is injected. The engine ECU
operates each kind of control based on the signals from
each type of sensor.
The actuator for controlling the amount, timing and

mixture of fuel injection is the injector, while the actuator
for controlling fuel pressure is the supply pump.
The amount of fuel to be injected is determined using a

basic injection amount, which is calculated based on the
state of the engine and driving conditions, with P122378
corrections added for parameters such as water
temperature, fuel temperature, intake pressure, etc.
The ECU (Item 1) [Figure 60-80-1] is located in the
The ECU controls the timing for starting to energize the engine compartment on the right hand upright.
injectors, first determining the timing for the main
injection and then that of other injections, such as pilot
injections.
By conducting a pilot injection, the initial fuel mixture is

kept to a minimum, mitigating the explosive initial
IMPORTANT
combustion and reducing NOx and noise. Avoid damage to the Engine Control Unit (ECU).
Water entering ECU atmospheric pressure sensor
The ECU calculates the set fuel injection pressure based will damage the ECU. Do not use high water pressure
on the engine load (last injection amount and engine around the ECU when cleaning the engine
RPM) and controls the amount the supply pump supplies compartment.
and the fuel pressure inside the rail. I-2357-0512

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 60-80-4
Cleaning
NOTE: The ECU connectors must to be free of all dirt

and debris before removing connectors.
NOTE: ECU removed for photo quality. 1

Figure 60-80-2
P114460
Remove any residual dirt and debris from the connector

and slide area with a small brush (Item 1) [Figure 60-80-
4].
2 Repeat all steps until there is no visible evidence of dirt,

grit or other debris.
P114458
NOTE: Inspect the connector and repeat cleaning

Use a spray bottle (Item 1) to apply water around the process if debris remains on the connector
connectors (Item 2) [Figure 60-80-2] to remove dirt and and ECU.
debris.
Figure 60-80-5
NOTE: Do not apply water when any connector is
removed.
Figure 60-80-3 2
3
1
1
P114461
Inspect the connector (Item 1) [Figure 60-80-5] for

2 damage and debris.
P114459
NOTE: To avoid getting debris in the terminal

openings, clean the connector facing the
Use air pressure to remove loose particles from the ECU ground.
head (Item 1) and the connector (Item 2) [Figure 60-80-
3]. Using a clean damp cloth or paper towel, not dripping
wet, brush off the heavy deposits on the housing (Item 2)
The connectors should be dry before disconnecting. but do not wipe on the terminal openings (Item 3) [Figure
60-80-5].

IMPORTANT 2 1
Avoid damaging the Engine Control Unit (ECU) and

electrical connectors. Use care when removing or
installing the ECU connectors.
I-2356-0512
Clean the connectors before removal. (See Cleaning on

Page 60-80-2.) P114357
Figure 60-80-6
Figure 60-80-9
2
1 1
P122379
P114465
Remove the connectors (Item 1) from the ECU (Item 2)

[Figure 60-80-6]. Lift the lever (Item 1) and push fully forward to remove
connector (Item 2) [Figure 60-80-8]. Pull connector
Figure 60-80-7 straight out to avoid damage [Figure 60-80-9].
NOTE: Removing or installing the connector at an

extreme angle will result in seal “scooping”,
creating an environment for fluid ingress.
Damage to the header or connector may
result if undue force is used.
NOTE: If resistance is encountered when opening the

lever, lock connector and repeat the cleaning
process.
Repeat the above procedure on the remaining connector.

1
P114356
Push the lock tab (Item 1) [Figure 60-80-7] in to release

the lock lever.

Figure 60-80-10 3
1
1
1
1 1
2 P114402
Remove the nuts (Item 1) and remove the ECU (Item 2)

P114400 from the bracket (Item 3) [Figure 60-80-12].

10].
Figure 60-80-11
P114401
Remove the nut and the ground wire (Item 1) [Figure 60-
80-11] from the ECU.

DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions that can damage your machine.
The last 40 codes stored in history can also be viewed
Left Panel using the Deluxe Instrumentation Panel.
Figure 60-90-1
Press a scroll button (Item

1) repeatedly until the
1
Active Warnings screen
icon (Inset) is highlighted.
1 1
The ACTIVE WARNINGS

screen displays active
2 service codes. Press [9] to
view the next service code
NA3272 if more than one is
present. Press [4] to
Press the Information button (Item 2) to cycle the data display a history of service
display (Item 1) [Figure 60-90-1] until the service code codes.
screen is displayed. If more than one service code is The WARNINGS
present, the codes will scroll on the data display. HISTORY screen will list
the Service Code Number
When no service code is present, [NONE] is displayed (CODE), Hourmeter
[Figure 60-90-1]. reading when the error
occurred (HOUR), and the
NOTE: Corroded or loose grounds can cause User (USER) who was
multiple service codes and / or abnormal logged in to operate the
symptoms. All instrument panel lights machine when the error
flashing, alarm sounding, headlights and occurred.
taillights flashing, can indicate a bad ground. Press [9] to view the next eight service codes.
The same symptoms can apply if the voltage
is low, such as loose or corroded battery A total of 40 codes can be stored. When more than 40
cables. If you observe these symptoms, codes occur, the oldest code will disappear and the
inspect grounds and positive leads first. newest code will be in the number 1 position.
Press the list number next

to the service code for
more detail.
Press the left scroll button

to back up one screen.

DIAGNOSTIC SERVICE CODES (CONT'D) The following letter codes may be displayed:
Service Codes List

CODE DESCRIPTION
Figure 60-90-2 Replace engine air filter.
AIRF
1 2
The controller is asking for a password.
CODE (Keyless Start and Deluxe Instrumentation
Panels only.)
The engine controller has determined the
COLD
engine must warm up.
The engine is performing a DeSOX process.
DESOX
Operate the machine under load.
Operator cab door is open. (Lift and Tilt
DOOR
functions will not operate.)
The wrong password was entered. (Keyless
NA3077 ERROR
NA3084
Start and Deluxe Instrumentation Panels only.)
NA3272
One or both instrument panel(s) not
REPLY
communicating with the controller.
Service codes can be either letters (Item 1) or numbers RFOFF Reversing fan is disabled.
(Item 2) [Figure 60-90-2].
SHTDN A shutdown condition exists.
CODE DESCRIPTION CODE DESCRIPTION

A0618 Wheel speed out of range A8205 ACD output ‘C’ short to battery
A3623 ACD not programmed A8206 ACD output ‘C’ short to ground
A4621 5 volt sensor supply out of range high A8207 ACD output ‘C’ open circuit
A4622 5 volt sensor supply out of range low A8232 ACD output ‘C’ overcurrent
A4721 8 volt sensor supply out of range high A8302 ACD output ‘D’ error ON
A4722 8 volt sensor supply out of range low A8303 ACD output ‘D’ error OFF
A7701 Machine key active A8305 ACD output ‘D’ short to battery
A7901 E-Stop active A8306 ACD output ‘D’ short to ground
A8002 ACD output ‘A’ error ON A8307 ACD output ‘D’ open circuit
A8003 ACD output ‘A’ error OFF A8332 ACD output ‘D’ overcurrent
A8005 ACD output ‘A’ short to battery A8402 ACD output ‘E’ error ON
A8006 ACD output ‘A’ short to ground A8403 ACD output ‘E’ error OFF
A8007 ACD output ‘A’ open circuit A8405 ACD output ‘E’ short to battery
A8032 ACD output ‘A’ overcurrent A8406 ACD output ‘E’ short to ground
A8102 ACD output ‘B’ error ON A8407 ACD output ‘E’ open circuit
A8103 ACD output ‘B’ error OFF A8432 ACD output ‘E’ overcurrent
A8105 ACD output ‘B’ short to battery A8502 ACD output ‘F’ error ON
A8106 ACD output ‘B’ short to ground A8503 ACD output ‘F’ error OFF
A8107 ACD output ‘B’ open circuit A8505 ACD output ‘F’ short to battery
A8132 ACD output ‘B’ overcurrent A8506 ACD output ‘F’ short to ground
A8202 ACD output ‘C’ error ON A8507 ACD output ‘F’ open circuit
A8203 ACD output ‘C’ error OFF A8532 ACD output ‘F’ overcurrent

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)

Drive right rear wheel angle sensor out of range
A8602 ACD output ‘G’ error ON D7525
high
Drive left rear wheel angle sensor out of range
A8603 ACD output ‘G’ error OFF D7526
high
A8605 ACD output ‘G’ short to battery D7527 Drive left swash plate out of position
A8606 ACD output ‘G’ short to ground D7528 Drive right swash plate out of position
A8607 ACD output ‘G’ open circuit D7529 Drive left joystick X-axis out of range low
A8702 ACD output ‘H’ error ON D7531 Drive left joystick Y-axis out of range low
A8703 ACD output ‘H’ error OFF D7532 Drive right joystick Y-axis out of range low
Drive right front wheel angle sensor out of range
A8705 ACD output ‘H’ short to battery D7533
low
Drive left front wheel angle sensor out of range
A8706 ACD output ‘H’ short to ground D7534
low
Drive right rear wheel angle sensor out of range
A8707 ACD output ‘H’ open circuit D7535
low
Drive left rear wheel angle sensor out of range
A8802 Reversing solenoid error ON D7536
low
A8803 Reversing solenoid error OFF D7537 Drive 5 volt sensor supply 1 out of range low
D7538 Drive 5 volt sensor supply 2 out of range low
D3905 Left joystick X-axis not in NEUTRAL D7539 Drive left swash plate sensor out of range high
D3907 Left joystick Y-axis not in NEUTRAL D7540 Drive left swash plate sensor out of range low
D4007 Right joystick Y-axis not in NEUTRAL D7541 Drive right swash plate sensor out of range high
D7501 Drive CAN joystick information error D7542 Drive right swash plate sensor out of range low
D7504 Drive no communication from drive controller D7543 Drive left forward drive solenoid error ON
D7505 Drive left joystick X-axis not in NEUTRAL D7544 Drive left reverse drive solenoid error ON
D7507 Drive left joystick Y-axis not in NEUTRAL D7545 Drive right forward drive solenoid error ON
D7508 Drive right joystick Y-axis not in NEUTRAL D7546 Drive right reverse drive solenoid error ON
Drive operating mode switch short to ground or
D7509 D7547 Drive right front steer extend short to battery
battery
D7510 Drive improper joysticks installed D7548 Drive left front steer extend short to battery
D7511 Drive left speed sensor not connected D7549 Drive right rear steer extend short to battery
D7512 Drive right speed sensor not connected D7550 Drive left rear steer extend short to battery
D7513 Drive right front wheel angle sensor stuck D7551 Drive steer pressure short to battery
D7514 Drive left front wheel angle sensor stuck D7552 Drive back-up alarm error ON
D7515 Drive right rear wheel angle sensor stuck D7553 Drive left forward drive solenoid error OFF
D7516 Drive left rear wheel angle sensor stuck D7554 Drive left reverse drive solenoid error OFF
D7517 Drive left swash plate not in NEUTRAL D7555 Drive right forward drive solenoid error OFF
D7518 Drive right swash plate not in NEUTRAL D7556 Drive right reverse drive solenoid error OFF
D7519 Drive left joystick X-axis out of range high D7557 Drive right front steer extend short to ground
D7521 Drive left joystick Y-axis out of range high D7558 Drive right front steer retract short to ground
D7522 Drive right joystick Y-axis out of range high D7559 Drive left front steer extend short to ground
Drive right front wheel angle sensor out of range
D7523 D7560 Drive left front steer retract short to ground
high
Drive left front wheel angle sensor out of range
D7524 D7561 Drive right rear steer extend short to ground
high


D7562 Drive right rear steer retract short to ground E00002704 EGR actuator position fault
D7563 Drive left rear steer extend short to ground E00002709 EGR actuator position fault
D7564 Drive left rear steer retract short to ground E00002710 EGR actuator position fault
D7565 Drive steer pressure short to ground E00002720 EGR position learning fault
D7566 Drive back-up alarm error OFF E00002730 EGR position learning fault
D7567 Drive no communication from Bobcat controller E00002903 Throttle position sensor fault
D7568 Drive angle sensors not calibrated E00002904 Throttle position sensor fault
D7569 Drive battery voltage out of range high E00008100 SCR fault
Drive interrupted power (also occurs after
D7570 E00008107 SCR fault
software updates)
D7571 Drive battery voltage out of range low E00008111 SCR fault
D7572 Drive pump not calibrated E00009102 Throttle position sensor fault
Drive operating mode switch flipped while
D7573 E00009103 Throttle position sensor fault
operating
D7574 Drive right wheel speed uncommanded motion E00009104 Throttle position sensor fault
D7575 Drive left wheel speed uncommanded motion E00009119 Throttle position sensor fault
D7576 Drive no communication from ACS controller E00009411 Rail pressure control fault
D7577 Drive left speed sensor out of range high E00009416 Rail pressure control fault
D7578 Drive right speed sensor out of range high E00009418 Rail pressure control fault
D7579 Drive left speed sensor out of range low E00009703 Water in fuel sensor fault
D7580 Drive right speed sensor out of range low E00009704 Water in fuel sensor fault
D7581 Drive right front steer retract short to battery E00009709 Water in fuel sensor fault
D7582 Drive left front steer retract short to battery E00009731 Water in fuel detected
D7583 Drive right rear steer retract short to battery E00010001 Engine oil pressure too low
D7584 Drive left rear steer retract short to battery E00010003 Engine oil pressure fault
D7585 Drive 5 volt sensor supply 1 out of range high E00010004 Engine oil pressure fault
D7586 Drive 5 volt sensor supply 2 out of range high E00010203 Intake air pressure sensor fault
D7587 Drive software update required E00010204 Intake air pressure sensor fault
D7588 Drive switched power stuck ON E00010502 Intake manifold temperature fault
D7589 Drive switched power error OFF E00010503 Intake manifold temperature sensor fault
D7590 Drive calibration performed E00010504 Intake manifold temperature sensor fault
D7591 Drive left swash plate sensor reversed E00010509 Intake manifold temperature sensor fault
D7592 Drive right swash plate sensor reversed E00010510 Intake manifold temperature sensor fault
D7593 Drive unresponsive right speed sensor E00010603 Manifold pressure sensor fault
D7594 Drive unresponsive left speed sensor E00010604 Manifold pressure sensor fault
D7595 Drive left speed sensor reverse direction E00010609 Manifold pressure sensor fault
D7596 Drive right speed sensor reverse direction E00010803 Barometric pressure fault
D7597 Drive controller programmed E00010804 Barometric pressure fault
D7598 Drive controller in calibration mode E00010809 Barometric pressure fault
Drive AWS controller in wheel position
D7599 E00011000 Engine temperature extremely high
calibration mode
E00011002 Engine coolant temperature fault
E00002700 EGR control fault E00011003 Water temperature sensor fault
E00002701 EGR control fault E00011004 Water temperature sensor fault
E00002703 EGR actuator position fault E00011031 Engine coolant temperature sensor fault


E00013200 Intake air volume fault E00063602 Crank position sensor fault
E00013201 Intake air volume fault E00063607 Cam or crank sensor fault
E00013203 MAF sensor fault E00063608 Crank position sensor fault
E00013204 MAF sensor fault E00063611 Crank position sensor fault
E00013209 MAF sensor fault E00063702 Cam signal fault
E00013215 Boost pressure fault E00063708 Cam signal fault
E00013231 MAF sensor fault E00063720 Cam signal fault
E00015700 Rail pressure fault E00063730 Cam signal fault
E00015702 Rail pressure sensor fault E00063919 ECU communication error
E00015703 Rail pressure sensor fault E00064103 Boost control fault
E00015704 Rail pressure sensor fault E00064104 Boost control fault
E00015710 Rail pressure fault E00065103 Injector #1 fault
E00015711 Rail pressure fault E00065105 Injector #1 fault
E00015721 Rail pressure control fault E00065106 Injector #1 fault
E00015722 Rail pressure control fault E00065120 Injector #1 fault
E00016803 System voltage too high E00065121 Injector #1 fault
E00016804 System voltage too low E00065131 Injector #1 fault
E00017103 MAF sensor fault E00065203 Injector #2 fault
E00017104 MAF sensor fault E00065205 Injector #2 fault
E00017200 Intake air temperature too high E00065206 Injector #2 fault
E00017202 Intake air temperature sensor fault E00065220 Injector #2 fault
E00017300 Exhaust over temperature fault E00065305 Injector #3 fault
E00017301 DOC exothermal efficiency fault E00065306 Injector #3 fault
E00017302 SCR inlet temperature sensor fault E00065320 Injector #3 fault
E00017400 Fuel temperature too high E00065321 Injector #3 fault
E00017402 Fuel temperature fault E00065331 Injector #3 fault
E00017403 Fuel temperature sensor fault E00065403 Injector #4 fault
E00017502 Engine oil temperature fault E00065420 Injector #4 fault
E00017531 Engine oil temperature sensor fault E00065421 Injector #4 fault
E00019000 Engine speed extremely high E00065431 Injector #4 fault
E00062802 ECU fault E00067603 Glow plug relay fault
E00062912 ECU fault E00067604 Glow plug relay fault
E00063011 Injector data fault E00067605 Glow plug relay fault
E00063023 ECU fault E00072302 Camshaft position sensor fault
E00063024 ECU fault E00072308 Camshaft position sensor fault
E00063025 ECU fault E00073120 Accelerometer fault
E00063031 ECU fault E00073121 Accelerometer fault
E00063307 Rail pressure fault E00107600 Rail pressure control fault
E00063600 Crank position sensor fault E00107601 Rail pressure control fault
E00063601 Crank position sensor fault E00107603 Rail pressure control fault


E00107604 Rail pressure control fault E00122130 ECU fault
E00107609 Rail pressure control fault E00122131 ECU safety monitoring fault
E00107702 ECU fault E00122138 ECU fault
E00118002 Turbo temperature fault E00122139 ECU fault
E00118003 Turbo temperature sensor fault E00122140 ECU fault
E00122103 ECU safety monitoring fault E00122148 ECU fault


E00122175 ECU fault E00324204 Exhaust gas temperature sensor fault
E00122177 ECU fault E00324600 Exhaust temperature extremely high
E00122178 ECU fault E00324603 EGR temperature sensor fault
E00122181 ECU fault E00325100 Differential pressure sensor fault
E00122182 ECU fault E00325101 Differential pressure sensor fault
E00122185 ECU fault E00325200 Exhaust temperature too high
E00122186 ECU fault E00350903 Sensor supply voltage fault
E00122188 ECU fault E00350911 5 volt sensor supply #1 fault
E00122191 ECU fault E00351011 5 volt sensor supply #2 fault
E00122192 ECU fault E00351111 5 volt aux sensor supply #2 fault
E00122193 ECU fault E00370100 Particulate matter extremely high
E00122194 ECU fault E00370115 Particulate matter warning
E00122195 ECU fault E00370116 Particulate matter too high
E00122196 ECU fault E00408203 Inlet metering valve fault
E00123901 High pressure fuel leak E00425600 Unknown SCR fault
E00134703 High pressure pump fault E00476500 Exhaust temperature extremely high
E00134704 High pressure pump fault E00476503 Exhaust gas temperature sensor fault
E00134707 High pressure pump fault E00476504 Exhaust gas temperature sensor fault
E00148502 ECU main relay fault E00476518 Exhaust gas temperature sensor fault
E00148507 ECU main relay fault E00524600 DEF level empty
E00148511 ECU main relay fault E00524615 DEF level too low
E00161203 Injector #1 and #4 fault E00524616 DEF level extremely low
E00161204 Injector #1 and #4 fault E00524617 DEF level too low
E00161211 Injector #1 and #4 fault E00524619 DCU CAN communication fault
E00161303 Injector #2 and #3 fault E00524621 Blocked EGR fault
E00161304 Injector #2 and #3 fault E00524622 Dosing interrupted fault
E00161311 Injector #2 and #3 fault E00524623 DEF consumption fault
E00279103 EGR motor fault E00524624 DEF quality fault
E00279104 EGR motor fault E00524625 Tampering fault
E00279105 EGR motor fault E00524626 DEF consumption fault
E00279107 EGR blocked fault E00532403 Glow plug signal fault
E00279108 EGR position fault E00532404 Glow plug signal fault
E00324200 Exhaust temperature extremely high E52352302 Injector #1 and #4 fault
E00324203 Exhaust gas temperature sensor fault E52352303 Injector #1 and #4 fault


E52352304 Injector #1 and #4 fault E52360402 ECU communication fault
E52352402 Injector #2 and #3 fault E52370013 ECU fault
E52352403 Injector #2 and #3 fault
E52352404 Injector #2 and #3 fault H0921 Boost sensor out of range high
E52352501 Injector fault H0922 Boost sensor out of range low
E52352702 ECU fault H1221 Right thumb switch out of range high
E52353500 Injector fault H1222 Right thumb switch out of range low
E52353602 EGR fault H1224 Right thumb switch not in NEUTRAL
E52353702 EGR fault H1321 Left thumb switch out of range high
E52353802 ECU fault H1322 Left thumb switch out of range low
E52353807 ECU fault H1324 Left thumb switch not in NEUTRAL
E52353902 Fuel pump fault H1421 Lift base pressure out of range high
E52354002 Fuel pump fault H1422 Lift base pressure out of range low
E52354103 EGR fault H1502 Ride control output error ON
E52354104 EGR fault H1503 Ride control output error OFF
E52354302 Throttle position sensor fault H1507 Ride control output open circuit
E52354403 Intake heater fault H1528 Ride control output failure
E52354404 Intake heater fault H1602 Ride control relay error ON
E52354702 ECU communication error H1603 Ride control relay error OFF
E52354802 ECU communication error H2105 Reverse fan solenoid short to battery
E52357204 EGR position sensor fault H2106 Reverse fan solenoid short to ground
E52357403 EGR actuator fault H2107 Reverse fan solenoid open circuit
E52357404 EGR actuator fault H2132 Reverse fan solenoid overcurrent
E52357507 EGR actuator fault H2305 Rear base output short to battery
E52357602 EGR motor fault H2306 Rear base output short to ground
E52357702 EGR temperature sensor fault H2307 Rear base output open circuit
E52357802 EGR fault H2332 Rear base output overcurrent
E52358002 Intake throttle fault H2405 Rear rod output short to battery
E52358203 Intake throttle lift sensor fault H2406 Rear rod output short to ground
E52358204 Intake throttle lift sensor fault H2407 Rear rod output open circuit
E52358917 Low water temperature in parked regeneration H2432 Rear rod output overcurrent
E52359016 Parked regeneration time out H2502 Diverter #2 short to battery
E52359102 ECU communication fault H2503 Diverter #2 short to ground
E52359202 ECU communication fault H2505 Diverter #2 short to battery
E52359302 ECU communication fault H2506 Diverter #2 short to ground
E52359402 ECU communication fault H2507 Diverter #2 open circuit
E52359502 ECU communication fault H2605 Front base output short to battery
E52359602 ECU communication fault H2606 Front base output short to ground
E52359800 DOC failure H2607 Front base output open circuit
E52359802 ECU communication fault H2632 Front base output overcurrent
E52359900 Exhaust temperature sensor fault H2705 Front rod output short to battery
E52360000 Pump calibration error H2706 Front rod output short to ground
E52360100 Exhaust gas temperature sensor fault H2707 Front rod output open circuit
E52360200 DPF fault H2732 Front rod output overcurrent
E52360315 Water temperature sensor fault H2805 Diverter short to battery


H2806 Diverter short to ground M0309 System voltage too low
H2807 Diverter open circuit M0310 System voltage too high
H2905 High-flow short to battery M0311 System voltage extremely high
H2906 High-flow short to ground M0314 System voltage extremely low
H2907 High-flow open circuit M0322 System voltage out of range low
H2932 High-flow overcurrent M0409 Engine oil pressure too low
H3128 Interrupted power failure M0414 Engine oil pressure extremely low
H3648 Multiple ACD conflict error M0415 Engine oil pressure in shutdown
H3904 Left joystick in error M0421 Engine oil pressure out of range high
H3912 Left joystick thumb switch not in NEUTRAL M0422 Engine oil pressure out of range low
H3913 Left joystick grip no communication M0509 Hydraulic charge pressure too low
H3916 Left joystick no communication M0510 Hydraulic charge pressure too high
H3928 Left joystick internal failure M0511 Hydraulic charge pressure extremely high
H3948 Left joystick multiple M0514 Hydraulic charge pressure extremely low
H4004 Right joystick in error M0515 Hydraulic charge pressure in shutdown
H4012 Right joystick thumb switch not in NEUTRAL M0521 Hydraulic charge pressure out of range high
H4013 Right joystick grip no communication M0522 Hydraulic charge pressure out of range low
H4016 Right joystick no communication M0610 Engine speed too high
H4028 Right joystick internal failure M0611 Engine speed extremely high
H4048 Right joystick multiple M0613 Engine speed no signal
H4302 Horn error ON M0615 Engine speed in shutdown
H4303 Horn error OFF M0618 Engine speed out of range
H4423 Auxiliary not programmed M0634 Engine speed invalid information from ECU
H4497 Auxiliary controller programmed M0710 Hydraulic fluid temperature too high
H4502 Right blinker error ON M0711 Hydraulic fluid temperature extremely high
H4503 Right blinker error OFF M0715 Hydraulic fluid temperature in shutdown
H4602 Left blinker error ON M0721 Hydraulic fluid temperature out of range high
H4603 Left blinker error OFF M0722 Hydraulic fluid temperature out of range low
H4721 8 volt sensor supply out of range high M0810 Engine coolant temperature too high
H4722 8 volt sensor supply out of range low M0811 Engine coolant temperature extremely high
H4821 5 volt sensor supply out of range high M0815 Engine coolant temperature in shutdown
H4822 5 volt sensor supply out of range low M0821 Engine coolant temperature out of range high
H7404 Main controller no communication M0822 Engine coolant temperature out of range low
Press to operate loader keypad no
H9004 M0826 Engine coolant temperature pre-shutdown
communication
M0909 Fuel level too low
L0102 Lights button error ON M0921 Fuel level out of range high
L0202 High-flow enable button error ON M0922 Fuel level out of range low
L0302 Auxiliary enable button error ON M1016 Hydraulic charge filter not connected
L0402 Information button error ON M1017 Hydraulic charge filter plugged
L7404 Main controller no communication M1121 Seat bar sensor out of range high
L7672 Left display panel needs programming M1122 Seat bar sensor out of range low
M1128 Seat bar sensor
M0116 Air filter not connected M1210 Intake air temperature too high
M0117 Air filter plugged M1211 Intake air temperature extremely high
M0144 Air filter derate level 1 M1305 Fuel hold solenoid short to battery
M0145 Air filter derate level 2 M1306 Fuel hold solenoid short to ground
M0216 Hydraulic / Hydrostatic filter not connected M1307 Fuel hold solenoid open circuit
M0217 Hydraulic / Hydrostatic filter plugged


M1402 Fuel pull solenoid error ON M2722 Throttle primary sensor out of range low
M1403 Fuel pull solenoid error OFF M2821 Throttle secondary sensor out of range high
M1407 Fuel pull solenoid open circuit M2822 Throttle secondary sensor out of range low
M1428 Fuel pull solenoid failure M2899 Throttle secondary sensor not calibrated
M1502 Traction lock pull output error ON M2910 Exhaust gas temperature too high
M1503 Traction lock pull output error OFF M3028 Controller memory failure
M1507 Traction lock pull output open circuit M3128 Interrupted power failure
ACS (AHC) no communication to Bobcat
M1528 Traction lock pull output failure M3204
controller
M1605 Traction lock hold solenoid short to battery M3304 Deluxe panel no communication
M1606 Traction lock hold solenoid short to ground M3404 Deluxe panel in error
M1607 Traction lock hold solenoid open circuit M3505 Hydraulic fan short to battery
M1705 Hydraulic lock valve short to battery M3506 Hydraulic fan short to ground
M1706 Hydraulic lock valve short to ground M3507 Hydraulic fan open circuit
M1707 Hydraulic lock valve open circuit M3532 Hydraulic fan overcurrent
M1732 Hydraulic lock valve overcurrent M3705 Two-speed second output short to battery
M1805 Lift spool lock output short to battery M3706 Two-speed second output short to ground
M1806 Lift spool lock output short to ground M3707 Two-speed second output open circuit
M1807 Lift spool lock output open circuit M3732 Two-speed second output overcurrent
M1832 Lift spool lock output overcurrent M3805 Auxiliary hydraulic lock short to battery
M1910 Engine compartment temperature too high M3806 Auxiliary hydraulic lock short to ground
Engine compartment temperature extremely
M1911 M3807 Auxiliary hydraulic lock open circuit
high
Engine compartment temperature out of range
M1921 M3832 Auxiliary hydraulic lock overcurrent
high
Engine compartment temperature out of range
M1922 M4028 Wrong ECU detected
low
M2005 Two-speed primary solenoid short to battery M4109 Alternator voltage too low
M2006 Two-speed primary solenoid short to ground M4110 Alternator voltage high
M2007 Two-speed primary solenoid open circuit M4111 Alternator voltage extremely high
M2032 Two-speed primary solenoid overcurrent M4228 Wrong DCU detected
M2102 Glow plug output error ON M4304 Keyless panel no communication
M2103 Glow plug output error OFF M4404 Auxiliary no communication
M2107 Glow plug output open circuit M4510 Water in fuel sensor too high
M2128 Glow plug output failure M4511 Water in fuel sensor extremely high
M2202 Starter output error ON M4521 Water in fuel sensor out of range high
M2203 Starter output error OFF M4522 Water in fuel sensor out of range low
M2207 Starter output open circuit M4530 Water in fuel sensor fault
M2228 Starter output failure M4621 5 volt sensor supply out of range high
M2302 Starter relay error ON M4622 5 volt sensor supply out of range low
M2303 Starter relay error OFF M4721 8 volt sensor supply out of range high
M2402 Fuel pull relay error ON M4722 8 volt sensor supply out of range low
M2403 Fuel pull relay error OFF M4802 Front light relay error ON
M2502 Traction pull relay error ON M4803 Front light relay error OFF
M2503 Traction pull relay error OFF M4902 Rear light relay error ON
M2602 Glow plug relay error ON M4903 Rear light relay error OFF
M2603 Glow plug relay error OFF M5002 Front light output error ON
M2721 Throttle primary sensor out of range high M5003 Front light output error OFF


M5007 Front light output open circuit M7007 Switched power output open circuit
M5028 Front light output failure M7028 Switched power output failure
M5102 Rear light output error ON M7102 Electric fan output error ON
M5103 Rear light output error OFF M7103 Electric fan output error OFF
M5107 Rear light output open circuit M7107 Electric fan output open circuit
M5128 Rear light output failure M7202 Electric fan relay error ON
M5202 Press to operate button error ON M7203 Electric fan relay error OFF
M5221 Press to operate button out of range high M7304 Remote control no communication
M5222 Press to operate button out of range low M7316 Remote control no communication to transmitter
M5305 Press to operate light short to battery M7423 Main controller not programmed
M5306 Press to operate light short to ground M7472 Main controller needs programming
M5405 Tilt spool lock short to battery M7497 Main controller programmed
M5406 Tilt spool lock short to ground M7504 Drive no communication
M5407 Tilt spool lock open circuit M7604 Left display panel no communication
M5432 Tilt spool lock overcurrent M7748 Key switch multiple
M5810 Fuel temperature too high M7839 Hourmeter changed
M5811 Fuel temperature extremely high M7974 Door open
M5815 Fuel temperature in shutdown M8402 DESOX service requested
M5826 Fuel temperature pre-shutdown M8450 DESOX regeneration needed - inhibit active
M5902 DPF regeneration switch error ON M8541 DPF automatic regeneration active
DPF automatic regeneration active (Operate
M6002 DPF inhibit regeneration switch error ON M8542
machine under load)
M6102 Remote parked regeneration switch error ON M8543 DPF regeneration required
M6202 Tailgate fan 1 error ON M8551 DPF regeneration needed – inhibit active
DPF regeneration needed – inhibit active
M6203 Tailgate fan 1 error OFF M8552
(Operate machine under load)
DPF remote parked regeneration required
M6228 Tailgate fan 1 Failure M8553
(Remote regeneration kit required)
DPF service regeneration required (Contact
M6302 Tailgate fan 2 error ON M8554
Bobcat dealer)
M6303 Tailgate fan 2 error OFF M8555 DPF service required
M6328 Tailgate fan 2 Failure M8560 DPF service regeneration active
M6402 Switched power relay error ON M8561 DPF service regeneration active
M6403 Switched power relay error OFF M8562 DPF service regeneration active
M6505 ECU power short to battery M8563 DPF service regeneration active
M6506 ECU power short to ground M8564 DPF service regeneration active
M6507 ECU power open circuit M8615 Engine speed derate in shutdown
M6604 ECU no communication M8625 Engine speed derate unresponsive
M6702 HVAC output error ON M8715 Torque derate in shutdown
M6703 HVAC output error OFF M8725 Torque derate unresponsive
Press to operate loader keypad no
M6707 HVAC output open circuit M9004
communication
M6728 HVAC output failure R7404 Main controller no communication
M6802 HVAC relay error ON
M6803 HVAC relay error OFF T9002 Service tool output ‘C’ error ON
M6904 DCU no communication T9003 Service tool output ‘C’ error OFF
M7002 Switched power output error ON T9102 Service tool output ‘D’ error ON
M7003 Switched power output error OFF T9103 Service tool output ‘D’ error OFF


T9202 Service tool output ‘E’ error ON U00321919 NOX pre-treatment sensor fault
T9203 Service tool output ‘E’ error OFF U00322021 NOX pre-treatment sensor fault
T9302 Service tool output ‘F’ error ON U00322022 NOX post-treatment sensor fault
T9303 Service tool output ‘F’ error OFF U00322023 NOX pre-treatment sensor fault
U00015822 DCU activation signal fault U00322024 NOX post-treatment sensor fault
U00017100 Environment temperature too high U00322025 NOX pre-treatment sensor fault
U00017101 Environment temperature too low U00322026 NOX post-treatment sensor fault
U00017103 Environment temperature sensor fault U00322103 NOX pre-treatment sensor fault
U00017104 Environment temperature sensor fault U00322104 NOX pre-treatment sensor fault
U00044400 Battery voltage high U00322302 NOX pre-treatment sensor fault
U00044401 Battery voltage too low U00322400 NOX pre-treatment sensor fault
U00044402 Battery voltage fault U00322401 NOX pre-treatment sensor fault
U00054419 DCU communication fault U00322403 NOX pre-treatment sensor fault
U00176100 DEF level too high U00322519 NOX pre-treatment sensor fault
U00176101 DEF level too low U00322604 NOX post-treatment sensor short circuit
U00176115 DEF level extremely low U00322605 NOX post-treatment sensor open circuit
U00176116 DEF level empty U00322619 NOX post-treatment sensor fault
U00176119 DEF level signal fault U00322701 NOX post-treatment sensor fault
U00176120 DEF fill level fault U00322703 NOX post-treatment sensor fault
U00176121 DEF fill level fault U00322704 NOX post-treatment sensor fault
U00303100 DEF temperature too high U00322719 NOX post-treatment sensor fault
U00303101 DEF temperature too low U00322722 NOX post-treatment sensor fault
U00303103 DEF temperature fault U00322724 NOX post-treatment sensor fault
U00303123 DEF overheating U00322919 NOX post-treatment sensor fault
U00303127 DEF temperature sensor fault U00323103 NOX post-treatment sensor fault
U00303131 DEF temperature signal fault U00323104 NOX post-treatment sensor fault
U00321604 NOX pre-treatment sensor short circuit U00323302 NOX post-treatment sensor fault
U00321605 NOX pre-treatment sensor open circuit U00323400 NOX post-treatment sensor fault
U00321619 NOX pre-treatment sensor fault U00323401 NOX post-treatment sensor fault
U00321723 NOX pre-treatment sensor fault U00336103 Dosing valve short to battery
U00321807 NOX pre-treatment sensor fault U00336104 Dosing valve short to ground
U00321819 NOX pre-treatment sensor fault U00336105 Dosing valve short to battery
U00321823 NOX pre-treatment sensor fault U00336112 Dosing valve temperature too high


U00336122 Dosing valve short to ground U00433712 Dosing valve tip temperature fault
U00336127 Dosing valve blocked U00433912 NOX controller fault
U00336303 DEF tank coolant valve short to battery U00434003 DEF line heater short to battery
DEF outlet line heater short to ground or open
U00336304 DEF tank coolant valve short to ground U00434205
circuit
U00336305 DEF tank coolant valve open circuit U00434402 Backflow fault
DEF backflow line heater short to ground or
U00336312 DEF tank coolant valve temperature too high U00434405
open circuit
DEF inlet line heater short to ground or open
U00349212 DCU fault U00434605
circuit
U00349231 DCU fault U00435303 DEF heater relay short to battery
U00350923 DCU fault U00435304 DEF heater relay short to ground
U00350924 DCU fault U00435305 DEF heater relay open circuit
U00351023 DCU fault U00435312 DEF heater relay overtemperature
U00351024 DCU fault U00435502 Outlet line heater fault
U00351123 DCU fault U00435503 Outlet line heater short to battery
U00351124 DCU fault U00435504 Outlet line heater short to ground
U00351223 DCU fault U00435505 Outlet line heater open circuit
U00351224 DCU fault U00435512 Outlet line heater overtemperature
U00351600 DEF quality too high U00435514 Outlet line heater fault
U00351601 DEF quality too low U00435602 Backflow line heater short to battery
U00351603 DEF quality sensor fault U00435603 Backflow line heater short to ground
U00351604 DEF quality sensor fault U00435604 Backflow line heater open circuit
U00351611 DEF quality sensor fault U00435605 Backflow line heater overtemperature
U00351631 DEF quality sensor fault U00435612 Backflow line heater fault
U00353203 DEF level sensor fault U00435702 Inlet line heater short to battery
U00353204 DEF level sensor fault U00435703 Inlet line heater short to ground
U00353211 DEF level sensor fault U00435704 Inlet line heater open circuit
U00431915 SCR post-treatment temperature fault U00435705 Inlet line heater overtemperature
U00431917 SCR post-treatment temperature fault U00435712 Inlet line heater fault
U00433401 DEF pump pressure too low U00436000 SCR pre-treatment temperature too high
U00433403 DEF pump pressure max U00436001 SCR pre-treatment temperature too low
SCR pre-treatment temperature sensor out of
U00433404 DEF pump pressure min U00436003
range high
SCR pre-treatment temperature sensor out of
U00433419 DEF pump pressure fault U00436004
range low
U00433420 DEF pump pressure too high U00436020 SCR pre-treatment temperature fault
U00433421 DEF pump pressure too low U00436021 SCR pre-treatment temperature fault
U00433422 Backflow pump fault U00436022 SCR pre-treatment temperature fault
SCR pre-treatment temperature sensor
U00433500 Metering control overpressure U00436025
tampering
U00433501 Metering control underpressure U00436300 SCR post-treatment temperature too high
U00433502 Monitoring of pressure buildup U00436301 SCR downstream temperature too low
SCR downstream temperature sensor out of
U00433512 Monitoring of overpressure U00436303
range high
SCR downstream temperature sensor out of
U00433707 Dosing valve tip temperature fault U00436304
range low


U00436322 SCR post-treatment temperature fault U00503519 NOX post-treatment CAN communication fault
U00436325 SCR downstream temperature sensor tampering U00503619 NOX post-treatment CAN communication fault
U00436400 NOX pre-treatment fault U00503719 NOX post-treatment CAN communication fault
U00436401 NOX pre-treatment fault U00543510 Pressure stabilization fault
U00436416 SCR fault U00543512 General pressure check fault
U00436418 SCR fault U00543529 DEF pump motor fault
U00436420 SCR fault U00570622 Supply module heater fault
U00436423 SCR fault U00570626 Supply module heater temperature fault
U00436503 DEF temperature sensor open circuit U00570627 Supply module heater temperature fault
U00436504 DEF temperature sensor short to ground U00570703 Supply module heater short to battery
U00436511 DEF temperature sensor failure U00570704 Supply module heater short to ground
U00437423 DEF pump motor speed fault U00570705 Supply module heater open circuit
U00437424 DEF pump motor speed fault U00570712 Supply module heater overtemperature
U00437428 DEF pump motor speed fault U00570723 Supply module heater temperature duty high
U00437430 DEF pump motor speed fault U00570724 Supply module heater temperature duty low
U00437503 DEF pump motor short to battery U00570726 Supply module heater temperature fault
U00437504 DEF pump motor short to ground U00570727 Supply module heater temperature fault
U00437505 DEF pump motor open circuit U00571302 NOX sensor self diagnostics
U00437512 DEF pump motor overtemperature U00571307 NOX sensor self diagnostics
U00437523 DEF pump motor fault U00571319 NOX sensor self diagnostics
U00437524 DEF pump motor fault U00571402 NOX sensor self diagnostics
U00437603 DEF backflow pump short to battery U00571407 NOX sensor self diagnostics
U00437604 DEF backflow pump short to ground U00571419 NOX sensor self diagnostics
U00437605 DEF backflow pump open circuit U05990419 CAN communications fault
U00437612 DEF backflow pump overtemperature U06016019 CAN communications fault
U00476500 DOC pre-treatment temperature too high U06041619 CAN communications fault
U00476501 DOC pre-treatment temperature too low U06144419 CAN communications fault
DOC pre-treatment temperature sensor out of
U00476503 U06145419 CAN communications fault
range high
DOC pre-treatment temperature sensor out of
U00476504 U06145519 CAN communications fault
range low
U00502419 NOX pre-treatment CAN communication fault U06463919 Memory fault
U00502519 NOX pre-treatment CAN communication fault U06463931 Memory fault
U00502619 NOX pre-treatment CAN communication fault U06478219 CAN communications fault
U00503119 NOX post-treatment CAN communication fault U06481719 CAN communications fault


U06516419 CAN communications fault W3232 ACS (AHC) tilt actuator wiring
U06522619 CAN communications fault W3233 ACS (AHC) tilt handle wiring
U06522621 CAN communications fault W3234 ACS (AHC) tilt actuator not in NEUTRAL
U06522622 CAN communications fault W3235 ACS (AHC) tilt handle / pedal not in NEUTRAL
U06522623 CAN communications fault W3236 ACS (AHC) lift actuator
U06522624 CAN communications fault W3237 ACS (AHC) lift actuator wiring
U06522625 CAN communications fault W3238 ACS (AHC) lift handle wiring
U06524719 CAN communications fault W3239 ACS (AHC) lift actuator not in NEUTRAL
U06526219 CAN communications fault W3240 ACS (AHC) lift handle / pedal not in NEUTRAL
U06526919 CAN communications fault W3241 ACS (AHC) no communication
U06527019 CAN communications fault W3249 ACS (AHC) lift actuator short to ground
U06529619 CAN communications fault W3250 ACS (AHC) tilt actuator short to ground
U06530019 CAN communications fault W3251 ACS (AHC) lift actuator short to battery
U10123907 DEF hose leak W3252 ACS (AHC) tilt actuator short to battery
U10124007 Evaluate filter clog W3253 ACS (AHC) lift handle / pedal short to ground
U10433207 NOX pre-treatment fault W3254 ACS (AHC) tilt handle / pedal short to ground
U10433209 NOX pre-treatment fault W3255 ACS (AHC) lift handle / pedal short to battery
U10433219 NOX pre-treatment fault W3256 ACS (AHC) tilt handle / pedal short to battery
U10433221 NOX pre-treatment fault W3257 ACS (AHC) lift actuator reduced performance
U10433223 NOX pre-treatment fault W3258 ACS (AHC) tilt actuator reduced performance
U10433224 NOX pre-treatment fault W3259 ACS (AHC) lift actuator wrong direction
U10438507 NOX post-treatment fault W3260 ACS (AHC) tilt actuator wrong direction
U10438509 NOX post-treatment fault W3261 ACS (AHC) handle lock short to ground
U10438519 NOX post-treatment fault W3262 ACS (AHC) handle lock short to battery
U10438522 NOX post-treatment fault W3263 ACS (AHC) pedal lock short to ground
U10564413 DCU fault W3264 ACS (AHC) pedal lock short to battery
U10564513 DCU fault W3265 ACS (AHC) sensor supply voltage out of range
U10564613 DCU fault W3266 ACS (AHC) battery voltage out of range
U52020212 DCU fault W3267 ACS (AHC) switch flipped while operating
U52020412 DCU fault W3268 ACS (AHC) lift handle information error
ACS (AHC) control mode toggle switched while
U52069812 DCU fault W3269
operating
U52069912 DCU fault W3270 ACS (AHC) right drive handle short to ground
U52070012 DCU fault W3271 ACS (AHC) right drive handle short to battery
U52070112 DCU fault W3274 ACS (AHC) left joystick X-axis out of range
U52160212 DCU sensor supply error W3275 ACS (AHC) interrupted unswitched power
W3276 ACS (AHC) CAN joystick information error
ACS (AHC) no communication to Bobcat
W3204 W3277 ACS (AHC) remote control information error
controller
W3223 ACS (AHC) calibration required W3297 ACS (AHC) controller programmed
W3224 ACS (AHC) calibration performed W3905 Left joystick X-axis not in NEUTRAL
W3225 ACS (AHC) actuator calibration failed W4005 Right joystick X-axis not in NEUTRAL
W3231 ACS (AHC) tilt actuator W4007 Right joystick Y-axis not in NEUTRAL

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Operation
WARNING 1 2 3

The Bobcat Interlock Control System (BICS™) must
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-1111
NA3267
Figure 60-100-1
There are three display lights (Items 1, 2, and 3) [Figure
60-100-2] located on the left instrument panel that must
be OFF to fully operate the machine.
When the seat bar is lowered, the engine is running, the

PRESS TO OPERATE LOADER button is activated, and
the parking brake is released; the lift, tilt, auxiliary
hydraulics, and traction drive functions can be operated.
1
When the seat bar is raised; the lift, tilt, auxiliary
hydraulics, and traction drive functions are deactivated.
P-90674D WARNING
The Bobcat Interlock Control System (BICS™) has a AVOID INJURY OR DEATH
pivoting seat bar with armrests (Item 1) [Figure 60-100- Before you leave the operator’s seat:
1]. The operator controls the use of the seat bar. • Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
WARNING • Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
AVOID INJURY OR DEATH drive functions are deactivated.
When operating the machine:
• Keep the seat belt fastened snugly. The seat bar system must deactivate these functions
• The seat bar must be lowered. when the seat bar is up. See your Bobcat dealer for
• Keep your feet on the pedal controls or footrests service if controls do not deactivate.
and hands on the controls. W-2463-1110
W-2261-0909
The BICS™ requires the operator to be seated in the

operating position with the seat bar fully lowered before
the lift, tilt, auxiliary hydraulics, and traction drive
functions can be operated. The seat belt must be
fastened anytime you operate the machine.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock And Parking Brake
(CONT'D) (Engine RUNNING)
Inspecting The BICS™ (Engine STOPPED - Key ON) 6. Fasten seat belt, disengage parking brake, press the
PRESS TO OPERATE LOADER button, and raise
See the SERVICE SCHEDULE for the correct service seat bar fully. Move steering levers or joystick(s)
interval. (See DIAGNOSTIC SERVICE CODES on Page slowly forward and backward. The TRACTION lock
60-90-1.) must be engaged. Lower the seat bar. Press the
PRESS TO OPERATE LOADER button.
Figure 60-100-3
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
1 2 3 TRACTION lock must be engaged.
NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed, and the parking
4 brake is disengaged.
Inspecting The Lift Arm Bypass Control
5 8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob 90°
clockwise. Pull up and hold lift arm bypass control
6
P-85413F
knob until lift arms slowly lower.
Inspecting Deactivation Of Lift And Tilt Functions
1. Sit in operator’s seat. Turn key switch to RUN. Lower (ACS And SJC)
seat bar and disengage parking brake. Press the 9. Sit in operator’s seat and fasten seat belt. Lower seat
PRESS TO OPERATE LOADER button (Item 6). Two bar, start engine, and press the PRESS TO
BICS™ lights (Items 1 and 2) [Figure 60-100-3] OPERATE LOADER button.
[SEAT BAR and LIFT AND TILT VALVE] on left
instrument panel must be OFF. The PRESS TO 10. Raise lift arms approximately 2 m (6 ft) off the ground.
OPERATE LOADER button will light.
11. Turn key switch to STOP and wait for the engine to
2. Raise seat bar fully. All three BICS™ lights (Items 1, come to a complete stop.
2, and 3) [Figure 60-100-3] [SEAT BAR, LIFT AND
TILT VALVE, and PARKING BRAKE] on left 12. Turn key switch to RUN. Press the PRESS TO
instrument panel must be ON. The PRESS TO OPERATE LOADER button, move the control (foot
OPERATE LOADER button light will turn OFF. pedal, hand control, or joystick) to lower the lift arms.
Lift arms must not lower.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED – Key ON) 13. Move the control (foot pedal, hand control, or joystick)
to tilt the bucket (or attachment) forward. The bucket
3. Sit in operator’s seat, lower seat bar, and press the (or attachment) must not tilt forward.
PRESS TO OPERATE LOADER button (Item 6).
Press the Auxiliary Hydraulics button (Item 5). The
auxiliary hydraulics light will turn ON (Item 4) [Figure
60-100-3]. Raise the seat bar. The light will turn OFF. WARNING
Inspecting The Seat Bar Sensor (Engine RUNNING) AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS™) must
4. Sit in operator’s seat, lower seat bar, engage parking deactivate the lift, tilt and traction drive functions. If it
brake, and fasten seat belt. does not, contact your dealer for service. DO NOT
modify the system.
5. Start engine and operate at low idle. Press the W-2151-1111
PRESS TO OPERATE LOADER button. While raising
the lift arms, raise the seat bar fully. The lift arms must
stop. Repeat using the tilt function.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Inspect wire connections on Bobcat controller to make sure connectors are locked into place.
3. Inspect pins in connectors for pins pushed back or bent.
4. Use seat bar Sensor Tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
1. Inspect sensor wire connection.
2. Use the BICS™ Sensor Tester MEL1428 with seat bar adapter MEL1567 to test sensor and controller.
3. Inspect for loose hardware.
4. Inspect keyed bushing to make sure magnet collar rotates with seat bar.
5. Inspect magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the Sensor Tester, inspect the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and Seat Bar Sensor
Adapter (MEL1567) for the following procedure:
Connect the Seat Bar Sensor Adapter leads (MEL1567)

to the Sensor Tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal on Page 60-
2]. 110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

SEAT BAR SENSOR (CONT'D) NOTE: Approximately 4 turns of the clevis bolt
should be adequate to release the spring
Removal tension. When tension is released, the clevis
pin can easily be rotated using the retaining
NOTE: This procedure is performed with the seat bar pin.
in the raised position and the technician in the
operator’s seat. Figure 60-110-7
Figure 60-110-5
1
3
P100745
2
P100742 Remove the retaining pin (Item 1) and clevis pin (Item 2).
Remove the seat bar mounting nut and bolt (Item 3)
Remove the sensor mounting nut and bolt (Item 1). [Figure 60-110-7].
Disconnect the sensor wiring connector (Item 2) [Figure
60-110-5].
Figure 60-110-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-110-6].

SEAT BAR SENSOR (CONT'D) Installation
Removal (Cont’d) Figure 60-110-10
Figure 60-110-8
3
1
4
P100748
P100746
Install the new keyed bushing (Item 1), magnet bushing
(Item 2) and seat bar sensor (Item 3) [Figure 60-110-10].
Pull the front of the seat bar down slightly from the top of Reinstall the metal pivot bushing (Item 4) [Figure 60-
the cab, while raising the sensor end of the seat bar up, 110-10].
away from the mount [Figure 60-110-8].
NOTE: The sensor must be centered on the metal
NOTE: The sensor end of the seat bar will raise easily pivot bushing. When centered, the assembly
ONLY if the front of the seat bar is pulled will slide freely into the mount.
slightly down from the top of the cab.
Figure 60-110-9 Figure 60-110-11
3 3
1
6 1
2 P100749
P100747
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9] Position the clevis (Item 1) over the mount (Item 2) and
on the cab side screen to hold the seat bar above the lower the end of the seat bar until the mounting bolt (Item
mount. 3) [Figure 60-110-11] is resting on the top of the mount.
Remove the clevis pin bushing (Item 2) [Figure 60-110- Remove the nut from the mounting bolt. Remove the
9]. Apply grease to the shoulder of the bushing to help mounting bolt and lower the seat bar until the seat bar
retain it during assembly. Reinstall the clevis pin bushing.
and mount holes align and the clevis is over the clevis pin
Remove and dispose of the keyed bushing (Item 3), bushing. Reinstall the seat bar mounting bolt. Apply
magnet bushing (Item 4), and seat bar sensor (Item Loctite® 243 to the nut threads. Install the nut and tighten
5)[Figure 60-110-9]. to 46 N•m (34 ft-lb) torque.
Remove and save the metal pivot bushing (Item 6)

[Figure 60-110-9].

SEAT BAR SENSOR (CONT'D)
Installation (Cont’d)
Figure 60-110-12
1
2
P100751 3
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-110-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5] and tighten to 6,8 N•m (60 in-lb)
torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.

SEAT BAR SENSOR (CONT'D) Figure 60-110-14
Bobcat Interlock Control System (BICS™) Circuit

Test
Figure 60-110-13
3
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the Sensor Tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-14] on the Sensor Tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-110-13].
NOTE: The Sensor Test light (Item 3) [Figure 60-110-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)
Figure 60-110-15
P-85413F
The BICS™ seat bar indicator light (Item 1) [Figure 60-

110-15] should turn OFF.
Figure 60-110-16
P-4699
Move the toggle switch (Item 1) [Figure 60-110-16] on

the Sensor Tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-15] should

illuminate.
If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.

TRACTION LOCK
Description
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS™).

TRACTION LOCK (CONT'D)
The following troubleshooting chart is provided for quick
reference in locating and correcting traction lock Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnal only. See adjustments can cause injury or death.
BATS for detailed troubleshooting procedures if an error W-2004-1285
code is present.
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.
(See Electrical System, Information Page 60-01.)
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Inspect brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Inspect the brake solenoid mounting nut for correct torque.
8. Inspect wire connections for loose connector body.
9. Inspect for loose or bent pins in connectors.
10. Inspect for loose spade connectors in fuse holder.
11. Inspect the left panel display for engine rpm, if no rpm inspect crankshaft sensor, camshaft sensor, wiring and
adjustment.

TRACTION LOCK (CONT'D)
Inspecting
Figure 60-120-1
P-85413F
Fasten the seat belt, disengage the parking brake button,

press the PRESS TO OPERATE LOADER Button (Item
1) and raise the Seat Bar fully. Move the steering levers
slowly forward and backward. The TRACTION lock (Item
4) should be engaged. Lower the Seat Bar. Press the
PRESS TO OPERATE LOADER Button (Item 1) [Figure
60-120-1].
Engage the parking brake pedal and move the steering

levers slowly forward and backward. The TRACTION lock
should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

CONTROL SYSTEM (ACS)
Description
The ACS option allows the operator to quickly switch

between foot and hand control modes. It uses the electric
actuators to control the lift and tilt spools, foot sensors,
handle sensors and a specially designed control handle.

CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
1
3
2
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be
removed from the handle sensor wires, use the following 1 - Terminal - Red
procedure. 2 - Terminal - Black
3 - Terminal - Green
Figure 60-130-2
1 1
1 1
P13725
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

Switch Handle Removal
Figure 60-130-4
3 1
2
P13735
2 1
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.

130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
P13725 P13732

harness connector (Black) that connects to the handle
1 lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

Switch Handle Removal (Cont'd)
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 152 mm (6 in) piece of
heat shrink tube side on the end of the wires. Remove
Cut the wires (Item 2) [Figure 60-130-12] below the the heat shrink tube from the end of the wires before
switch handle and remove switch handle. routing through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Pull harness (Item 1) [Figure 60-130-13] out the bottom

of the control lever tube.

CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont’d) Right Switch Handle
Figure 60-130-15 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
1 F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700 C-Terminal - Purple/White
Left Switch Handle

Install the new switch handle and wires from the top of
the control lever. Ten-Pin Connector
A-Terminal - Orange
Route wire (Item 1) [Figure 60-130-15] through the B-Terminal - Dk. Blue
casting, along side the handle sensor and into the control C-Terminal - White
lever tube. D-Terminal - Purple
E-Terminal - Yellow/Red
NOTE: Do not pull the wire harness tight, allow a F-Terminal - Tan
small amount of slack or slight bend at the G-Terminal - Pink
handle pivot area. Verify the control handle H-Terminal - Orange/Black
returns to NEUTRAL position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Remove tape from wires for installation and install the

152,4 mm (6 in) of heat shrink tube (Item 1) [Figure 60-
130-16] approximately 76,2 mm (3 in) into the control
lever. Apply heat to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
1 P13735
Install the wires into the connectors as listed below:

P-90995
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18 1 - Terminal - Red/White
2 - Terminal - Black/White
3 - Terminal - Purple/White
Figure 60-130-20
1
1
1
3
P-90994 2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
P13735
connectors.
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1 - Terminal - Yellow/Red
2 - Terminal - Open
3 - Terminal - Orange/Black

CONTROL SYSTEM (ACS) (CONT'D) Actuator Connector Disassembly And Assembly
Switch Handle Installation (Cont'd) NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-21
Figure 60-130-22
P-21804
P-66842
Connect the handle harness connectors to the sensor

and lock solenoid connectors [Figure 60-130-21]. Inspect the actuator wiring harness connector (Item 1)
[Figure 60-130-22] and replace if broken.
Figure 60-130-23
N-17741
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Lift And Tilt Actuator

1. Terminal - Black/Green-Larger diameter wire (16
gauge)
2. Terminal - Green-Larger diameter wire (16 gauge)
3. Terminal - Red/Green-Larger diameter wire (16
gauge)
4. Terminal - Open
5. Terminal - Red-Smaller diameter wire (18 gauge)
6. Terminal - Open
7. Terminal - Open
8. Terminal - Black-Smaller diameter wire (18 gauge)

CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
130-24] from the handle lock solenoid connector. Figure 60-130-27
Figure 60-130-25
P-21789
1
P-21832
Remove the two screws (Item 1) [Figure 60-130-25]

holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38

in-lb) torque.
Remove handle lock solenoid assembly from handle.

Foot Sensor Removal And Installation
Figure 60-130-28
2‘
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].

Remove the hairpin clip and the pin (Item 1) [Figure 60-
130-28] from the foot sensor.
Figure 60-130-29
P-90982
Disconnect the wire harness (Item 1) [Figure 60-130-29]

from the foot sensor.

CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Lock Solenoid Removal And Installation
Foot Sensor Disassembly And Assembly Figure 60-130-33
Figure 60-130-31
1 1
P-90992
1
P-24269
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Tighten the bolts to 10,2 N•m (90 in-lb) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite® #242 to the threads. and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-32
Figure 60-130-34
5
4
3
2
1
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130- Replace the O-ring (Item 1) [Figure 60-130-34].
32].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-32]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA5717 / B-15781E
REF. NO. DESCRIPTION

1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 ENGINE SPEED CONTROL
6 STEERING LEVERS
7 LIFT ARM PEDAL
8 TILT PEDAL
9 LIFT ARM BYPASS CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a ohmmeter to test
for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D
Refer to the Identification Chart ACD Group 0, 1, 2, or 3

for more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
12, 13,
B-16447 14 B-16448
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC. (See Connecting Remote Start 2
1
Tool on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter
valve. Sole- Hydraulic Coupler Wiring
noid Num-
Front Auxiliary Pressure Release is Number ber
accomplished by manually pushing the male
and female couplers in at the front auxiliary 1 Front Male (Rod) 4330
block. 2 Front Female (Base) 4340
3 Diverter Rear (Rod) 4430
The High Flow Button in the left side
instrument panel must be pushed ON to 4 Diverter Rear (Base) 4440
activate solenoid number seven at the gear 5 Bleed / Lock Valve 4480
pump. (Base)
6 Bleed / Lock Valve (Rod) 4450
7 High Flow on Pump 4460


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,
B-16447 14 B-16448
3
6 4
the Service PC. (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5

solenoid numbers 3,4,5, and 6 at the diverter
noid Num-
pump. (Base)


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
12, 13,
B-16447 14 B-16448
3
6 4
1
5

solenoid numbers 3,4,5, and 6 at the diverter
noid Num-
pump. (Base)


1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
12, 13,
B-16447 14 B-16448
3
6 4
1
5

noid Num-
pump. (Base)

ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA5718 / B-15781E

4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9 TILT PEDAL
13 NOT USED

ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D



13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

noid Num-
pump. (Base)


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

noid Num-
pump. (Base)


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

noid Num-
pump. (Base)


13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front 11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899
P-90900 14 P-90900A
3
6 4
1
5

noid Num-
pump. (Base)

ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA5719 / B-19874A

1 SPEED MANAGEMENT
Also: TWO-SPEED CONTROL
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 ENGINE SPEED CONTROL (HAND OPERATED)
9 JOYSTICKS
10 FOOTRESTS
11 ENGINE SPEED CONTROL (FOOT OPERATED)
14 NOT USED
16 NOT USED
18 FLOAT CONTROL

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D



1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

noid Num-
pump. (Base)


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

noid Num-
pump. (Base)


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

noid Num-
pump. (Base)


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
3
6 4
1
5

noid Num-
pump. (Base)

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool The tools listed will be needed to do the following
procedure:
procedure: Order from Bobcat Parts P/N: 7217666 - Remote Start
Tool (Service Tool) Kit
MEL1563 - Remote Start Tool Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
7022042 - Remote Start Tool (Service Tool)
Figure 60-150-1 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
1 2 6689745 - BOSS® Service Tool Harness
Figure 60-150-2
P16119
3
The Service PC (Item 1) with the Remote Start Tool (Item 1
2) [Figure 60-150-1]. When connected to the loader, the
P-76450
Service PC is used to monitor, conduct diagnostics, and
upgrade software.
The Service PC (Item 1) with the Remote Start Tool
NOTE: Make all connections with the key in the OFF (Service Tool) (Item 2) [Figure 60-150-2]. When
position. connected to the loader, the Service PC is used to
monitor, conduct diagnostics, and upgrade software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated NOTE: Make all connections with the key in the OFF
serial port on the Service PC. position.
NOTE: The recommended serial cable length should Connect the Remote Start Tool (Service Tool) Computer
not exceed 4,6 m (15 ft). A serial cable longer Service Tool Harness (Item 3) [Figure 60-150-2] to the
than 4,6 m (15 ft) will create a degraded signal designated serial port on the Service PC.
causing communication errors.
NOTE: The recommended serial cable length should
Connect the other end to the connector on the Remote not exceed 4,6 m (15 ft). A serial cable longer
Start Tool. than 4,6 m (15 ft) will create a degraded signal
causing communication errors.
Connect the Remote Start Tool to the loader. (See
REMOTE START TOOL KIT - MEL1563 on Page 10-60- Connect the other end to the connector on the Remote
1.) Start Tool (Service Tool).
NOTE: Refer to BobcatDealerNET.com for PC Connect the Remote Start Tool (Service Tool) to the
requirements and the latest Service Analyzer loader. (See REMOTE START TOOL (SERVICE TOOL)
software. KIT - 7217666 on Page 10-61-1.)
NOTE: Refer to BobcatDealerNET.com for PC

requirements and the latest Service Analyzer
software.

CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting
controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC. (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
NOTE: Password protected machines must have the
The Hydrostatic Pump Calibration (SJC) provides set password entered to perform the calibration
points to the Drive controller to actuate the hydrostatic procedure.
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a If a Service PC is not available, (See Lift And Tilt
desired travel path cannot be attained or replacing the Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
hydrostatic pump, hydrostatic motor, or controller. After Calibration (ACS) on Page 60-160-11.).
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the NOTE: Warm the hydraulic fluid to room temperature
hydrostatic pump control. 22°C (72°F), stop the engine and clear all
active service codes before running the test.
For more information on Steering Drift Compensation
(See Description on Page 60-170-1.) Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
NOTE: The Actuator Test is the only test that uses a will be performed and the results can be viewed on the
Service PC. The Lift and Tilt Calibration (ACS Service PC (Laptop) monitor.
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic fluid is
warmed, go to the next step and loosen the bolts that
Actuator Testing (Cont’d) mount the actuator to the control valve. Loosen the bolts
just enough so the actuator can be moved slightly up /
This test will engage both actuators to fully stroke the down or side / side.
spools then allow the centering springs to return the
spools to NEUTRAL. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the NEUTRAL points then following probable causes in Column 1 [Figure 60-160-
allow the centering springs to return the spools to 2]. Check the probable causes in the order they are
NEUTRAL. listed. Repairing one cause may be all that is required.
Re-run the test to verify.
When complete, the Actuator Test will show a pass mode
or fail mode. The pass mode indicates that no problems NOTE: Actuator and spool misalignment. Re-tighten
were detected. The fail mode indicates one or a the two bolts evenly, turn the first bolt one
combination of three problems below. turn, then turn the other bolt one turn until
both bolts are tight.
• Actuator slow return to NEUTRAL. The spool returns
to NEUTRAL too slowly. If the Actuator Test failed due to a slow return to
NEUTRAL after checking the probable causes in Column
• Actuator did not fully extend / retract. During the test, 1 [Figure 60-160-2], check the following probable causes
the spool was not able to fully stroke in both in Column 2 [Figure 60-160-2].
directions.
• Contamination in the spool.
• Actuator out of NEUTRAL. The spool did not return to
the NEUTRAL window during the test. • The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
NOTE: A time out will occur if the test cannot be centering spring, replace if necessary.
completed within 8 seconds. If this happens,
retry the test. • The wire harness or connectors may have an
intermittent short. Inspect the connections and wire
Figure 60-160-2 harnesses.
Run Actuator Test
• The controller may be defective, replace the
controller.
Pass Fail
Retest With Warm Hydraulic Fluid
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to NEUTRAL, follow the
troubleshooting tree to pinpoint the probable cause.

CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, inspect the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.
• The spool end cap may be defective or the centering

centering spring, replace if necessary.
If the initial Actuator Test results in the fail mode actuator

out of NEUTRAL, inspect the following.
• The actuator may be defective, replace the actuator.
• The spool end cap may be defective or the centering

centering spring, replace if necessary.

CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.

password entered to perform the calibration
procedure.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See P-85958 P-85958
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed Move the right joystick to the forward-right corner position
when replacing the hydraulic control valve, lift [Figure 60-160-4] and hold in position.
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Figure 60-160-3
SJC
P-85307
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
P-85413F
P-85493A
At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the key switch (Item 1) (Item 1) [Figure 60-160-7] while holding the right joystick
[Figure 60-160-5] to the RUN position. Machines in position.
equipped with the deluxe panel, press RUN / ENTER.
Release the joystick.
NOTE: Do not start the engine.
NOTE: During the calibration cycle, the system will
Figure 60-160-6 beep. Once the calibration is complete, code
W3224 (Calibration Successful) or W3225
SJC (Calibration Failure) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-85307
The loader Control Pattern Switch (Item 1) [Figure 60-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.

CALIBRATION (CONT'D) Figure 60-160-9
Hydrostatic Pump Calibration (SJC)
WARNING
W-2017-0286 P-85493A
NOTE: If the speed sensors are removed or

With the seat bar down, turn the key switch (Item 1)
disconnected the drive calibration procedure
[Figure 60-160-9] ON.
must be performed.
NOTE: Do not start the engine.
NOTE: If swash plate sensors have been removed
and reinstalled, replaced or adjusted the drive
Figure 60-160-10
calibration procedure must be performed.
SJC
procedure.
Operator must be in the seat and the seat bar down.
Close the cab door. (If equipped.)
Figure 60-160-8
SJC 1
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

10] will start flashing.
P-85307
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-8] in the ISO position.
Verify that the parking brake switch is in the OFF position.

Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-11
B-19873
P-85960
B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-160-13] and hold in position.
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
P-85413F
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413F 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-160-12] while holding the left joystick in
position.
Audible beeps will sound, release handle.

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC
Figure 60-160-15
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-85961 17] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Allow the left joystick to go to the NEUTRAL position Figure 60-160-18

[Figure 60-160-15].
Figure 60-160-16
P107184
1
P-85413F Move the Engine Speed Control (Item 1) [Figure 60-160-

18] to high idle.
Press the PRESS TO OPERATE LOADER Button (Item NOTE: If at any time, during calibration, the operator
1) [Figure 60-160-16]. needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
Audible beeps will sound. NEUTRAL position. The calibration procedure
will stop. To return to calibration mode, the
Start the engine from the RUN position. DO NOT TURN operator must start the complete procedure
TO OFF POSITION. This would cancel the calibration from the beginning.
mode and the procedure would have to be repeated.

Hydrostatic Pump Calibration (SJC) (Cont'd)
WARNING
W-2017-0286
Figure 60-160-19 NA5744
The loader tires or tracks will momentarily reverse then

rotate forward and “stair step” the speed (Item 1) [Figure
60-160-20] until it reaches full speed and then “stair step”
down and come to a stop.
Continue to hold the left joystick in the forward position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Forward calibration is complete.
B-19873 NOTE: If the wheels or tracks do not stop moving in

P-85962 Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Move and hold the left joystick to the forward position the calibration procedure from the beginning.
[Figure 60-160-19] until the forward calibration is
completed.

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-21 the calibration procedure from the beginning.
There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 75-98 error code will clear. There should be no other
codes in the display area.
Allow the joystick to go to the NEUTRAL position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
NEUTRAL.
B-19873 Press the PRESS TO OPERATE LOADER button. Move

P-85963 the left joystick to forward position [Figure 60-160-19]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-21] until the reverse calibration is 160-21] and check for normal reverse wheel or track
completed. rotation.
Figure 60-160-22 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.

1
After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION (OPERATOR MODE) on Page 60-
170-1.)
If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 60-10-10.)
NA5744
The loader tires or tracks will momentarily reverse then

rotate in reverse and “stair step” the speed (Item 1)
[Figure 60-160-22] until it reaches full speed and then
“stair step” down and come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

Lift And Tilt Calibration (ACS)

1
The controller uses a calibration sequence to optimize
the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.

procedure.
P-85493A
The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See With the seat bar down, turn the key switch (Item 1)
Actuator Testing on Page 60-160-1.) [Figure 60-160-24] ON.
This calibration procedure must be followed NOTE: Do not start the engine.
when replacing a hydraulic control valve,
actuator or ACS controller. Failure to calibrate Figure 60-160-25
after component replacement may result in
poor performance or reduced life of
actuator(s).
Figure 60-160-23
ACS
P-85413F
1
Push the PRESS TO OPERATE button (Item 1) [Figure
60-160-25] to unlock the hand controls.
P-85307B
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-23] in

the hand control mode.
Close the cab door. (If equipped.)

Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-26
Stroke Both Handles Fully In and Hold Them
P-85413F
Push the PRESS TO OPERATE button (Item 1) [Figure

B-16628 60-160-27] to begin calibration.
NOTE: The ACS icon will light up and if you listen

Fully stroke both control handles in toward the center of closely the cycling of the actuators can be
the cab and hold the handles [Figure 60-160-26]. heard. The ACS icon will stay lit until the key
switch is cycled or the loader is started and a
Lift the seat bar, high enough for the PRESS TO function is operated.
OPERATE light (Item 1) [Figure 60-160-27] to go OFF.
NOTE: During the calibration cycle, the system will
Lower the seat bar. beep three times. Once the calibration is
complete, code W3224 (Calibration
Performed) will be generated.
Release the control handles.
Calibration is complete.

STEERING DRIFT COMPENSATION (OPERATOR Operation
MODE)
NOTE: Changes CANNOT be performed until the seat
Description bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Steering Drift Compensation can be used to reduce pressed to activate the BICS™.
steering drift to maintain a desired travel path in forward
and reverse directions. Perform PRE-STARTING PROCEDURE and STARTING
THE ENGINE procedures:
Examples of applications where this feature can be used:
1. Fasten seat belt.
• To compensate for normal variations such as track
tension and track wear. 2. Lower seat bar.
• Using side shift attachments such as trenchers, 3. Put joysticks in NEUTRAL position.
planers, and silt fence installers.
4. Start the engine.
• Driving on uneven terrain such as crowned road
surfaces. 5. Press the PRESS TO OPERATE LOADER button.
Figure 60-170-1 6. Current drive response setting is displayed briefly in

the data display.
Steering Drift Compensation
NOTE: (SJC) Raising the seat bar or changing control
mode (ISO / H) will cause the machine to
disengage from steering drift compensation.
The last displayed setting will remain in effect
until the machine is turned OFF.
NA3232A
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from NEUTRAL to [SFL10] or [SRL10] left, and
from NEUTRAL to [SFR10] or [SRR10] right. [SF---]
[SR---] is displayed when set for NEUTRAL [Figure 60-
170-1].

STEERING DRIFT COMPENSATION (OPERATOR Press the right scroll button on the left panel or the right
MODE) (CONT’D) button on the left control to adjust the machine back
toward center. The display will decrease down to
Operation (Cont’d) NEUTRAL displayed as [SF---] (Item 5). Another press of
the upper right button will cause [SFR01] (Item 6) to
Figure 60-170-2 appear in the data display (Item 1) [Figure 60-170-2].
The number will increase by one each time you press the
button up to a maximum of [SFR10]. The higher the
number, the greater the amount of steering drift
compensation to the right.
Forward steering drift compensation setting can be

2 adjusted with the steering controls in NEUTRAL or during
forward travel. Reverse steering drift compensation
3 setting can be adjusted during reverse travel. The letter
[R] will appear in place of the letter [F] in the data display
1 when setting reverse steering drift compensation.
NA3267 (EXAMPLES: [SRL01], [SRR01], and [SR---].
Exiting The Steering Drift Compensation Menu:

4 5 6
Press the Information button (Item 3) [Figure 60-170-2]
NA3227 / NA3229 / NA3231
to exit from the steering drift compensation adjustment
Left Right menu.
OR
If no buttons are pressed for 10 seconds, the display

screen will change to the hourmeter.
7
P107005D P107006D
Press the Information button (Item 3) to cycle the data

display until the steering drift compensation menu is
displayed. The current steering drift compensation setting
will appear in the data display (Item 1) [Figure 60-170-2].
Press the left or right scroll button (Item 2) [Figure 60-

170-2] on the left panel to adjust the setting. Adjustments
to steering drift compensation are effective immediately
and saved automatically.
OR
Press the left or right button (Item 7) [Figure 60-170-2]

on the left control to adjust the setting. Adjustments to the
steering drift compensation are effective immediately and
saved automatically.
Press the left scroll button on the left panel or the left
button on the left control to adjust the machine left.
[SFL01] (Item 4) through a maximum of [SFL10] will
appear in the data display (Item 1) [Figure 60-170-2].
The number will increase by one each time you press the
button. The higher the number, the greater the amount of
steering drift compensation to the left.

STEERING DRIFT COMPENSATION (SERVICE MODE) Operation
Description NOTE: Service Analyzer Software Version 81.3 or

higher is required for service mode.
The service mode allows a service technician to fine tune
straight travel, separate from the settings an operator Connect the Remote Start Tool (Service Tool). (See
may chose for a specific application. Saving an REMOTE START TOOL (SERVICE TOOL) KIT -
adjustment in service mode resets the operator mode to 7217666 on Page 10-61-1.)
NEUTRAL [ST--] or “0” on the scale.
Figure 60-171-2
Figure 60-171-1
Steering Drift Compensation
P122059
The Remote Start Tool (Item 1) [Figure 60-171-2]

enables service mode. Attach the tool to the loader
outside upright and route / tie the harness to avoid any
NA3232D
pinch points during machine operation.
Steering drift compensation contains a total of 21 NOTE: The remote start remains OFF during the
settings. Steering drift compensation can be set to any procedure but must be connected to enable
point from NEUTRAL to [STL10] left, and from NEUTRAL service mode.
to [STR10] right. [ST---] is displayed when set for
NEUTRAL [Figure 60-171-1].
WARNING
• Always keep bystanders away from the work area
and travel path.
• The operator must always look in the direction of
travel.
W-2813-1209
Use a location with level ground and without bystanders

and drive the loader to determine the settings.
Operate the loader and warm the hydraulic fluid before

making adjustments.
NOTE: Service mode adjustment will set operator

settings to NEUTRAL.

STEERING DRIFT COMPENSATION (SERVICE MODE) Figure 60-171-3
(CONT’D)
Operation (Cont’d)
Perform PRE-STARTING PROCEDURE and STARTING

THE ENGINE procedures:
1. Close door.
2. Fasten seat belt.
3. Lower seat bar. 1

NA3267
4. Put controls in NEUTRAL position.

2 3 4
5. Start the engine.
NA9046/NA9047/NA9048
6. Press the PRESS TO OPERATE LOADER button.
Left Right
7. Current drive response setting is displayed briefly in
the data display. Wait for machine to cycle to machine
hours.
NOTE: (SJC) Raising the seat bar or changing control

mode (ISO / H) will cause the machine to 5 6
disengage from steering drift compensation.
The last displayed setting will remain in effect P107005D P107006D
until the machine is turned OFF.
8. Press and hold the PRESS TO OPERATE LOADER Press the buttons on the left joystick (Item 5 and 6)
button for three seconds to enter drive response [Figure 60-171-3] to adjust. The number will change by
menu. one each time the button is pressed. Use the left button
to increase machine left or the right button to increase
9. Press the PRESS TO OPERATE LOADER button to machine right.
enter steering drift compensation adjustment.
Forward adjustment is performed with left joystick in
10. Current setting will appear. NEUTRAL or during forward travel. Reverse adjustment
is performed during reverse travel. Adjustments are
effective immediately.
NOTE: Using a high throttle setting will make the

machine response to adjustment more
obvious.
To save a desired setting, press and hold the PRESS TO

OPERATE LOADER button for three seconds. [SET] will
appear in the left panel (Item 1) [Figure 60-171-3] and
the machine will exit from the adjustment menu.

CONTROL PANEL SETUP Vitals
Right Panel Setup (Deluxe Instrumentation Panel)
Icon Identification Press a scroll button (Item

Figure 60-180-1 Vitals screen icon (Inset)
is highlighted.
1 1
Displays select system

operating levels.
You can monitor real-time displays of:
• Engine Speed
NA3189 • Engine Oil Pressure
• Engine Coolant Temperature
• Fuel Consumption
• System Voltage
ICON DESCRIPTION • Hydraulic Charge Pressure
• Hydraulic Fluid Temperature
DATE / TIME • Engine Oil Temperature
USER / HOURMETER The Deluxe Instrumentation Panel is easy to use.

Continue to set your own preferences for operating /
CURRENT JOB HOURS monitoring your Bobcat loader.
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
HOME icon (Return to MAIN screen)
LEFT SCROLL button
RIGHT SCROLL button
ENTER button

CONTROL PANEL SETUP (CONT’D)
Right Panel Setup (Deluxe Instrumentation Panel) (Cont’d)
Date And Time English / Metric Display
Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Display screen icon (Inset) Display screen icon (Inset)
is highlighted. is highlighted.
1 1 1 1
Select [4. DISPLAY

Select [1. CLOCKS].
SETTINGS].
Press [1] to cycle between

Select [1. TIME].
ENGLISH and METRIC.
Use the keypad to enter

Auto Idle Time Delay
time.
Select AM / PM / 24hr.
Press [ENTER] to 1) repeatedly until the
continue. Security screen icon
(Inset) is highlighted.
1 1
Select [2. DATE].
Select [3. ENGINE

SETTINGS].
Use the keypad to enter

date. Use the keypad to enter
the desired delay time
Press [ENTER] to between 4 and 250
continue. seconds.
Press [ENTER] to save

and continue. Press left
scroll button to exit without
saving.

Job Clock Reset

Security screen icon
1 1
Select [1. PASSWORDS /

LOCKOUTS].
Enter owner password

and press [ENTER].
Select [1. USER

SETTINGS].
Select user.
Select [3. RESET JOB

STATISTICS].
Press [9] to reset job

statistics.
Press left scroll button or

[0] to exit without saving.

Machine Lockouts (High Flow And Two-Speed) Machine Lockouts (Travel Speed) (SJC Only)
Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Security screen icon Security screen icon
(Inset) is highlighted. (Inset) is highlighted.
1 1 1 1
Select [1. PASSWORDS / Select [1. PASSWORDS /

LOCKOUTS]. LOCKOUTS].
Enter owner password Enter owner password

and press [ENTER]. and press [ENTER].
Select [3. HIGH FLOW].

Select [5. TRAVEL
OR
SPEED].
Select [4. TWO-SPEED].
HIGH FLOW
TRAVEL SPEED
Press user number to
cycle between LOCKED Select user.
and UNLOCKED.
FORWARD / REVERSE
TWO-SPEED TRAVEL SPEED LIMIT
Press user number to Enter forward travel speed

cycle between LOCKED limit as a percentage and
and UNLOCKED. press [ENTER] to save.
Enter reverse travel speed

limit as a percentage and
NOTE: High-Flow and Two-Speed lockouts for the press [ENTER] to save.
owner are active even if the Password
Lockout feature is unlocked.

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Password Setup is available on machines with a Deluxe

Instrumentation Panel. Press a scroll button (Item
Password Description Security screen icon
All new machines with a Deluxe Instrumentation Panel
1 1
arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start Select [1. PASSWORDS /
the engine. LOCKOUTS].
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password:
A permanent, randomly selected password set at the and press [ENTER].
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known or to change the owner
password.
Owner Password:
Select [1. USER
Allows for full use of the loader and to setup the SETTINGS].
Deluxe Instrumentation Panel. There is only one
owner password. The owner password must be used
to change the owner or user passwords. Owner
should change the password as soon as possible for
security of the loader.
User Password: Select [1. OWNER].
Allows starting and operating the loader; cannot

change password or any of the other setup features.
For the procedures to change passwords (See Changing

The Owner Password on Page 60-190-1.) and (See
Changing The User Passwords on Page 60-190-2.)
Select [2. CHANGE
PASSWORD].
Enter new owner

password and press
[ENTER].
You will be prompted to

reenter the new owner
password.

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Passwords feature so that a password does not need to be used
every time the engine is started.

Security screen icon Press a scroll button (Item
(Inset) is highlighted. 1) repeatedly until the
1 1 Security screen icon
Select [1. PASSWORDS / 1 1
LOCKOUTS].
Select [1. PASSWORDS /
LOCKOUTS].

and press [ENTER].

and press [ENTER].
Select [1. USER

SETTINGS].
Select [2. MACHINE

LOCK].
Select user.
NOTE: The procedure above can be followed to reset

the machine lock so that the machine requires
a password to start the engine.
Select [2. CHANGE
PASSWORD].
Enter new user password

and press [ENTER].

PASSWORD SETUP (KEYLESS START PANEL)
Password Description
Master Password: Owner Password:
A permanent, randomly selected password set at the Allows for full use of the loader. Must be used to
factory that cannot be changed. This password is change the owner password.
used for service by the Bobcat dealer if the owner
password is not known or to change the owner
password.
_______________________________________________________________________________________________
Changing The Owner Password Password Lockout Feature
Turn the key switch to the RUN position to turn on the This feature allows the owner to unlock the password
loaders electrical system. feature so that a password does not need to be used
every time the engine is started.
Enter the five digit owner password using the number
keys (1 through 0) if locked. Turn the key switch to the RUN position to turn on the
loaders electrical system.
Figure 60-191-1
keys (1 through 0).
Press the unlock key (Item 2) [Figure 60-191-1].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 The loader can now be started without using a password.

2
NOTE: Use the following procedure to reset the
P-90805
machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2) Turn the key switch to the RUN position to turn on the
[Figure 60-191-1] keys for 2 seconds. loaders electrical system.
The lock key red light will flash and the left panel display Press the lock key (Item 1) [Figure 60-191-1].
screen will show [ENTER].
The lock key red light will flash and the left panel display
Enter a new five digit owner password using the number screen will show [CODE].
keys (1 through 0). An asterisk will show in the left panel
display screen for each key press. Enter the five digit owner password using the number
keys (1 through 0). The unlock key green light will flash,
The left panel display screen will show [AGAIN]. then the lock key red light will become solid.
Enter the new five digit owner password again. You must now enter the password every time to start the
loader.
The lock key red light will become solid.

MAINTENANCE CLOCK This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
Description maintenance clock is reset.
The Maintenance Clock alerts the operator when the next Figure 60-200-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-200-1
2
1
NA3086 NA3198
During machine operation, a 2 beep alarm will sound The Deluxe Instrumentation Panel (if equipped) will
when there are less than 10 hours until the next planned display a bar (Item 1) [Figure 60-200-3] showing time
maintenance.
remaining until next service. This bar will turn red when
service is past due. NEXT MAINTENANCE DUE will
The remaining hours before maintenance is required will
appear in the data display (Item 1) for 5 seconds while change to MAINTENANCE PAST DUE and display the
the service icon (Item 3) and hourmeter icon (Item 2) number of hours past due.
[Figure 60-200-1] flash.
Keys [4] and [9] can be used to adjust the service
NOTE: The display will show negative numbers after interval when the owner is logged in [Figure 60-200-3].
counting down to zero.
The display will then revert back to the previous display

and will appear for 5 seconds every time the machine is
started until the maintenance clock is reset.
Figure 60-200-2
NA3195
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.
Figure 60-200-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.

Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
200-11] to reset and set the maintenance clock.

Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
NA3273
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.
Press and hold the information button (Item 2) for 7

seconds until [RESET] appears in the display screen
(Item 1) [Figure 60-200-16].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.

BACK-UP ALARM SYSTEM Figure 60-210-2
Description
The back-up alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the controls into the reverse
position is required with hydrostatic transmissions, before
the back-up alarm will sound. 1
Inspection

2
Figure 60-210-1
P121187A
Inspect the back-up alarm electrical connections (Item 1),

wire harness (Item 2) [Figure 60-210-2], and back-up
alarm switches (if equipped) (Item 1) [Figure 60-210-3]
for tightness and damage. Repair or replace any
damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on Page 60-210-2.)
P-90644B
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.

BACK-UP ALARM SYSTEM (CONT’D) Figure 60-210-4
Adjusting Switch Position

1
NOTE: Joystick equipped machines do not have
back-up alarm switches and cannot be
adjusted.
2
Standard Controls And ACS (If Equipped) 3
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Put the steering levers in the NEUTRAL position.
Figure 60-210-3
P-85723A
Loosen the screws (Item 3) [Figure 60-210-4] securing

the back-up alarm switch. (Left side shown)
1
Position the back-up alarm switch so that the roller (Item
1) just makes contact with the bellcrank (Item 2) [Figure
60-210-4] without compressing the switch spring.
Torque the screws (Item 3) [Figure 60-210-4] securing

the switch to the bracket to 1,0 - 1,4 N•m (9 - 12 in-lb).
Repeat adjustment procedure for the other switch.
P109277 Lower the operator cab. (See Lowering on Page 10-30-

3.)
The back-up alarm switches (Item 1) [Figure 60-210-3] Inspect back-up alarm system for proper function. (See
are located alongside the steering bellcranks. Both Inspection on Page 60-210-1.)
switches must be adjusted properly for the back-up alarm
to operate correctly.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in NEUTRAL / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The back-up alarm or switch wires are disconnected.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in NEUTRAL / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches.
Standard Controls And ACS (If Equipped)
Figure 60-210-5
on Page 10-30-2.)
Figure 60-210-6
2
2
1
P100048 1
Disconnect the alarm connectors (Item 1) [Figure 60-

210-5] from the alarm.
P-85723A
Remove the two nuts (Item 2) [Figure 60-210-5].
Remove the alarm and bracket from the loader. Place the steering levers in the NEUTRAL position.
Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch (Item 2) [Figure 60-210-6] off
the mounting bracket.
Mark the wires for ease of assembly and disconnect

them from the switch.
Installation: Slide the alarm switches onto the mounting

bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjust the switches (See
Adjusting Switch Position on Page 60-210-2.) and inspect
back-up alarm operation (See Inspection on Page 60-
210-1.) are required.

FRONT HORN
Remove the left side lower panel. (See Removal And

Figure 60-220-1
P-90901
Figure 60-220-2
1 3
P-90902
Disconnect wire harness (Item 1) [Figure 60-220-1] and

[Figure 60-220-2] from the front horn.
Remove the two bolts and nuts (Item 2) [Figure 60-220-

1] and [Figure 60-220-2].
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].

FRONT HORN (CONT’D)
W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6, 7

2. The front horn switch is damaged.
3. The front horn is damaged.
4. The front horn or switch wires are disconnected.
7. The joystick controller is not working correctly. (SJC Equipped Machines)

FRONT HORN (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6

2. The front horn is damaged.
3. The front horn wires are disconnected.
6. The joystick controller is not working correctly.

CAMSHAFT AND CRANKSHAFT POSITION SENSOR Crankshaft Position Sensor
Remove the fan duct panels. (See Removal And 3

Camshaft Position Sensor

1
Figure 60-230-1
2
1 P114265
3
Disconnect the wire harness (Item 1), remove the

2 mounting bolt (Item 2) and remove the sensor (Item 3)
[Figure 60-230-2].
P121136
The camshaft sensor (Item 1) is located below the EGR

cooler. Disconnect the wire harness (Item 2), remove the
bolt (Item 3) [Figure 60-230-1] and remove the sensor.

ENGINE COMPARTMENT TEMPERATURE SENSOR Figure 60-240-3
Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)
1
WARNING 1
HOT SURFACES CAN CAUSE SERIOUS INJURY

• Do not touch.
• Allow to cool before servicing. P121609
W-2533-1012
Figure 60-240-1 Rotate the SCR clamps (Item 1) [Figure 60-240-3] to

remove. Discard the clamps.
NOTE: Do not reuse SCR clamps.

1
Installation: Tighten the nuts to 8 - 10 N•m (71 - 89 in-lb)
2 torque.
1 1
Figure 60-240-4
2
1
P121249
Remove the four bolts (Item 1) and the engine cover

(Item 2) [Figure 60-240-1].
Figure 60-240-2
1 P115863B
1 Remove the V-Band clamp (Item 1) and the gasket (Item

1 2) [Figure 60-240-4]. Discard the V-Band clamp and
gasket.
NOTE: Do not reuse the V-Band clamp or gasket.
Installation: Tighten the nuts to 8 - 10 N•m (71 - 89 in-lb)

torque.
P121610
Remove the SCR clamp nuts (Item 1) [Figure 60-240-2].

ENGINE COMPARTMENT TEMPERATURE SENSOR
(CONT’D)
Reposition the SCR to allow access to the temperature

sensor.
Figure 60-240-5
1 2
P115928
Remove the electrical connector (Item 1) [Figure 60-240-

5] from the sensor.
Remove the nut and sensor (Item 2) [Figure 60-240-5].
Installation: Tighten the nut to 15 N•m (11 ft-lb) torque.

TELEMATICS Figure 60-250-2
Description 2
This machine may be equipped with telematics.
Telematics enables dealers to track machine location and 1 1

receive notifications when the machine codes or is due
for scheduled maintenance.
A factory installed telematics module is located under the 3

headliner above the rear window. For aftermarket kit
installation location see the kit installation instructions.

P127731
Remove the headliner. (See Removal And Installation on
Page 50-190-1.)
Remove the four nuts and bolts (Item 1) and remove the
Figure 60-250-1 telematics module (Item 2) from the mounting plate (Item
3) [Figure 60-250-2].
1
2 2
3 3
P127730
Remove the electrical connector (Item 1) and the two

antenna connections (Item 2) [Figure 60-250-1].
Remove the two bolts (Item 3) and remove the telematics

module assembly (Item 4) [Figure 60-250-1] from the
loader.
Installation: Tighten the two antenna connections (Item

2) [Figure 60-250-1] to 0,9 N•m (8 in-lb) torque.

TELEMATICS (CONT”D)
Procedure
This device is equipped with three Status LED’s.

1. GPS
2. COM 1 - For wireless network status
3. COM 2 - Not used
The LED’s use the following blink patterns to indicate

service.
COM 1 - LED (Orange) Definitions

Condition COM 1 - LED
Modem Off Off
Comm On - Searching Slow Blinking
Network Available Fast Blinking
Registered but no Alternates from Solid to
Inbound Acknowledgment Fast Blink every 1s
Registered and Receiv-
ing Inbound Acknowledg- Solid
ment
GPS - LED (Yellow) Definitions

Condition GPS - LED
GPS Off Off
GPS On Slow Blinking
GPS Time Sync Fast Blinking
GPS Fix Solid
Com 1 will go through the sequence listed above. Initial

experience is:
• Slow Blink ~ 15 seconds.
• Fast Blink ~ 40 seconds.
• Solid LED achieved within 1 minutes.
• If solid LED is not achieved after 1 minute, the
system will reset and try again. This may occur
several times if the appropriate type of cell coverage
is marginal in the area.
GPS:
• Slow Blink - not observed, may be a very brief
moment.
• Fast Blink ~ 2 minutes.
• Solid LED achieved within 2 minute.
Times may vary depending on systems ability to
pickup GPS satellites.
More information can be found on BobcatDealerNet.com:

Connected Machine.

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-26
Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-28
Injector Signal - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-30
Injector Signal - Testing (In-Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-32
Oil Pressure Testing (At Oil Sensor On Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-34
Oil Pressure Testing (At Turbocharger Oil Inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-36
ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

Foot Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-4
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Diesel Exhaust Fluid (DEF) / AdBlue® Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
DeSOX Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-3
SCR System Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality . . . . . . . . . . . . . . . . . 70-30-6
SCR System Component Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6
EGR Impeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-7
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption . . . . . . . . . . . . . . . . . . . 70-30-7
SCR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-8
Dosing Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-10
Dosing Control Unit (DCU) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-30-11
Supply Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-13
Supply Module Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-14
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation . . . . . . . . . 70-30-16
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation . . . . . . . 70-30-19
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation . . 70-30-21
DIESEL OXIDATION CATALYST (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Hydraulic Reversing Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-60-5
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Hydraulic Fan Motor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-8
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-18
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-18
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Oil Pump Relief Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Oil Suction Tube Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Oil Filter Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Oil Cooler Bypass Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
High Pressure Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
High Pressure Pump Drive Gear Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-3
Fuel Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Bypass Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Temperature Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Recirculation Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-5
Fuel Rail Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Injector Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Intake Air Heater Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Intake Air Heater Tube Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-10
Valve Step Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Valve Stem Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
Rocker Arm Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-14
Rocker Arm Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-15
Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-15
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Piston And Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Timing Wheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Cylinder Block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-8
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Engine Component Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Idle Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
Idle Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-2

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1

ENGINE INFORMATION
Description
Figure 70-10-1
P121107
The loader is equipped with a Bobcat direct injected

D34P turbocharged and inter-cooled diesel engine with a
displacement of 3,4 L (208 in3). The engine is rated at an
SAE J gross 69,6 kW (93.3 hp) @ 2400 rpm and has a
closed breather system [Figure 70-10-1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with an air intake heater and electronic timer with cold
start advance function for assisting in cold starts.
To meet emission regulations it is also equipped with a

Selective Catalytic Reduction (SCR) system and an
Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and

is located near the high pressure pump. The model
number is located on the valve cover. Use these numbers
to obtain the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor, the hydraulic / hydrostatic
fluid temperature sensor, fuel temperature and the HVAC
system.

ENGINE INFORMATION (CONT’D)
Specifications
Valve Springs
Free Length (Intake and Exhaust) 55,23 mm (2.17 in)
Tilt Allowable Limit (Intake and Exhaust) Below 1,8 mm (0.071 in)
Valve
Valve Clearance (Intake) 0,4 mm (0.016 in)
Valve Clearance (Exhaust) 0,45 mm (0.018 in)
Valve Stem OD (Intake) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Stem OD (Exhaust) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Face Width (Intake) 2,14 mm (0.084 in)
Valve Face Width (Exhaust) 1,63 mm (0.064 in)
Valve Face Angle 44,5° - 45.0°
Valve Guide Bore 7.0 - 7.015 mm (0.2756 - 0.2762 in)
Valve Guide Length 43,4 - 43,6 mm (1.7087 - 1.7165 in)
Valve Timing
Intake Valve (Open) 16 degrees B.T.D.C.
(Close) 54 degrees A.B.D.C.
Exhaust Valve (Open) 38 degrees B.B.D.C.
(Close) 24 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 16,15 mm (0.6358 in)
I.D. of Rocker Arm Bushings 16,03 mm (0.6311 in)
Camshaft
Journal O.D. 44,950 - 44,966 mm (1.7697 - 1.7703 in)
Bearing I.D. 45,0 - 45,025 mm (1.7717 - 1.7726 in)
Oil Clearance 0,065 - 0,106 mm (0.0026 - 0.0042 in)
Camshaft End Play 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cam Lobe Height (Intake) 39,78 mm (1.566 in)
Cam Lobe Height (Exhaust) 38,716 mm (1.524 in)
Side Clearance Allowable Limit 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cylinder Bore
Cylinder Bore I.D. 97,990 - 98,010 mm (3.8579 - 3.8587 in)
Piston Rings
Ring Gap (Top Ring) 0,25 - 0,40 mm (0.0098 - 0.0157 in)
Ring Gap (2nd Ring) 0,55 - 0,70 mm (0.0217 - 0.0276 in)
Ring Gap (Oil Ring) 0,20 - 0,40 mm (0.0079 - 0.0157 in)
Side Clearance of Ring Groove:
Top Ring 0,083 - 0,137 mm (0.0033 - 0.0054 in)
Second Ring 0,070 - 0,110 mm (0.0276 - 0.0043 in)
Oil Ring 0,030 - 0,070 mm (0.0012 - 0.0028 in)
Pistons
Piston Pin Bore 31,008 - 31,014 mm (1.2208 - 1.2210 in)

Specifications (Cont’d)
Connecting Rod
Piston Pin O.D. 35,995 - 36,000 mm (1,4171- 1.4173 in)
Small End Bushing I.D. 36,025 - 36,038 mm (1.4183 - 1.4188 in)
Oil Clearance Between Piston Pin and Small End Bushing 0,025 - 0,043 mm (0.0010 - 0.0017 in)
Oil Pump
Oil Pressure Rated rpm 294 - 539 kPa (2,94 - 5,39 bar) (43 - 78 psi)
Idle Speed Allowable Limit 147 - 294 kPa (1,47 - 2,94 bar) (21 - 43 psi)
Crankshaft
Connecting Rod Large End Bore 66,000 - 66,015 mm (2.5984 - 2.5990 in)
Connecting Rod Oil Clearance (Large End Bore) 0,026 - 0,064 mm (0.0001 - 0.0025 in)
Connecting Rod End Play 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Crankshaft Journal O.D. 74,955 - 74,970 mm (2.9510 - 2.9516in)
Oil Clearance Between Journal and Bearing 0,029 - 0,059 mm (0.0011 - 0.0023 in)
Crankshaft End Play 0,10 - 0,31 mm (0.0039 - 0.0122 in)
I.D. of Cylinder Block Main Bearing Bore
Class A 79,000 - 79,007 mm (3.1102 - 3.1105 in)
Class B 79,007 - 79,014 mm (3.1105 - 3.1108 in)
Class C 79,014 - 79,021 mm (3.1108 - 3.1111 in)
OD of Crankshaft Main Journal
Class A 74,955 - 74,960 mm (2.9510 - 2.9512 in)
Class B 74,960 - 74,965 mm (2.9512 - 2.9514 in)
Class C 74,965 - 74,970 mm (2.9514 - 2.9516 in)
Main Bearing Thickness
Blue 1,995 - 2,000 mm (0.0785 - 0.0787 in)
Yellow 2,000 - 2,005 mm (0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm (0.0789 - 0.0791 in)
Timing Gear
Timing Gear Backlash:
High Pressure Pump Gear To Idle Gear 0,081 - 0,196 mm (0.0032 - 0.0077 in)
Idle Gear To Crankshaft Gear 0,087 - 0,202 mm (0.0034 - 0.0080 in)
Idle Gear To Camshaft Gear 0,087 - 0,213 mm (0.0034 - 0.0084 in)
Crankshaft Gear To Oil Pump Gear 0,066 - 0,247 mm (0.0026 - 0.0097 in)
Thermostat
Valve Opening Temperature 82°C (180°F)
Valve Fully Open 97°C (207°F)

Sensor Location
Vehicle Side
Figure 70-10-2
2 6
4 5 3
P121122
1. Mass Air Flow Sensor (MAF) (Item 1) [Figure 70-10-

2]
2. Coolant Temperature Sensor (Item 2) [Figure 70-10-

2]
3. Camshaft Position Sensor (Item 3) [Figure 70-10-2]
4. Crankshaft Position Sensor (Item 4) [Figure 70-10-2]
5. EGR Valve Actuator (Item 5) [Figure 70-10-2]
6. Exhaust Gas Temperature Sensor (Item 6) [Figure

70-10-2]

Sensor Location (Cont’d)
Tailgate (Service) Side
Figure 70-10-3
2 2
5
3
P121123
1. Intake Manifold Pressure Sensor (MAP) (Item 1) Figure 70-10-4

[Figure 70-10-3]
2. Knock Sensor (Item 2) [Figure 70-10-3]
3. Oil Pressure / Temperature Sensor (Item 3) [Figure

70-10-3]
4. Intake Manifold Temperature Sensor (Item 4) [Figure 1

70-10-3]
5. Fuel Temperature Sensor (Item 5) [Figure 70-10-3]
P121135
Common Rail Pressure Sensor (Item 1) [Figure 70-10-

4].

ENGINE INFORMATION (CONT’D) Figure 70-10-7
Figure 70-10-5
1
1
P121136
2
Camshaft Position Sensor (Item 1) [Figure 70-10-7].

P121138
Figure 70-10-8
Mass Air Flow Sensor (MAF) (Item 1) [Figure 70-10-5].
Engine Compartment Temperature Sensor (Item 2)

[Figure 70-10-5].
Figure 70-10-6
1 P121131
Crankshaft Position Sensor (Item 1) [Figure 70-10-8].
P121128
Coolant Temperature Sensor (Item 1) [Figure 70-10-6].

Figure 70-10-9
P121134
Intake Manifold Pressure Sensor (MAP) [Figure 70-10-

P121137 11].
Figure 70-10-12
EGR Valve Actuator (Item 1) [Figure 70-10-9].
Figure 70-10-10
P121127
P121129 Knock Sensor (Left Side) (Item 1) [Figure 70-10-12].
Exhaust Gas Temperature Sensor (Item 1) [Figure 70-

10-10].

Figure 70-10-13
1
P121133
Intake Manifold Temperature Sensor (Item 1) [Figure 70-

P121132 10-15].
Figure 70-10-16
Knock Sensor (Right Side) (Item 1) [Figure 70-10-13].
Figure 70-10-14
P121125
P121126 Fuel Temperature Sensor (Item 1) [Figure 70-10-16].
Inlet Metering Valve (Item 2) [Figure 70-10-16].

Oil Pressure / Temperature Sensor (Item 1) [Figure 70-
10-14].

Figure 70-10-17
1
2 2
P115875
Diesel Oxidation Catalyst (DOC) Temperature Sensor

P115946 (Item 1) [Figure 70-10-19].
Diesel Oxidation Catalyst (DOC) Upstream NOx Sensor

Engine Control Unit (ECU) (Item 1) [Figure 70-10-17]. (Item 2) [Figure 70-10-19].
Atmospheric Pressure Sensor (Item 2) [Figure 70-10- Figure 70-10-20

17].
Figure 70-10-18
1 P115867
P115883 Selective Catalytic Reduction (SCR) Temperature Sensor

(Outlet Side) (Item 1) [Figure 70-10-20].
Water in Fuel Sensor (Item 1) [Figure 70-10-18]. Selective Catalytic Reduction (SCR) Downstream NOx
Sensor (Item 2) [Figure 70-10-20].

Figure 70-10-21
P120660
Selective Catalytic Reduction (SCR) Temperature Sensor

(Inlet Side) (Item 1) [Figure 70-10-21].

Torque Values
Thread Size
Strength Classification
(Dia. x Pitch)
8.8 10.9 12.9
M6 x 1,0 9,8 N•m 12,3 N•m 14,7 N•m
(7.2 ft-lb) (9 ft-lb) (10.8 ft-lb)
M8 x 1,25 21,6 N•m 30,4 N•m 37,3 N•m
(15.9 ft-lb) (22.4 ft-lb) (27.5 ft-lb)
M8 x 1,0 23,5 N•m 32,8 N•m 40,2 N•m
(17.4 ft-lb) (24.2 ft-lb) (29.7 ft-lb)
M10 x 1.5 43,1 N•m 60,8 N•m 72,6 N•m
(31.8 ft-lb) (44.8 ft-lb) (53.5 ft-lb)
M10 x 1,0 49 N•m 68,6 N•m 82,4 N•m
(36.2 ft-lb) (50.6 ft-lb) (60.8 ft-lb)
M12 x 1,75 73,5 N•m 103 N•m 122,6 N•m
(54.2 ft-lb) (76 ft-lb) (90.4 ft-lb)
M12 x 1,5 78,5 N•m 109,8 N•m 131,5 N•m
(57.9 ft-lb) (81 ft-lb) (97 ft-lb)
M14 x 1,5 127,5 N•m 181,4 N•m 215,7 N•m
(94 ft-lb) (134 ft-lb) (159 ft-lb)

Torque Values (Cont’d)
Thread Size Strength

Component Tightening Torque
(Diameter X Pitch) Class
54 N•m (40 ft-lb) initial torque
Main Bearing Cap Bolt M12x1.5x133 12.9 Plus 90° second torque
Plus 90° third torque
44 N•m (33 ft-lb) initial torque
Cylinder Head Bolt M12x1.25x29 9.8 Plus 90° second torque
Plus 90° third torque
29,4 N•m (21.7 ft-lb) initial torque
Connecting Rod Bolt M9x1.0x66 10.9
Plus 90° second torque
Crankshaft Pulley Bolt M14x1.5 10.9 245 - 265 N•m (181 - 195 ft-lb)
Cylinder Head Cover Bolt M6x1.0 8.8 7,8 N•m (5.8 ft-lb)
Injector Bracket Bolt M8x1.25 12.9 39 - 46 N•m (29 - 34 ft-lb)
Thermostat Bolt M8x1.25 8.8 22 N•m (16 ft-lb)
Turbocharger Hollow Screw M10x1.0 19,6 N•m (14.5 ft-lb)
Turbocharger Nut M8x1.25 22 N•m (16 ft-lb)
Water Pump Nut and Bolt M8x1.25 22 N•m (16 ft-lb)
Rocker Arm Adjust Nut M8x1.0 14,7 N•m (10.8 ft-lb)
High Pressure Pump Drive Gear Nut M14x1.5 58,8 - 68,6 N•m (43.4 - 50.6 ft-lb)
High Pressure Pump Nut M8x1.25 22 N•m (16 ft-lb)
Turbocharger Oil Delivery Tubeline Nut Nut 19,6 N•m (14.5 ft-lb)
High Pressure Fuel Line Nut - High Pressure
Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
Pump
High Pressure Fuel Line Nut - Common Rail Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
High Pressure Fuel Line Nut - Injector Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)

Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction tube.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump tube strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

Engine Removal And Installation
Figure 70-10-22
P100332
Use the engine removal tool (MEL1653-1) [Figure 70-10-

22] and the attachment (MEL1653-11) [Figure 70-10-23]
and (MEL1653-8) [Figure 70-10-24] to aid in the removal
and installation of the engine.
P-76872
Figure 70-10-23
P115885

Engine Removal And Installation (Cont'd)
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P115920
• Keep out of this area when lift arms are raised Remove the engine ground cable and chassis ground
unless supported by an approved lift arm cable (Item 1) [Figure 70-10-25].
D-1009-0409 Remove the engine starter positive cable (Item 2)
[Figure 70-10-25] from the starter.
Figure 70-10-26
WARNING
support device can allow the lift arms or attachment 2
W-2059-0598

Raise the operator cab. (See Raising on Page 10-30-2.) 1

P115921
Remove the tie strap (Item 1) and disconnect the
Remove the battery from the loader. (See Removal And
connector (Item 2) [Figure 70-10-26].
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-5.)
Remove the SCR. (See SCR Removal And Installation
on Page 70-30-8.)
Remove the DOC. (See Removal And Installation on

Page 70-40-1.)
Remove the AC compressor (if equipped). (See Removal


Figure 70-10-27
3
1
2
1
3
P115819
2

P115922 the bottom of the filter.

Disconnect the two wires (Item 1), remove the wire mount filter assembly (Item 3) [Figure 70-10-29].
bolt (Item 2) and reposition the air heater wire (Item 3)
[Figure 70-10-27]. Figure 70-10-30
WARNING
AVOID INJURY OR DEATH 1
explosion or fire.
W-2103-0508
Figure 70-10-28
P121241
2
Remove the hose / clamp (Item 1) [Figure 70-10-30]
from the charge air cooler (left side).
P115923
Remove the fuel inlet line (Item 1) and the fuel return line
(Item 2) [Figure 70-10-28] from the high pressure pump.
Install caps and plugs.

Figure 70-10-31
1
1
2
P120680
Remove the three coolant hoses (Item 1) [Figure 70-10-

P121242 33].
Figure 70-10-34
Remove the hose / clamp (Item 1) [Figure 70-10-31]
from the charge air cooler (right side).
2
Figure 70-10-32
2 P115926
Loosen and reposition the hose clamp (Item 1) [Figure

P115924 70-10-34].
Remove the tie strap (Item 2) [Figure 70-10-34].

Remove the radiator hose / clamp (Item 1) and (Item 2)
[Figure 70-10-32].

Figure 70-10-35
4
1
1
2
3
3 P115928
2 Remove the wire connector from the mass air flow sensor
P115857A (Item 1) and the engine compartment temperature
sensor (Item 2) [Figure 70-10-37].
Disconnect the wire harnesses (Item 1) [Figure 70-10- Remove the tie strap (Item 3) and the two bolts (Item 4)
35]. [Figure 70-10-37].
Remove the two bolts (Item 2) and reposition the NOx Remove the assembly from the machine.
bracket (Item 3) [Figure 70-10-35].
Figure 70-10-38
Figure 70-10-36
P115872
P115858A
Remove the engine connector (Item 1) from the ECU

Loosen the hose clamp (Item 1) [Figure 70-10-36] and (Item 2) [Figure 70-10-38]. (See Removal And
disconnect the hose from the air cleaner. Installation on Page 60-80-3.)
NOTE: The connectors / ECU must be thoroughly

cleaned. DO NOT USE PRESSURIZED
WATER. Use compressed air and small brush.


1
Figure 70-10-39
P115820

P115929
Figure 70-10-42

70-10-39].
Figure 70-10-40
1
2 1
1
P115828
Remove the fuel hose / clamp (Item 1) [Figure 70-10-42]

from the filler neck.
P115930
Cut the tie straps (Item 1) and reposition the wire harness
(Item 2) [Figure 70-10-40].

Figure 70-10-43
1
1 2
P115927
Remove the inlet hose (Item 1) [Figure 70-10-44] from

P115821 the fan.
Remove the outlet hose (Item 2) [Figure 70-10-44] from

Remove the clamp / hose (Item 1) [Figure 70-10-43] the fan.
from the tank.
Figure 70-10-45
NOTE: Plug the fuel tank opening.
Remove the fan duct. (See Fan Duct Removal And

Installation on Page 70-60-4.) 2
1
IMPORTANT 3

damage the system.
P115931
I-2003-0888
Remove the bolt (Item 1) and P-clip (Item 2) from the

hose (Item 3) [Figure 70-10-45]. (Both sides.)

Figure 70-10-46
P115934
1
Remove the case drain hose (Item 1) [Figure 70-10-48]
from the drain manifold.
P115932
Figure 70-10-49
Mark the location of the four hoses (Item 1) [Figure 70-
10-46] and disconnect.
Installation: Tighten the hoses to 154 - 165 N•m (114 -

122 ft-lb).
1
NOTE: The fittings on the hydrostatic pump must be
tightened to 190 - 216 N•m (140 - 160 ft-lb)
torque.
Remove the case drain hose (Item 2) [Figure 70-10-46]

from the pump.
Figure 70-10-47
P115935
Disconnect the hydrostatic pump connectors (Item 1)

1 [Figure 70-10-49].
1
P115933
Remove both suction hoses (Item 1) [Figure 70-10-47]

from the pump.
Remove the charge pump inlet hose (Item 2) [Figure 70-

10-47].

Figure 70-10-50
P106919
Disconnect the wire harness (Item 1) from the main

P115936 frame harness and the harness (Item 2) [Figure 70-10-
52] from the fuel level sending unit.
Remove the inlet hose (Item 1) [Figure 70-10-50] from Figure 70-10-53
the bottom of the hydraulic control valve.
Figure 70-10-51
P115939
P100806 Remove rear engine mounting nut and bolt (Item 1)

[Figure 70-10-53].
Disconnect the two Bob-Tach electrical solenoid coil Installation: Tighten the mounting nut and bolt to 122 -
connectors (Item 1) [Figure 70-10-51] from the loader 135 N•m (90 - 100 ft-lb) torque.
electrical harness (if equipped).

Figure 70-10-54
P115944
Remove the bolt (Item 1) and bolt / ground cable (Item 2)

P115940 [Figure 70-10-56].
Remove the battery hold down plate (Item 3) [Figure 70-

Remove the engine mounting bolt (Item 1) [Figure 70- 10-56].
10-54] from the left side of the engine.
Figure 70-10-57
Installation: Tighten the mounting bolt to 122 - 135 N•m
Figure 70-10-55 1
2
2
P115938
Install the engine removal bracket (Item 1) on the engine

P115941 using the SCR mounting hardware (Item 2) [Figure 70-
10-57].
Remove the engine mounting bolt (Item 1) [Figure 70-

10-55] from the right side of the engine.
Installation: Tighten the mounting bolt to 122 - 135 N•m


Figure 70-10-58
1 1
3
1 P106863
Raise the engine and pull the engine out of the loader far
P115942 enough to remove the Power Bob-Tach hoses (Item 1)
[Figure 70-10-60] (if equipped).
Install the engine removal tool (Item 1) and the extension Remove the engine / hydrostatic pump assembly from
(Item 2) into the engine removal bracket (Item 3) [Figure the loader.
70-10-58].
Figure 70-10-59
P115943
Connect a chain hoist (Item 1) to the engine removal tool

(Item 2) [Figure 70-10-59].

Engine Mount Replacement Washer

Engine
Figure 70-10-61 Mounting
Bracket
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-62].
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
Use the following procedure to install new rear engine lb) torque.
mount:
Figure 70-10-63
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 1
locations. 4
Replace all three engine mounts one rear and two sides.
5 2
Use the parts shown to install the new engine mounts
[Figure 70-10-61]: 6 3
Hex Nut - (Item 1) 7
Washer - (Item 2)
Cup Washer - (Item 3)

P-85990A
Engine Mount - (Item 4)
Tube Spacer - (Item 5) Use the parts shown to install the new side engine
mounts [Figure 70-10-63]:
Mounting Bolt - (Item 1)
Mounting Bolt - (Item 8)
Tube Spacer - (Item 4)
Retaining Nut - (Item 7)

Engine Mount Replacement (Cont’d)
Figure 70-10-64
Washer
Engine
Mounting
Bracket
Engine
Mount
Snubbing
Washer
Spacer
Loader
Frame P-85987
Install the new engine mount as shown in the cut away

side view [Figure 70-10-64].
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
lb) torque.

ENGINE INFORMATION (CONT’D) NOTE: High pressure lines and return fuel lines are
single use lines. Replace with new.
Compression - Testing
Sealing washers must be replaced with new
NOTE: Specifications are subject to change without when installing the injectors. Save the old
notice. sealing washers to use with the compression
adapter.
Prior to performing an engine compression test with a
gauge, it is recommended to perform a compression test Figure 70-10-66
using Bobcat Engine Analyzer software to determine if a
potential compression issue exists.
1
Wash the machine and then thoroughly clean the
external portion of the fuel system components and the
surrounding area of the engine compartment with
compressed air. Perform engine service in a clean
environment.
After warming up the engine, stop the engine, wait five

minutes for fuel pressure bleed down then remove all the
injectors. (See Fuel Injector Removal And Installation on
2
Page 70-80-7.)
Figure 70-10-65 NA13030
Install the compression tester and test adapter (part

number 7299831) for diesel engines into the nozzle hole
(Item 1) [Figure 70-10-66].
Use one of the old sealing washers to seal the adapter.
Remove the fuel line at the fuel filter outlet so no fuel is

expelled.
Plug the fuel line and cap the fuel filter outlet to help
maintain fuel system cleanliness.
P127114 NOTE: Always use a fully charged battery for

performing this test.
When removing the injectors leave the fuel lines Monitor the engine crank speed to ensure that a
connected to the fuel rail. Reroute the lines to allow any minimum of 180 rpm is achieved or reading will not be
small amount of fuel that may be present during the test valid.
to be collected [Figure 70-10-65].
Connect the Bobcat Engine Analyzer Diagnostic Tool and
Leaving the fuel lines connected to the fuel rail will also run the Compression test in Bobcat Engine Analyzer.
help prevent debris from entering the fuel rail. This test will cause the engine to crank while the test is
running. Observe the maximum compression reading on
Store each of the injectors in a new clean plastic bag. the compression gauge during cranking, not the test
results shown on the computer screen.
NOTE: Number the plastic bags to ensure that
injectors are installed in the same cylinders Repeat this procedure multiple times per cylinder until an
from which they were removed. average reading is recorded.
Do not get the injectors out of order. If the

injectors get out of order, it is necessary to
perform injector coding. (See Injector Coding
on Page 70-80-9.)

Compression - Testing (Cont’d)
Use the table below to determine if the results are within

acceptable limits.
Compression Factory 2,9 - 3,5 MPa / 200 rpm

Pressure spec. (29 - 35 bar / 200 rpm)
(420 - 508 psi / 200 rpm)
Allowable 2,5 MPa / 200rpm
Limit (25 bar / 200 rpm)
(290 psi / 200 rpm)
Variance Factory 300Kpa (3 bar) (44 psi)
Among Spec.
Cylinders Allowable 300Kpa (3 bar) (44 psi)
Limit
If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the nozzle
hole and measure the compression again.
If the compression pressure increases after applying oil,

cylinder wall and/or piston ring damage may be possible.
A bore scope may be used to look for internal damage
prior to engine disassembly.
If the compression pressure is still less than the allowable

limit, check the top clearance, valves and cylinder head.

Injector Signal - Testing
NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.
7299829 - Injector Signal Tester
MEL1563 or 7217666 - Remote Start Tool 2
WARNING
P115882

Remove the connector (Item 1) from the injector (Item 2)
[Figure 70-10-68].
Figure 70-10-69
W-2019-0907
Open the rear door. 1 2

on Page 70-30-8.)
NOTE: Ensure the battery is fully charged before

testing.
Figure 70-10-67
P127169
Install the signal tester (Item 1) to the connector (Item 2)

[Figure 70-10-69].
NOTE: Injector connector must be properly oriented

with tester connector or damage will occur.
1
Do not pull on wires or LED holder.

P115882 REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)
Locate the fuel injectors (Item 1) [Figure 70-10-67].

Injector Signal - Testing (Cont’d)
Figure 70-10-70
P-76439
Press the RUN button (Item 1) [Figure 70-10-70] on the

Remote Start Tool.
Figure 70-10-71
P127170
The signal tester light (Item 1) [Figure 70-10-71] should

flash once.
To repeat the test, press the STOP button (Item 2)

[Figure 70-10-70] and wait one minute.
If the signal tester light flashes, the electrical system is

working.
If the signal tester light is on continuously or not at all,

there is an electrical malfunction.
Repeat the above procedure for the remaining injectors.

Injector Signal - Testing (In-Line)
NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.
The tools listed will be needed for the following

procedure:
7313846 - Injector Signal Tester

2
MEL1563 or 7217666 - Remote Start Tool
WARNING P115882

Remove the connector (Item 1) from the injector (Item 2)
[Figure 70-10-73].
Figure 70-10-74
• Tools are being used. 2
W-2019-0907
4
Open the rear door.
NOTE: Ensure the battery is fully charged before 1

testing.
3
Figure 70-10-72
P127216
Install the signal tester (Item 1) to the harness connector

(Item 2) [Figure 70-10-74].
1 Install the signal tester connector (Item 3) to the injector

(Item 4) [Figure 70-10-74].
NOTE: Injector connector must be properly oriented

with tester connector or damage will occur.
P115882
Do not pull on wires or LED holder.
Locate the fuel injectors (Item 1) [Figure 70-10-72]. Connect the remote start tool. (See REMOTE START
7217666 on Page 10-61-1.)

ENGINE INFORMATION (CONT’D) If the signal tester light is on continuously or not at all,
there is an electrical malfunction.
Injector Signal - Testing (In-Line) (Cont’d)
Repeat the above procedure for the remaining injectors.
Figure 70-10-75
P-76439
Press the RUN button (Item 1) [Figure 70-10-75] on the

Remote Start Tool.
Figure 70-10-76
P127217

flash once.
Press the START button (Item 2) [Figure 70-10-75] on

the Remote Start Tool.

flash continuously.
To repeat the test, press the STOP button (Item 3)

[Figure 70-10-75] and wait one minute.
If the signal tester light flashes, the electrical system is

working.

Oil Pressure Testing (At Oil Sensor On Block)

1
Prior to performing an engine oil pressure gauge test, it is
recommended to monitor oil pressure using Bobcat
Service Analyzer software to determine if a potential oil
pressure issue exists.
2
procedure:
7332314 - Oil sensor block adapter kit
locally. Must be rated for pressures above 689 kPa (100
psi). P133776
Pressure gauge rated for 689 kPa (100 psi).

Open the rear door. Install the fitting (Item 1) into the adapter (Item 2) [Figure
70-10-79].
Figure 70-10-77
Figure 70-10-80
1 1
P133751
P133752
Locate the oil pressure / temperature sensor (Item 1)
[Figure 70-10-77].
Install the adapter (Item 1) [Figure 70-10-80] in the
Figure 70-10-78 engine block.
P133750
Remove the bolts (Item 1) and the sensor (Item 2)

[Figure 70-10-78].

Oil Pressure Testing (At Oil Sensor On Block)

(Cont’d)
Figure 70-10-81
1
P133753
2
Install the gauge (Item 1) to the hose (Item 2) [Figure 70-
10-83].
P133750
Start the engine and allow it to reach operating
temperature. Testing with cold oil may give inaccurate
Install the sensor (Item 1) and the 50 mm long bolts readings. Record the oil pressures at idle and at rated
(included in the kit), (Item 2) [Figure 70-10-81] and engine RPM.
tighten.
The following chart shows the oil pressure range at idle
Figure 70-10-82 and at rated RPM.
D34
Rated RPM 2400
Oil Pressure @ Rated RPM 400 - 500 kPa
Oil Temperature = 100°C (212°F) (58 - 72 psi)
Idle RPM 1050
Oil Pressure @ Idle RPM 150 - 250 kPa
Oil Temperature = 100°C (212°F) (22 - 36 psi)
P133754
Install the hose (Item 1) [Figure 70-10-82] to adapter

fitting and tighten.

Oil Pressure Testing (At Turbocharger Oil Inlet)
Prior to performing an engine oil pressure gauge test, it is

recommended to monitor oil pressure using Bobcat
Service Analyzer software to determine if a potential oil
pressure issue exists. 1
procedure:
7332314 - Turbocharger and oil sensor block adapter kit

locally. Must be rated for pressures above 689 kPa (100
psi). P133770
Pressure gauge rated for 689 kPa (100 psi).

Install the turbocharger adapter fitting (Item 1) [Figure
NOTE: This procedure is being performed on the 2.4
70-10-85] from the kit.
Bobcat engine. The air filter assembly has
been removed for photo clarity.
Figure 70-10-86
NOTE: Access to the turbocharger oil inlet line, (on
the SCR equipped 3.4 Bobcat engine), should
be performed through the front opening by 1
removing the fan duct and panels.
Figure 70-10-84
1 P133771
Install the 90 degree adapter fitting (Item 1) [Figure 70-

10-86] from the kit.
P133769
Remove the turbocharger oil inlet line fitting (Item 1)

[Figure 70-10-84].

Oil Pressure Testing (At Turbocharger Oil Inlet)

(Cont’d)
Figure 70-10-87
P133775
Start the engine and allow it to reach operating

temperature. Testing with cold oil may give inaccurate
P133772 readings. Record the oil pressures at idle and at rated
engine RPM [Figure 70-10-89].
Install the hose adapter fitting (Item 1) [Figure 70-10-87]. Oil pressure at the turbocharger oil inlet should be at
least 10 psi within 4 seconds of engine start. If this is not
Figure 70-10-88 achieved turbocharger damage is possible. Ensure the
correct engine oil viscosity is being used for the ambient
temperature. Oil pressure at the turbocharger oil inlet will
typically be about 5-10 psi lower than at the sensor.
P133774
Install the hose with gauge (Item 1) [Figure 70-10-88] to

the adapter fitting.

ENGINE SPEED CONTROL (HAND) Figure 70-20-3
Figure 70-20-1 1
1
2
1 P107696
Remove the fastener (Item 1) and the two screws (Item 2)

P107184 [Figure 70-20-3] from the right side switch panel.
Figure 70-20-4
Remove the knob (Item 1) [Figure 70-20-1] from the
engine speed control.
Figure 70-20-2
1
P107697
Carefully remove the speed control decal (Item 1)

P107695 [Figure 70-20-4].
Remove the fastener (Item 1) and the screw (Item 2)

[Figure 70-20-2] from the right switch panel.

ENGINE SPEED CONTROL (HAND) (CONT’D)
Figure 70-20-5
P107706
Remove the two screws (Item 1) [Figure 70-20-5].
Figure 70-20-6
P107475
Disconnect the electrical connector (Item 1) and remove

the engine speed control (Item 2) [Figure 70-20-6].
Reverse procedure for installation.

ENGINE SPEED CONTROL (FOOT) Figure 70-21-3

1 1
Figure 70-21-1
2 P106591
Remove the four bolts (Item 1) [Figure 70-21-3].
Tilt the assembly towards the center of the loader.

P106589
Figure 70-21-4
Remove the two nuts (Item 1) from the right side footrest
(Item 2) [Figure 70-21-1].
2
Remove the footrest from the loader.
Figure 70-21-2
1
P107707
2
1
Disconnect the electrical connector (Item 1) from the
engine speed control (Item 2) [Figure 70-21-4].
Remove panel assembly from the loader.

P106590
Loosen the bolt (Item 1) and remove the engine speed

control foot pedal (Item 2) [Figure 70-21-2].
NOTE: Mark the speed control foot pedal prior to

removal to aid in assembly.

ENGINE SPEED CONTROL (FOOT) (CONT'D) Figure 70-21-7
Figure 70-21-5
P107710
The pivot assemblies shown disassembled [Figure 70-

P-90755A 21-7].
NOTE: No lubrication is necessary or recommended

Remove the two bolts (Item 1) and the snap ring (Item 2) on the engine speed control.
[Figure 70-21-5] from the engine speed control
assembly. Figure 70-21-8
Figure 70-21-6
P107711
P107709
The engine speed control foot pedal pivot assembly
shown disassembled, [Figure 70-21-8] replace worn
Remove pivot nut and bolt (Item 1) and the spring (Item parts as needed.
2) [Figure 70-21-6].
NOTE: No lubrication is necessary or recommended
on the engine speed control.

ENGINE SPEED CONTROL (FOOT) (CONT'D)
Figure 70-21-9
P107712
Remove the two screws (Item 1) and the engine speed

control (Item 2) [Figure 70-21-9].
Installation: Tighten screws to 2,2 - 2,6 N•m (20 - 23 in-

lb) torque.
Figure 70-21-10
P107713
The engine speed control [Figure 70-21-10] shown

disassembled.
Align the tab (Item 1) with the slot (Item 2) [Figure 70-21-
10] during reassembly.
NOTE: After disassembly and assembly of the speed

control or replacement of the foot control
sensor, foot throttle calibration must be
performed. (See Foot Throttle Calibration on
Page 70-21-4.)

ENGINE SPEED CONTROL (FOOT) (CONT'D) Figure 70-21-13
Foot Throttle Calibration
Figure 70-21-11
1
NA3283
The alarm will beep four times and [FOOT] will appear in
NA3281 the display screen [Figure 70-21-13].
Figure 70-21-14
Diagnostic service code [M2899] will appear in the
display screen if the foot operated engine speed control
pedal requires calibration [Figure 70-21-11].
1
NOTE: Do not press the foot operated engine speed
control pedal until instructed. The calibration
procedure will fail and must be repeated if the
pedal is pressed partially or out of sequence.
Stop the engine.
Figure 70-21-12
P107096
1 1
Fully press the foot operated speed control pedal (Item 1)

[Figure 70-21-14] and hold for five seconds. Release the
pedal.
P-90687A P-85307Y
Turn the key switch to RUN (Item 1) [Figure 70-21-12]

but do not start the engine.
Press and hold the auto idle button (Item 1) [Figure 70-
21-11].

ENGINE SPEED CONTROL (FOOT) (CONT'D)
Foot Throttle Calibration (Cont’d)
Figure 70-21-15
NA3267
The display screen will change to the hourmeter after

approximately five seconds [Figure 70-21-15].
NOTE: Do not attempt to start the engine or press the

foot operated engine speed control pedal
again until [FOOT] clears from the display
screen and the hourmeter appears. The
calibration procedure will fail and must be
repeated.
The calibration procedure is now complete. The loader

can be started or turn the key switch OFF.
The calibration can be repeated if necessary.

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM
Description
The engine exhaust system is equipped with a selective catalytic reduction (SCR) system. The SCR is an emissions
reduction device that removes nitrogen oxides from the exhaust gases.
The SCR system consists of the dosing module, DCU (Dosing Control Unit) and other components. The DEF (Diesel
Exhaust Fluid) / AdBlue® is stored in the DEF / AdBlue® tank. Once it is needed, it is pressurized by the supply module
and is delivered to the dosing module under a certain level of pressure.
The machine will periodically perform a process to clean sulfur oxides from the SCR. This process is called DeSOX.
The SCR requires Diesel Exhaust Fluid (DEF) / AdBlue® to perform the DeSOX process.
NOTE: Diesel exhaust fluid (DEF) and AdBlue® are different names for the same fluid.
Figure 70-30-1
P121002A

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Level
DEF /
ENGINE ENGINE
FLUID LEVEL ADBLUE® DISPLAY SERVICE
STAGE ALARM TORQUE RPM
LEVEL INDICATOR MALFUNCTION SCREEN CODES
DERATE DERATE
ICON
Four Green
Full
Lights
Three Green
75%
Lights
Two Green
50%
Lights
25% - One Green E00524617
Warning On DEF L [1] Three Beeps
10% Light U00176115
Three Beeps
E00524615
Less Than One Yellow (Additional
Level 1 On DEF L [1] E00524617 25%
10% Light beep every 20
U00176115
minutes)
Three Beeps
E00524615
for each code
Less Than One Red E00524616
Level 2 On DEF L [2] (Additional 50% 60%
5% Light E00524617
beep every 10
U00176115
minutes)
Three Beeps E00524600
for each code E00524616
Less Than One Red Low Idle
Final Flashing DEF L (Additional E00524617
2.5% Light Only
beep every 2 U00176101
minutes) U00176116
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
NOTE: The level indicator, DEF / AdBlue® malfunction icon, and display screen are located on the left panel. (See
Left Panel on Page 60-50-1.)

DeSOX Process
There are three DeSOX processes:
• Passive DeSOX (Automatically performed by the machine unless inhibited)
• Forced DeSOX (Machine requested; operator initiated)
• Inhibit DeSOX (Option)
—————————————————————————————————————————————————————
Passive DeSOX Process Forced DeSOX Process
Figure 70-30-2 The machine may request a forced DeSOX if a passive

DeSOX was not finished.
Figure 70-30-3
NA3288
The DeSOX process will begin automatically every 200

NA3289
hours. The alarm will beep once and [DESOX] will
appear in the data display [Figure 70-30-2].
The alarm will beep twice, the engine malfunction icon
The display will revert to the hourmeter when the process will light, and [DESOX] will flash in the data display
is finished or press the information button to return to the [Figure 70-30-3]. Service code [E00008107] will also be
hourmeter immediately. displayed. The engine control unit (ECU) will reduce
engine torque by 40%.
The DeSOX process can last 15 minutes or longer.
The operator must turn the engine speed control to the
It is recommended to continue operating the machine high idle position. Keep the engine speed control in the
under load until the DeSOX process is finished. high idle position until the process is finished.
If the machine is turned OFF during a passive DeSOX The forced DeSOX process will last 20 minutes.
process, the process will resume the next time the
machine is started after acceptable conditions are It is recommended to continue operating the machine
reached. under load until the DeSOX process is finished.

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-5
(CONT’D)
DeSOX Process (Cont’d)
Inhibit DeSOX Process (Option)
An optional kit is available to prevent the machine from

performing a DeSOX process.
Figure 70-30-4
NA3289
The engine malfunction icon will light [Figure 70-30-5]

and the alarm will beep twice if a DeSOX process is
needed while inhibited. Service code [E00008107] will
also be displayed. The engine torque will reduce by 40%
if the operator continues to operate the machine while
inhibited.
NA3302
Press the bottom of the DeSOX Inhibit switch (Right

Switch Panel) [Figure 70-30-4] to prevent the loader
from performing a DeSOX process. The switch will light
while DeSOX is inhibited. The inhibit will reset when the
machine is turned OFF.
Press and hold the bottom of the DeSOX Inhibit switch for
approximately 5 seconds to permanently prevent the
loader from performing a DeSOX process. The switch will
light while DeSOX is inhibited. Press and release the
bottom of the DeSOX Inhibit switch to reset and allow the
machine to perform a DeSOX process.
If a DeSOX process has started, pressing and holding

the bottom of the DeSOX Inhibit switch for 3 seconds will
stop the process.

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM EGR Impeded
(CONT’D)
Figure 70-30-8
SCR System Codes
The following SCR system codes alert the operator of

conditions that require attention. Continued operation of
the machine under these conditions will result in reduced
machine performance.
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory

Quality
Figure 70-30-6
NA3305
[EGR] will appear in the data display [Figure 70-30-8] to

alert the operator that the exhaust gas recirculation
(EGR) system is impeded. (See EGR Impeded on Page
70-30-7.)
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing

Interruption
NA3303 Figure 70-30-9
[DEF Q] will appear in the data display [Figure 70-30-6]

to alert the operator that the DEF / AdBlue® quality is
unsatisfactory. (See Diesel Exhaust Fluid (DEF) /
AdBlue® Unsatisfactory Quality on Page 70-30-6.)
SCR System Component Tampering
Figure 70-30-7
NA3306
[DOSE] will appear in the data display [Figure 70-30-9]

to alert the operator that there has been an interruption in
DEF / AdBlue® dosing. (See Diesel Exhaust Fluid (DEF)
/ AdBlue® Dosing Interruption on Page 70-30-7.)
NA3304
[SCR] will appear in the data display [Figure 70-30-7] to

alert the operator that an SCR system component has
been tampered with. (See SCR System Component
Tampering on Page 70-30-6.)

Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality
The machine can detect unsatisfactory quality DEF / AdBlue® and will alert the operator.
ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE
Warning On DEF Q [1] Three Beeps E00524624 [3]

Three Beeps (Additional
Level 1 Flashing DEF Q [1] E00524624 [3] 25%
beep every 20 minutes)
Level 2 Flashing DEF Q [2] E00524624 [3] 50% 60%
Three Beeps (Additional Low Idle
Final Flashing DEF Q E00524624 [3]
beep every 2 minutes) Only
[3] Also code U00351600, U00351601, or U00351631 will be displayed.
NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)
SCR System Component Tampering
The machine can detect tampering with SCR system components and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE
Warning On SCR [1] Three Beeps E00524625 [3]

Level 1 Flashing SCR [1] E00524625 [3] 25%
Level 2 Flashing SCR [2] E00524625 [3] 50% 60%
Final Flashing SCR E00524625 [3]
[3] One or more ‘U’ codes could also be displayed.
50-1.)

EGR Impeded
The machine can detect an impeded exhaust gas recirculation (EGR) system and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE
Warning On EGR [1] Three Beeps E00524621 [3]

Level 1 Flashing EGR [1] E00524621 [3] 25%
Level 2 Flashing EGR [2] E00524621 [3] 50% 60%
Final Flashing EGR E00524621 [3]
[3] Also code U06522621. Additional ‘E’ codes could also be displayed.
50-1.)
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption
The machine can detect an interruption in DEF / AdBlue® dosing and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE
Warning On DOSE [1] Three Beeps E00524622 [3]

Level 1 Flashing DOSE [1] E00524622 [3] 25%
Level 2 Flashing DOSE [2] E00524622 [3] 50% 60%
Final Flashing DOSE E00524622 [3]
[3] One or more ‘U’ codes could also be displayed.
50-1.)

(CONT’D)
SCR Removal And Installation

2
WARNING
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch. 1
• Allow to cool before servicing.
W-2533-1012
P115863
Open the rear door.
Remove the rear grille and side panels. (See Removing Loosen the nut (Item 1) and remove the clamp (Item 2)
on Page 50-60-1.) [Figure 70-30-11].
Drain the engine coolant from the cooling system. (See Installation: Tighten the nut to 8 - 10 N•m (71 - 89 in-lb)
Removing And Replacing Coolant on Page 10-90-5.) torque.
NOTE: It is recommended that any clamps be
replaced with new if removed during service. Figure 70-30-12
Always use new gaskets when servicing.
Figure 70-30-10
1
1
2
1 1
P115864
Disconnect the right side heat sensor connector (Item 1)

[Figure 70-30-12].
P121249
Remove the four bolts (Item 1) and the engine cover

(Item 2) [Figure 70-30-10].

(CONT’D)
SCR Removal And Installation (Cont’d)
Figure 70-30-13 1
1
1 P120664
2
Disconnect the metering valve connector (Item 1)

[Figure 70-30-15].
P115865
Figure 70-30-16
Remove the four nuts and bolts (Item 1) from the SCR
mount bracket (Item 2) [Figure 70-30-13].
Installation: If the nuts (Item 3) [Figure 70-30-13] are

loosened torque to 8 - 10 N•m (71 - 89 in-lb) torque.
Figure 70-30-14
1
P115867
Remove the NOx sensor (Item 1) [Figure 70-30-16] and

move it aside.
NOTE: When the Downstream and Upstream NOx

sensors are both removed mark the sensors
P115866 for correct installation into the SCR or DOC.
Use anti-seize when replacing or reinstalling

Disconnect the heat sensor (Item 1) [Figure 70-30-14]. temperature and NOx sensors.
Installation: Tighten the NOx sensor to 40 - 60 N•m (30 -

44 ft-lb) torque.

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Dosing Module Removal And Installation
(CONT’D)
Figure 70-30-18
SCR Removal And Installation (Cont’d)
Figure 70-30-17
1 2
1
1
P121170
2
P115868 Remove the three bolts (Item 1) and the dosing module
(Item 2) [Figure 70-30-18].
Remove the two coolant lines (Item 1) and remove the Figure 70-30-19
DEF / AdBlue® line (Item 2) [Figure 70-30-17].
Remove the SCR from the engine.

1
P121175A
Inspect the dosing module for damage and replace if

necessary (Item 1) [Figure 70-30-19].
Replace the gasket (Item 2) [Figure 70-30-19].

(CONT’D)
1
Dosing Control Unit (DCU) Removal And Installation
1
DANGER
2
P121171
P-90328
Remove the four bolts (Item 1) and relocate the bracket
AVOID DEATH
(Item 2) [Figure 70-30-20].
Figure 70-30-21
D-1009-0409
WARNING 4

to fall and cause injury or death. P121172
W-2059-0598
Disconnect the wire harness (Item 1), the ground

Raise the lift arms and install an approved lift arm connection (Item 2) and the sensor connector (Item 3)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-21].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the tie strap (Item 4) [Figure 70-30-21].

(CONT’D)
Dosing Control Unit (DCU) Removal And Installation 2 1

(Cont’d)
Figure 70-30-22
1
1
2 P121178
1 Remove the nuts and bolts (Item 1). Remove the DCU
from the bracket (Item 2) [Figure 70-30-24].
P121173
Remove the DCU bracket mounting nuts and bolts (Item

1) [Figure 70-30-22] from the left fender.
Remove the DCU from the loader.
Figure 70-30-23
3
2
1
1
P121177
Remove the mounting bolts (Item 1) and the DCU (Item

2) from the bracket (Item 3) [Figure 70-30-23].

(CONT’D)
Supply Module Removal And Installation
DANGER 2
P121186
P-90328
Push down on the retaining clip (Item 1) and remove the
AVOID DEATH
wire harness (Item 2) [Figure 70-30-25].
Figure 70-30-26
D-1009-0409
1
WARNING 1

to fall and cause injury or death. P121185
W-2059-0598
Remove the three nuts and bolts (Item 1) [Figure 70-30-

Raise the lift arms and install an approved lift arm 26] from the left fender.
Installation: Tighten the three nuts and bolts (Item 1)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 70-30-26] to 17,0 - 21,0 N•m (12.5 - 15.5 ft-lb)
torque.

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Supply Module Filter Removal And Installation
(CONT’D)
Figure 70-30-28
Supply Module Removal And Installation (Cont’d)
Figure 70-30-27
2
2
1
P121225
P121176 Remove the filter cover (Item 1) from the supply module
(Item 2) [Figure 70-30-28].
Remove the inlet hose (Item 1), outlet hose (Item 2) and Installation: Tighten the filter cover (Item 1) [Figure 70-
the return hose (Item 3) [Figure 70-30-27] from the 30-28] to 20,0 N•m (15.0 ft-lb) torque.
supply module.
Figure 70-30-29
Remove the supply module from the loader.
P121226
Remove the equalizer element (Item 1) [Figure 70-30-

29].

(CONT’D)
Supply Module Filter Removal And Installation

(Cont’d)
Figure 70-30-30
P121228
Rotate the filter removal tool clockwise as shown (Item 1)

[Figure 70-30-32].
P121231 Figure 70-30-33
Use the filter removal tool (7267635) [Figure 70-30-30]

to aid in the removal of the filter.
Figure 70-30-31
1 P121230
Remove the filter (Item 1) [Figure 70-30-33].
Install new filter and equalizer element.

P121227
Insert the filter removal tool (Item 1) [Figure 70-30-31]

into the filter till it clips on guide.

(CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation
1
DANGER 3
P121191
P-90328 Remove the nut and bolt (Item 1) [Figure 70-30-34].

AVOID DEATH
Remove the two bolts (Item 2) and the duct panel (Item 3)
[Figure 70-30-34].
Figure 70-30-35
D-1009-0409 1
WARNING
to fall and cause injury or death. 2
W-2059-0598 P100007
Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
Remove the fan duct. (See Fan Duct Removal And



(CONT’D)

And Installation (Cont’d)
Figure 70-30-36
1 1 2
1
2
P121198A
1 Remove the nut (Item 1) and loosen the nut and bolt
(Item 2) [Figure 70-30-38].
P121193 Installation: Torque the nut to 2,8 - 3,1 N•m (25 - 27 in-
lb) torque.
Remove the three nuts and bolts (Item 1) from the fill tube Figure 70-30-39
mount bracket (Item 2) [Figure 70-30-36].
Installation: Torque the nuts and bolts (Item 1) [Figure

70-30-36] to 11 N•m (100 in-lb) torque.
Figure 70-30-37
2 1
1
3
2 P121196A
Reposition the hold down strap (Item 1) [Figure 70-30-

39].
P121194
Mark and disconnect the coolant lines (Item 1) and the

DEF / AdBlue® lines (Item 2) [Figure 70-30-37].
Disconnect the wire harness (Item 3) [Figure 70-30-37].
NOTE: Coolant lines must be hooked up correctly or

the fluid may not thaw properly and result in
an error code and engine derate.

(CONT’D)

And Installation (Cont’d)
Figure 70-30-40
1
1
P121195A
Remove the bolts (Item 1) and reposition the bracket

(Item 2)[Figure 70-30-40].
Remove the DEF / AdBlue® tank from the loader.
Installation: Tighten the bolts to 9,5 N•m (84 in-lb)

torque.

(CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor

Figure 70-30-41
1
1 2
1
2
1
P127576
Figure 70-30-44
P127571
Mark and disconnect the coolant lines (Item 1) and the

DEF / AdBlue® lines (Item 2) [Figure 70-30-41].
2
NOTE: Coolant lines must be hooked up correctly or
the fluid may not thaw properly and result in
an error code and engine derate.
Figure 70-30-42
1
P127574
Disconnect the wire harness (Item 1) from the DEF

sensor (Item 2) [Figure 70-30-44].
Remove the DEF sensor.
P127573
Remove the six screws (Item 1) [Figure 70-30-42].
NOTE: To avoid contamination, throughly clean the

tank and sensor assembly before removal.

(CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor

Figure 70-30-45
NA12776B
Remove the four nuts and bolts (Item 1) from the sensor
mount (Item 2) [Figure 70-30-45].

in-lb) torque.
Remove the DEF sensor assembly from the loader.

(CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve

1
DANGER 3
P121191
P-90328 Remove the nut and bolt (Item 1) [Figure 70-30-46].

AVOID DEATH
Remove the two bolts (Item 2) and the duct panel (Item 3)
[Figure 70-30-46].
Figure 70-30-47
D-1009-0409
WARNING
to fall and cause injury or death. 2
W-2059-0598 P100007
Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)


(CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve

Figure 70-30-48 1
2
3
3 2
1
4 P121232
Remove the bolts (Item 1) and the tie straps (Item 2)

[Figure 70-30-50].
P121223 Remove the clamp / hose (Item 3) and the coolant valve
(Item 4) [Figure 70-30-50].
Disconnect the coolant valve wire harness (Item 1) Figure 70-30-51

[Figure 70-30-48].
Figure 70-30-49
1
1 1
P121233
P121224 Note the flow arrow (Item 1) [Figure 70-30-51] during

assembly.
Remove the mounting nuts (Item 1) [Figure 70-30-49].

DIESEL OXIDATION CATALYST (DOC) Figure 70-40-2
WARNING
2
HOT SURFACES CAN CAUSE SERIOUS INJURY 1
• Do not touch.
• Allow to cool before servicing.
W-2533-1012
Open the rear door. P115876

on Page 70-30-8.) Loosen the clamp (Item 1) and the DOC mount clamps
(Item 2)[Figure 70-40-2]. Reposition the clamps.
NOTE: It is recommended that any clamps be
replaced with new if removed during service. Installation: Tighten the clamp (Item 1) [Figure 70-40-2]
to 8 - 10 N•m (71 - 89 in-lb) torque.
Always use new gaskets when servicing.
Installation: Tighten the DOC mount clamps (Item 2)
Figure 70-40-1 [Figure 70-40-2] to 11 - 13 N•m (97 - 115 in-lb) torque.
Figure 70-40-3
1
2
P115875
P115877
Disconnect the temperature sensor (Item 1) and remove
the NOx sensor (Item 2) [Figure 70-40-1].
Lift the DOC (Item 1) [Figure 70-40-3] up and out of the
NOTE: When the downstream and upstream NOx engine compartment.
sensors are both removed mark the sensors
for correct installation into the SCR or DOC.
Use anti-seize when replacing or reinstalling

temperature and NOx sensors.
Installation: Tighten the NOx sensor to 40 - 60 N•m (30 -

44 ft-lb) torque.

AIR CLEANER Figure 70-50-3
Housing Removal And Installation

1
Remove the rear grille and hood covers from the loader. 1
(See Removing on Page 50-60-1.)

1
Figure 70-50-1
P122084
1
air cleaner housing.
Figure 70-50-4
2
P122083
1
Remove the two bolts (Item 1) and set the dosing control
mount (Item 2) [Figure 70-50-1] to the side.
Figure 70-50-2
P122562
Raise the air cleaner and disconnect the hose (Item 1)

[Figure 70-50-4]. Remove the air cleaner assembly from
1 the loader.
P122115
Loosen the hose clamp (Item 1) [Figure 70-50-2] and

air cleaner housing.

ENGINE COOLING SYSTEM Figure 70-60-2
Radiator Removal And Installation
Remove the rear grille, side panels and shield. (See

1
Drain the coolant. (See Removing And Replacing
Coolant on Page 10-90-5.)

Remove the fuel cooler. (See Fuel Cooler Removal And P122120
Remove the air cleaner housing. (See Housing Removal Remove the hose (Item 1) [Figure 70-60-2].
Figure 70-60-3
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203 1
Figure 70-60-1
P122124
1
P122119

ENGINE COOLING SYSTEM (CONT'D) Figure 70-60-6
Radiator Removal And Installation (Cont'd)
Figure 70-60-4
1
1
P122111

P122113
Figure 70-60-7
Figure 70-60-5 1
1
P122107
Remove the two bolts for the coolant reservoir (Item 1)

P122112 [Figure 70-60-7].

ENGINE COOLING SYSTEM (CONT'D) Figure 70-60-10
Radiator Removal And Installation (Cont'd)
Figure 70-60-8
1
1
P122123
2
Remove the nuts (Item 1) [Figure 70-60-10].
P122114
Figure 70-60-11
Remove the coolant reservoir (Item 1) and the bracket

(Item 2) [Figure 70-60-8].
Figure 70-60-9 1
P122125
1
Attach the lifting device (Item 1) and remove the radiator/
oil cooler (Item 2) [Figure 70-60-11].
P122108
Remove the two hoses (Item 1) [Figure 70-60-9].

ENGINE COOLING SYSTEM (CONT'D) Hydraulic Reversing Fan Description
Hydraulic Fan Description This machine may be equipped with a Reversing Fan.
The hydraulic fan is used to cool the engine and hydraulic The function of the reversing fan is to clear dust and
/ hydrostatic systems. The hydraulic fan consists of a fan debris from the rear grille. This is accomplished by
and hydraulic motor that is controlled by a proportioning software control of a reversing valve in the fan motor
valve. assembly.
The proportioning valve meters the flow through the fan A reversing cycle consists of the following steps and
motor. The proportioning valve receives signals from the takes about 16 seconds total.
controller which gathers information from the engine and
1. Flow to the rotating group is ramped down.
hydraulic temperature sensors.
2. Reversing valve shifts, switching inlet and outlet ports.
NOTE: The proportioning valve is factory set and can
not be adjusted.
3. Flow to the rotating group is ramped up, spinning the
fan in reverse direction. Full fan speed is held for about 3
The fan speed is determined by the engine coolant
seconds.
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed can
4. Flow to the rotating group is ramped down.
range from 0 - 4000 rpm.
5. Reversing valve shifts back to NEUTRAL.
The hydraulic fan speed at cold engine startup will range
from 0 - 500 rpm until the engine coolant and the
6. Flow is ramped up and normal cooling is restored.
hydraulic fluid reach normal operating temperatures.
Reversing frequency varies from 30 to 5 minute intervals
depending on fluid temperature.
During normal operating temperatures the fan speed may
range from approximately 1900 - 3500 rpm.
NOTE: To protect vital systems, the fan will not
reverse when fluid temperatures are low
(below 60°F). To prevent overheating, the fan
will not reverse when fluid temperatures are
very high (engine coolant over 210°F, or
hydraulic fluid over 226°F in auto mode or
230°F in manual mode).
Fan Duct Removal And Installation
Figure 70-60-12
1 1
P100275
Unhook the rubber straps (Item 1) [Figure 70-60-12] and

remove the fan duct.

Hydraulic Fan Motor Assembly Removal And

Installation
Standard Models
1
2
IMPORTANT 4 4

parts clean. Always use caps and plugs on hoses, 3
P115778A
damage the system.
I-2003-0888
Remove the fan motor inlet hose (Item 1) and outlet hose
Figure 70-60-13 (Item 2) [Figure 70-60-14].
Remove the charge pressure tubeline (Item 3) [Figure

70-60-14].
1 Disconnect the electrical connectors (Item 4) [Figure 70-

60-14].
Figure 70-60-15
1 1
P115777
Remove the fan case drain hose (Item 1) [Figure 70-60-

13] from the back of the fan motor assembly.
2 P115776
Remove the four nuts (Item 1) [Figure 70-60-15].
Remove fan assembly (Item 2) [Figure 70-60-15].
NOTE: The fan mounting nuts are a single use part

and should be replaced whenever the nuts are
removed.

Hydraulic Fan Motor Assembly Removal And

Installation (Cont’d)
Reversing Models
Figure 70-60-16
1
3 3
1 4
P128987
Disconnect both electrical connectors (Item 1) [Figure

2 70-60-18].
Figure 70-60-19
P127582
Remove the fan motor inlet hose (Item 1), charge

pressure tubeline (Item 2) and the case drain hoses (Item
3) [Figure 70-60-16].
1 1
60-16].
Figure 70-60-17
2 P115776
Remove the four nuts (Item 1) [Figure 70-60-19].
1 NOTE: The fan mounting nuts are a single use part

and should be replaced whenever they are
removed.
Remove the hydraulic fan motor assembly (Item 2)

[Figure 70-60-19].
P128986
Remove the fan motor outlet hose (Item 1) [Figure 70-

60-17].
Cap and plug all hoses and fittings.

Hydraulic Fan Motor Removal And Installation

2
All Models 2
Figure 70-60-20
3
1
1
P115642A
Use the following procedure to remove the fan hub from

the fan motor shaft:
1
Install a bushing (Item 1) [Figure 70-60-22] in the hub to
P115692A
protect the fan motor shaft and threads during removal.
Remove the four bolts (Item 1) and the cover plate (Item Use two bolts (Item 2) to position a puller (Item 3) on the
2) [Figure 70-60-20]. bushing (Item 1) as shown [Figure 70-60-22].
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb) NOTE: If a puller is not available one can be made if
torque. needed to remove the hub from the shaft.
Figure 70-60-21 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.
Figure 70-60-23
1
2 2
P115641
1
Remove the nut (Item 1) [Figure 70-60-21] from the P115643
motor shaft.
Installation: Tighten the nut to 61 - 74 N•m (45 - 55 ft-lb) Remove and discard the two nuts and cotter pins (Item 1)
torque. [Figure 70-60-23].
Remove the two washers (Item 2) [Figure 70-60-23].
Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb)

torque.

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Disassembly And Assembly
Hydraulic Fan Motor Removal And Installation Standard Models

(Cont’d)
Figure 70-60-25
All Models (Cont’d)
Figure 70-60-24
P115320
P115644 Remove the filter (Item 1) [Figure 70-60-25].
Installation: Lubricate threads and filter O-ring prior to

Remove and discard the two bolts (Item 1) [Figure 70- installation. Tighten the filter (Item 1) [Figure 70-60-25]
60-24] then remove motor. to 37 - 45 N•m (27 - 33 ft-lb) torque.
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb) Figure 70-60-26
torque.
NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.
1
P115321A
Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-26].
Installation: Tighten the proportional valve (Item 3)

[Figure 70-60-26] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Installation: Tighten the coil mounting nut (Item 1)


Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)
Standard Models (Cont’d)
Figure 70-60-27
1
1
P-76726
2 2 Replace the O-ring (Item 1) [Figure 70-60-29].
Figure 70-60-30
P115322
Replace the O-rings (Item 1) and back-up rings (Item 2)

1
[Figure 70-60-27]. 2
3
Figure 70-60-28
P115328
1 Remove and inspect the fitting (Item 1), the spring (Item
2), and the check valve (Item 3) [Figure 70-60-30] for
damage and replace as needed.

P115323A 30] and lubricate with oil before installing.
Remove the pressure transducer (Item 1) [Figure 70-60-

28].
Installation: Tighten the pressure transducer to 10 N•m

(88 in-lb) torque.

ENGINE COOLING SYSTEM (CONT’D) Reversing Models
Hydraulic Fan Motor Disassembly And Assembly Figure 70-60-33

(Cont’d)
Standard Models (Cont’d)
Figure 70-60-31 1
1 P128972
Remove the filter (Item 1) [Figure 70-60-33].
P115329 Installation: Lubricate threads and filter O-ring prior to

installation. Tighten the filter to 37 - 45 N•m (27 - 33 ft-lb)
torque.
Remove the four bolts (Item 1) [Figure 70-60-31].
Figure 70-60-34
Installation: Tighten the bolts (Item 1) [Figure 70-60-31]
to 37 - 45 N•m (27 - 33 ft-lb) torque.
Figure 70-60-32
2
1
3
P128974
3
4
P115326 the reversing valve (Item 3) [Figure 70-60-34].
Installation: Tighten the reversing valve (Item 3) [Figure

Remove the fan motor (Item 1) from the filter adapter 70-60-34] to 41 - 50 N•m (30 - 37 ft-lb) torque.
(Item 2) [Figure 70-60-32].
Remove the seals (Item 3 and 4) [Figure 70-60-32]. [Figure 70-60-34] to 4 N•m (3 ft-lb) torque.
To continue fan motor disassembly and assembly

(Standard Model) see [Figure 70-60-44 on Page 13].


(Cont’d) 1
Reversing Models (Cont’d)
Figure 70-60-35
P128977
Replace the two O-rings (Item 1) and back-up ring (Item

2 2 2) [Figure 70-60-37].
Figure 70-60-38
P128976
Replace the four O-rings (Item 1) and six back-up rings

(Item 2) [Figure 70-60-35].
Figure 70-60-36
P115323A
3
2
Remove the pressure transducer (Item 1) [Figure 70-60-
38].
1 Installation: Tighten the pressure transducer to 10 N•m

P128975 (88 in-lb) torque.
the proportional valve (Item 3) [Figure 70-60-36].
Installation: Tighten the proportional valve (Item 3)




(Cont’d)
Figure 70-60-39
P128979
1 Remove the four bolts (Item 1) [Figure 70-60-41].

lb) torque.
P-76726
Figure 70-60-42
Replace the O-ring (Item 1) [Figure 70-60-39]. 1 2
Figure 70-60-40
1
3 2
3 4
P128980
4
Remove the fan motor (Item 1) from the filter adapter

P128978 (Item 2) [Figure 70-60-42].
Remove the seals (Item 3 and 4) [Figure 70-60-42].

Remove and inspect the fitting (Item 1), spring (Item 2)
and the check valve (Item 3) [Figure 70-60-40] for
damage and replace as needed.

40] and lubricate with oil before installing.


2
(Cont’d) 1

5
Figure 70-60-43
3
4
P115460
Remove the front cover (Item 1) from the pump housing

(Item 2) [Figure 70-60-45].
1
1 Remove the seals (Item 3 and 4) [Figure 70-60-45].

P128982
Remove the pump assemble (Item 5) [Figure 70-60-45].
Replace the O-rings on the three plugs (Item 1) [Figure Figure 70-60-46
70-60-43].
All Models
Figure 70-60-44
P115458
1 Inspect the condition of the gear faces and the mating

surfaces of the wear blocks [Figure 70-60-46]. If
P115457 excessive wear or damage is visible, replace the fan
motor.
Remove the two bolts (Item 1) and the slinger (Item 2) Inspect the bushings in the wear blocks [Figure 70-60-
[Figure 70-60-44]. 46]. If excessive wear is visible, replace the fan motor.


(Cont’d)
2
All Models (Cont’d) 1
Figure 70-60-47
1 2 3
P115460A
Install the pump assembly (Item 1) and the new seal

(Item 2) [Figure 70-60-49] in the housing.
NOTE: Orientation of the seals must be followed for

P115459 correct operation of the fan motor.
Figure 70-60-50
Remove the snap ring (Item 1), washer (Item 2) and the
3 1
Figure 70-60-48
2 1 3
2
P115476
Install a new black rubber seal (Item 1) with the channel

P115459 (Item 2) [Figure 70-60-50] of seal facing down and press
firmly into grove of casing.
Install a new washer (Item 1), snap ring (Item 2) and seal Press a new yellow plastic seal (Item 3) [Figure 70-60-
(Item 3) [Figure 70-60-48]. 50] firmly onto the black rubber seal.


(Cont’d)
1
All Models (Cont’d)
Figure 70-60-51
P115326A
Install a new seal (Item 1) [Figure 70-60-53] into the fan

motor.
1 NOTE: Orientation of the seals must be followed for

P115475A correct operation of the fan motor.
Figure 70-60-54
The ejector pads (Item 1) [Figure 70-60-51] on the
yellow plastic seal will be facing up.
NOTE: Verify that both seals are flush with the

surface of the housing. 1
2
Figure 70-60-52
P115430
Install a new black rubber seal (Item 1) with the channel

1 (Item 2) [Figure 70-60-54] of seal facing down and press
firmly into grove of casing.
P115457
Assemble the pump housing and the front cover. Install

the two bolts (Item 1) and install a new slinger (Item 2)
[Figure 70-60-52].

ENGINE COOLING SYSTEM (CONT’D) NOTE: An alternate method to verify pin installation
is to remove the fitting (Item 1) [Figure 70-60-
Hydraulic Fan Motor Disassembly And Assembly 56] opposite the proportional valve and
(Cont’d) inspect inside the cavity.
All Models (Cont’d) Install the guide pins into the fan motor and assemble the
adapter to the motor in the same direction it was
Figure 70-60-55 removed.
1 Figure 70-60-57
2
3
1
P115432
P115329
Press a new yellow plastic seal (Item 1) firmly onto the
black rubber seal (Item 2) [Figure 70-60-55].
Assemble the fan motor and the filter adapter. Install the
The ejector pads (Item 3) [Figure 70-60-55] on the four bolts (Item 1) [Figure 70-60-57].
yellow plastic seal will be facing up.
Installation: Tighten the four bolts (Item 1) [Figure 70-
NOTE: Verify that both seals are flush with the 60-57] to 37 - 45 N•m (27 - 33 ft-lb) torque.
surface of the housing.
Figure 70-60-56
P127815
Ensure the anti-cavitation retaining pin (Item 1) [Figure

70-60-56] remains installed in the new fan adapter. If the
pin was ejected or was not fully seated then verify the ball
is in place and fully seat the pin prior to assembly to
prevent reduced cooling fan performance.

ENGINE COOLING SYSTEM (CONT'D) Water Pump Removal And Installation
Blower Housing Removal And Installation Drain the fluid from the radiator. (See Removing And
Replacing Coolant on Page 10-90-5.)
Remove the alternator belt. (See Belt Replacement on

IMPORTANT Page 60-30-1.)
Figure 70-60-59
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888
Remove the air conditioning condenser (if equipped). 1

Remove the radiator. (See Radiator Removal And

Figure 70-60-58
P121038
1
Remove the four bolts (Item 1) from the water pump
3 pulley (Item 2) [Figure 70-60-59].
Remove the water pump pulley (Item 2) [Figure 70-60-

59].
Disconnect the coolant hoses.
Figure 70-60-60
2
P122126
Pull up and remove the blower housing (Item 1) [Figure

70-60-58] from the loader.
NOTE: A seal (Item 2) [Figure 70-60-58] has been 2

installed between the radiator and the radiator
mount to improve debris control in the
cooling package area.
NOTE: Locate seal ends along front edge of shroud 1

(Item 3) [Figure 70-60-58]. P121039
Remove the four bolts (Item 1) and the water pump (Item
2) [Figure 70-60-60].
Installation: Apply Loctite® 272 to the water pump

mounting bolts. Torque the bolts to 22 N•m (16 ft-lb).

ENGINE COOLING SYSTEM (CONT’D) Thermostat - Testing
Thermostat Housing Removal And Installation Figure 70-60-63
Figure 70-60-61
P121042
P121040
Place the thermostat and a thermometer in a container of
water. Gradually heat the water and inspect the operation
Reposition the clamps (Item 1) and remove the hose of the thermostat [Figure 70-60-63].
(Item 2) [Figure 70-60-61].
Thermostat valve 0,3 mm (0.01 in)
Figure 70-60-62 Opening temperature @ 82° (180°F)
Thermostat valve 8 mm (0.32 in)
4 Full Open @ 97°C (207°F)
P121041
Reposition the clamps (Item 1) and remove the hose

(Item 2) [Figure 70-60-62].
Remove the four bolts (Item 3) and the thermostat

housing (Item 4) [Figure 70-60-62].
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

LUBRICATION SYSTEM
Description
The oil pump delivers oil from the oil pan through the oil cooler and filter, to the main oil passage in the cylinder block.
From the cylinder block, oil is delivered to the piston cooling jets, crankshaft main bearings, connecting rod bearings,
camshaft bearings, rocker arms and turbocharger. Oil also is delivered to the idler gear located at the front of the engine.
Figure 70-70-1
P114327A
1. Oil Pump 8. Idler Gear
2. Relief Valve 9. Piston
3. Bypass Valve 10. Crankshaft Main Bearing
4. Oil Cooler 11. Connecting Rod Bearing
5. Oil Filter 12. Camshaft Bearing
6. Bypass Valve 13. Rocker Arm
7. Piston Cooling Jet 14. Turbocharger

LUBRICATION SYSTEM (CONT’D) Figure 70-70-4
Oil Pan Removal And Installation

1
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
70-10-15.)
Drain the engine oil. (See Removing And Replacing Oil

And Filter on Page 10-110-2.)
Figure 70-70-2 2
P115953
Install the oil pan (Item 2) [Figure 70-70-4].
NOTE: Assemble the adhesive-applied parts within

ten minutes.
2
Tighten the bolts (Item 1) [Figure 70-70-4] from inside
toward outside and clockwise to the specified torque.
P115953 Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.
Remove the oil pan mounting bolts (Item 1) and the oil
pan (Item 2) [Figure 70-70-2].
Unscrew the bolts (Item 1) [Figure 70-70-2] from outside

toward inside and counterclockwise.
Figure 70-70-3
P121045
Apply Loctite® 5902 to the assembly surface of the oil

pan [Figure 70-70-3].
Confirm that the liquid gasket coating surface is free of

water, dust and oil in order to maintain sealing effect.

LUBRICATION SYSTEM (CONT’D)
Oil Pump Removal And Installation
Remove the flywheel housing cover. (See Housing

Figure 70-70-5
P121044
Remove the four bolts (Item 1) and the oil pump (Item 2)
[Figure 70-70-5].
Installation: Align the oil pump O-rings with the engine

oil inlet and outlet. Torque the bolts to 22 N•m (16 ft-lb).
Figure 70-70-6
1
1
P112948A
Remove the O-rings (Item 1) [Figure 70-70-6].
NOTE: The oil pump is not serviceable. When

installing the oil pump, inspect the pump gear
for correct backlash. (See Gear Backlash on
Page 70-120-1.)

LUBRICATION SYSTEM (CONT’D) Oil Suction Tube Removal And Installation
Oil Pump Relief Valve Description Remove the oil pan. (See Oil Pan Removal And
The oil pump relief valve is set to 496 kPa (4,9 bar) (72
psi). Figure 70-70-7
2
3
4
P115964
Remove the oil delivery tube (Item 2), oil suction tube
(Item 3) and the O-rings (Item 4) [Figure 70-70-7].

LUBRICATION SYSTEM (CONT’D) Oil Filter Head Removal And Installation
Oil Cooler Removal And Installation Remove the oil cooler. (See Oil Cooler Removal And
Drain the engine oil. (See Removing And Replacing Oil
And Filter on Page 10-110-2.) Figure 70-70-10
Drain the coolant. (See Removing And Replacing

Coolant on Page 10-90-5.)
Figure 70-70-8
1
1
1 1
P121057A
1 1 Remove the mounting bolts (Item 1) [Figure 70-70-10]

and the filter head.
P121057
Remove the mounting bolts (Item 1) [Figure 70-70-8]. Figure 70-70-11
Remove the cooler from the filter head.
Figure 70-70-9
1
1
1
1
P112893A

P121057A

LUBRICATION SYSTEM (CONT’D)
Oil Cooler Bypass Description
The oil cooler bypass is set to 145 kPa (1,4 bar) (21 psi).

FUEL SYSTEM
Description
Figure 70-80-1
8 7
3
2
9
NA9882
The fuel is drawn from the fuel tank (Item 1) to the fuel filter (Item 2). From the filter, fuel is drawn to the transfer pump /
high pressure pump (Item 3). Fuel at as high of a pressure as 180000 kPa (1800 bar) (26,000 psi) is delivered from the
fuel pump to the common rail (Item 4). From the rail, fuel is delivered to the fuel injector (Item 5). Unused fuel from the
injector flows back to the pump (Item 3). Unused fuel from the pump will flow to the fuel bypass valve (Item 6) or the fuel
recirculation valve (earlier version) (Item 7) or (later version) (Item 8). When the fuel is colder than 27°C (81°F), the valve
will be open. When the valve is open, fuel will flow through the valve and back to the inlet side of the fuel filter (Item 2).
When the fuel is warmer than 27°C (81°F), the valve will be closed. When the valve is closed, fuel will flow to the fuel
cooler (Item 9) [Figure 70-80-1] and back to the fuel tank.

High Pressure Pump Removal And Installation
WARNING 2
1

not use your bare hand. Wear safety goggles. If fluid 3
P121059A
W-2072-0807
Remove the bolt (Item 1), the dipstick and dipstick tube
NOTE: Allow 5 minutes after the engine is shut down (Item 2) [Figure 70-80-3].
for the fuel pressure to bleed down.
Disconnect the wire harness connectors (Item 3) [Figure
Remove the oil filter head. (See Oil Filter Head Removal 70-80-3].
Installation: Replace the O-ring on the dipstick tube and
Remove the intake air heater. (See Intake Air Heater tighten the bolt to 9,8 N•m (7.2 ft-lb) torque.
Figure 70-80-4
Remove the intake stake. (See Intake Air Heater Tube
2
Figure 70-80-2
1
3
1
P121064
1 Remove the two fuel return lines (Item 1) [Figure 70-80-

P115923A 4].
Remove the bolt (Item 2) and the fuel injection line (Item
Remove the fuel inlet line (Item 1) and the fuel return line 3) [Figure 70-80-4].
(Item 2) [Figure 70-80-2] from the high pressure pump.
Install caps and plugs. Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.
Installation: Tighten the fuel injection nuts to 29,4 N•m

(21.7 ft-lb) torque.
NOTE: Both the high pressure fuel lines and return

fuel line are a one time use line. Replace the
fuel lines with new fuel lines after removal.

FUEL SYSTEM (CONT’D) High Pressure Pump Drive Gear Removal And
Installation
High Pressure Pump Removal And Installation
(Cont’d) Figure 70-80-6
Figure 70-80-5
1
3
2
2
P115956
1
P115955
Remove the nut (Item 1) and the drive gear (Item 2) from
the high pressure pump drive gear (Item 3) [Figure 70-
Remove the three nuts (Item 1) and the high pressure 80-6].
pump (Item 2) [Figure 70-80-5].
Installation: Tighten the nut to 58,8 - 68,6 N•m (43.4 -
Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque. 50.6 ft-lb) torque.
Note: Timing of the pump is not critical. If the

gearcase cover is removed, time the pump as
shown. (See Gear Timing on Page 70-120-2.) If
the gearcase cover is installed, timing of the
pump is not needed.

FUEL SYSTEM (CONT’D) Fuel Bypass Valve Removal And Installation
Fuel Cooler Removal And Installation Figure 70-80-8
Remove the rear grille from the loader. (See Removing

on Page 50-60-1.)
Figure 70-80-7 2
1 1
3
2
P121124
1
1 Remove the clamps (Item 1) [Figure 70-80-8] and fuel
lines.
P121216A
Remove the bolt (Item 2) [Figure 70-80-8].
Remove the fuel lines (Item 1), bolt (Item 2) and the fuel Remove the bypass valve.
cooler (Item 3) [Figure 70-80-7].
Installation: Install the bypass valve according to the
flow arrow printed on the valve.
Fuel Temperature Sensor Removal And Installation
Figure 70-80-9
P127639
Remove the electrical connector (Item 1) and the fuel

temperature sensor (Item 2) [Figure 70-80-9].
Installation: Tighten the fuel temperature sensor to 8,8 -

11,8 N•m (78 - 104 in-lb) torque.

FUEL SYSTEM (CONT’D) Later Version
Fuel Recirculation Valve Removal And Installation Figure 70-80-12
Earlier Version
2
Figure 70-80-10
2
1
P121594
Remove the bolts (Item 1) and reposition the fuel filter

P121594 (Item 2) [Figure 70-80-12].
Figure 70-80-13
Remove the bolts (Item 1) and reposition the fuel filter
(Item 2) [Figure 70-80-10].
1
2
Figure 70-80-11
2
2 4
4
2
3
3 1 P121605
Pull out the FRV bracket (Item 1) and remove the clamps
P121638 and fuel lines (Item 2). Remove the fuel connector (Item
3) and the tie strap (Item 4) [Figure 70-80-13].
Pull out the FRV bracket (Item 1) and remove the clamps Remove the fuel recirculation valve.
and fuel lines (Item 2). Remove the fuel connector (Item
3) and the bolts and nuts (Item 4) [Figure 70-80-11]. Installation: Use the procedure on page 70-80-9 to
remove air from the fuel system.
Remove the fuel recirculation valve.
Installation: Use the procedure on page 70-80-9 to

remove air from the fuel system.

Fuel Rail Assembly Removal And Installation
WARNING 2
4 1
3
P121066
W-2072-0807
Remove the fuel return line (Item 1) and disconnect the

NOTE: Allow engine to cool completely. fuel rail pressure sensor (Item 2) [Figure 70-80-15].
Remove the SCR. (See SCR Removal And Installation Remove the bolt (Item 3) and the fuel injection line (Item
on Page 70-30-8.). 4) [Figure 70-80-15].
Remove the intake air heater. (See Intake Air Heater Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.
Remove the intake stake. (See Intake Air Heater Tube (21.7 ft-lb) torque.
Figure 70-80-16
Figure 70-80-14
1
1 1 1
1 1
P121067
P121065
Remove the fuel rail assembly mounting bolts (Item 1)

Remove the injection lines (Item 1) [Figure 70-80-14]. and the fuel rail assembly (Item 2) [Figure 70-80-16].
Installation: Tighten the fuel injection nuts to 29,4 N•m Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.
(21.7 ft-lb) torque.
NOTE: Take care not to damage the fuel rail during
removal and installation.

fuel line are a one time use line. Replace the

FUEL SYSTEM (CONT'D) Figure 70-80-18
Fuel Injector Removal And Installation

3 2
WARNING
penetrate skin or eyes, causing serious injury or 1
1
death. Fluid leaks under pressure may not be visible. 1
Use a piece of cardboard or wood to find leaks. Do 1
P115882
W-2072-0807
Remove the fuel injection lines (Item 1) [Figure 70-80-

NOTE: When replacing any of the injectors the ID 18].
code must be written to the ECU using the
Bobcat Engine Analyzer Diagnostic Tool. Remove the injector wire harness (Item 2) and return fuel
line (Item 3) [Figure 70-80-18].
NOTE: Allow engine to cool completely.
Remove the SCR. (See SCR Removal And Installation (21.7 ft-lb) torque.
on Page 70-30-8.).
Figure 70-80-17 fuel line are a one time use line. Replace the
2
1 Figure 70-80-19
1
2
3
1 P114430
Push the lock tabs (Item 1) in to release the hose (Item 2) P115959
from the valve cover fitting (Item 3) [Figure 70-80-17]
and remove the hose.
Remove the bolts (Item 1) and the valve cover (Item 2)
[Figure 70-80-19].
Installation: Tighten the bolts to 7,8 N•m (5.8 ft-lb)

torque.

FUEL SYSTEM (CONT'D) Figure 70-80-22
Fuel Injector Removal And Installation (Cont’d)
Figure 70-80-20
1
1
P112930A
Remove the injector (Item 1) [Figure 70-80-22].

P112928
Figure 70-80-23
Remove the seal (Item 1) [Figure 70-80-20] from the

cover.
Figure 70-80-21
1 1
2
P121444
2
Remove the sealing washer (Item 1) from the bottom of
the injector (Item 2) [Figure 70-80-23].
P112929A
NOTE: The sealing washers must be replaced with
new sealing washers when installing the
Remove the bolt (Item 1) and the injector retainer (Item 2) injectors.
[Figure 70-80-21].
Installation: If equipped with a fuel recirculation valve,
Installation: Tighten the bolt to 39,2 - 46,1 N•m (29 - 34 (See Removing Air From The Fuel System on Page 70-
ft-lb) torque. 80-11.) to remove air from the fuel system.

Injector Coding
NOTE: When replacing any of the injectors the ID 2

code must be written to the ECU using the
Bobcat Engine Analyzer Diagnostic Tool.
1
Each injector has there own Identification code to inform
the ECU of the injectors performance (compensating for
slight mechanical differences).
Connect the Bobcat Engine Analyzer Diagnostic Tool.
Figure 70-80-24
P127161
The injector ID code (Item 1) is written on the top of the

injector (Item 2) [Figure 70-80-26].
2
Figure 70-80-27
1
1
P127162
From the menu, click “Part Replacement” button (Item 1),

then click C3I Injector Coding “Apply” button (Item 2) 2
[Figure 70-80-24].
Figure 70-80-25 P127160
Write the ID code(s) (Item 1) [Figure 70-80-27] to the

correct cylinder box for the injector.
NOTE: There are no letters i or o in the injector code,

the numbers 1 and 0 are used for the code.
Click on “Write” button (Item 2) [Figure 70-80-27] to save

the code(s) to the ECU.
P127160
The current injector codes that are stored in the ECU will
be displayed [Figure 70-80-25].

FUEL SYSTEM (CONT’D)
Injector Coding (Cont’d)
Figure 70-80-28
2
1
P127162
From the menu, click “Part Replacement” button (Item 1),

then click Injector “Apply” button (Item 2) [Figure 70-80-
28].
Start the engine and let the machine run at full throttle for
ten minutes to allow ECU learning.

Removing Air From The Fuel System WARNING

After removing or replacing fuel system components
(high pressure pump, fuel rail, injectors or fuel cooler) the AVOID INJURY OR DEATH
following procedure must be used to remove air from the Always clean up spilled fuel or oil. Keep heat, flames,
fuel system if equipped with a fuel recirculation valve. sparks or lighted tobacco away from fuel and oil.
NOTE: The same procedure can be used for either explosion or fire.
the earlier or later fuel recirculation valve. W-2103-0508
Figure 70-80-30
WARNING
enters skin or eyes, get immediate medical attention 1
W-2072-0807
Figure 70-80-29
NA11009SA
2
P121155A Pinch off the indicated fuel hose (Item 1) [Figure 70-80-
30] using a locking hose pinching plier or similar tool.
Open the air vent plug (Item 1) [Figure 70-80-29] on the
Squeeze the hand pump (primer bulb) (Item 2) [Figure
70-80-30] twenty times or until the primer bulb is difficult
to squeeze.
Start the machine and let machine idle for two minutes.
bubbles.
Shut the machine off and remove the pinching plier from
the fuel hose (Item 1) [Figure 70-80-30].

Removing Air From The Fuel System (Cont’d)
Figure 70-80-31
P121155A
Open the air vent plug (Item 1) [Figure 70-80-31] on the


bubbles.

CYLINDER HEAD Figure 70-90-3
Intake Air Heater Removal And Installation 1

5
2
Figure 70-90-1
3
P115996
2
Remove the bolt (Item 1) and the boost pressure sensor

P115922 (Item 2) [Figure 70-90-3].
Remove the four retaining bolts (Item 3) and the air

Disconnect the two wires (Item 1), remove the wire mount heater (Item 4) and gasket (Item 5) [Figure 70-90-3].
bolt (Item 2) and reposition the air heater wire (Item 3)
[Figure 70-90-1]. Installation: Tighten the retaining bolts to 22 N•m (16 ft-
lb) torque.
Figure 70-90-2
Installation: Tighten the boost pressure sensor bolt to
2 9,8 N•m (7.2 ft-lb) torque.
P121056
Disconnect the boost pressure sensor connector (Item 1)

and remove the clamp / hose (Item 2) [Figure 70-90-2].

CYLINDER HEAD (CONT’D)
Intake Air Heater Tube Removal And Installation
Remove the intake air heater. (See Intake Air Heater

Figure 70-90-4
6 5
3
3
2
4
1 P115997
Remove the EGR pipe bolts (Item 1) and the EGR pipe
(Item 2) and gaskets (Item 3) [Figure 70-90-4].
Remove the retaining bolts (Item 4) and the intake air

heater tube (Item 5) and gasket (Item 6) [Figure 70-90-
4].
Installation: Tighten the retaining and EGR bolts to 22


CYLINDER HEAD (CONT’D) Figure 70-90-7
Valve Clearance Adjustment 2
NOTE: Valve clearance must be inspected and

adjusted when engine is cold.

on Page 70-30-8.).
1 1 1
Remove the DOC. (See Removal And Installation on
Page 70-40-1.)
Figure 70-90-5
2 P115881
1
Remove the three wire harness holders (Item 1) from the

valve cover (Item 2) [Figure 70-90-7].
Figure 70-90-8
3
2 1
1 P114430
Push the lock tabs (Item 1) in to release the hose (Item

2)from the valve cover fitting (Item 3) [Figure 70-90-5]
and remove the hose. 2
Figure 70-90-6 1
P115882
2 2 2
2
Remove the bolts (Item 1) and the valve covers (Item 2)
[Figure 70-90-8] from the engine.
1 1 1
1
P115880
Remove the four heat shield bolts (Item 1) and the

mounting brackets (Item 2) [Figure 70-90-6].

Valve Clearance Adjustment (Cont’d) 2
Figure 70-90-9
1 1
2
P114410A
Loosen the nut (Item 1) and adjust the screw (Item

P114409A 2) [Figure 70-90-11] to obtain the correct clearance.
Installation: Tighten the nut to 15 N•m (11 ft-lb) torque.

Measure the valve clearance between the rocker arm
(Item 1) and the valve bridge head (Item 2) [Figure 70-
90-9].
The intake valve clearance is 0,4 mm and the exhaust

valve clearance is 0,45 mm.
Figure 70-90-10
Cylinder
#1 #2 #3 #4
Number
Exhaust
Exhaust
Exhaust
Exhaust
Intake
Intake
Intake
Intake
Rotation
Angle
TDC (#1
Cylinder) • • • •
360°
Rotation • • • •
To adjust the valve clearance reference the chart [Figure

70-90-10].
With the #1 cylinder set at compression top dead center

set the valves on #1 cylinder intake and exhaust. #2
cylinder intake valve and #3 cylinder exhaust valve.
Rotate engine 360° to make #4 cylinder at top dead

center. Adjust the #2 cylinder exhaust valve, #3 cylinder
intake valve and #4 cylinder intake and exhaust valve.

Cylinder Head Removal And Installation

1 3 1
1
Remove the engine. (See Engine Removal And
Remove the alternator. (See Removal And Installation on

Page 60-30-5.)
Remove the fuel injectors. (See Fuel Injector Removal 2

1 1
And Installation on Page 70-80-7.) 1
Remove the intake stake. (See Intake Air Heater Tube

P121106
Remove the oil filter head. (See Oil Filter Head Removal
Remove the bolts (Item 1) and the intake manifold (Item
Remove the fuel rail assembly. (See Fuel Rail Assembly 2) [Figure 70-90-13].
Remove the EGR. (See Removal And Installation on
Page 70-150-2.) Remove the intake temperature sensor (Item 3) [Figure
70-90-13].
Remove the thermostat housing. (See Thermostat
Housing Removal And Installation on Page 70-60-18.) Installation: Tighten the sensor to 29,4 N•m (21.7 ft-lb)
torque.
Figure 70-90-12
Figure 70-90-14
1
3 1
1 2 1
3 2
P121105
P115971
Remove the bolts (Item 1) and the exhaust manifold (Item

2) [Figure 70-90-12]. Remove the bolts (Item 1) [Figure 70-90-14].
Installation: Tighten the bolts to 30,4 N•m (22.4 ft-lb) Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
torque. torque.
Remove the turbocharger exhaust gas temperature Loosen the bolts (Item 2) and remove the heat shield
sensor (Item 3) [Figure 70-90-12]. (Item 3) [Figure 70-90-14].
Installation: Tighten the sensor to 44,1 N•m (32.5 ft-lb)

torque.

Cylinder Head Removal And Installation (Cont’d)

1
Figure 70-90-15
2
1
3 P114447A
Remove the seal (Item 1) [Figure 70-90-17] from the

P115973 cover.
Figure 70-90-18
Remove the bolts (Item 1) and the gasket (Item 2)
[Figure 70-90-15].
The mark of TOP (Item 3) [Figure 70-90-15] should be 2 1

facing upward when installed.
Figure 70-90-16
1 P112935
Remove the bolts (Item 1) and the rocker arm assembly

(Item 2) [Figure 70-90-18].
Be sure to adjust the valve clearance. (See Valve

P115988 Clearance Adjustment on Page 70-90-3.)
Loosen the bolts (Item 1) and remove the valve cover

(Item 2) [Figure 70-90-16].
Installation: Tighten the bolts to 7 - 8 N•m (5 - 6 ft-lb)

torque.

Cylinder Head Removal And Installation (Cont’d)
Figure 70-90-19
4
12 5 13
1 16 8 1
9 17
15 7 2 10 18
11 3 6 14
2
P114455
Installation: Tighten the head bolts in the sequence

P112936 shown [Figure 70-90-21].
Initial torque 44 N•m (33 ft-lb).

Remove the push rods (Item 1) and valve spring bridges
(Item 2) [Figure 70-90-19]. 2nd torque 90°.
Figure 70-90-20 3rd torque 90°.
NOTE: Before installing the cylinder head, piston

step height must be measured to determine
2 the correct head gasket thickness required.
1
Figure 70-90-22
P112937
Remove the head bolts (Item 1), cylinder head (Item

2)[Figure 70-90-20] and gasket.
1
P114045
Rotate the crankshaft until the piston is at top dead

center. Measure the piston step height in the areas
shown (Item 1) [Figure 70-90-22].
Repeat the procedure for all four pistons

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation (Cont’d) Figure 70-90-24
Figure 70-90-23
4
3
2
1
P114035
P114448
Compress the valve spring and remove the retainers
(Item 1). Release the valve spring compression tool.
Select the correct class head gasket. The class of gasket Remove the spring seat (Item 2), spring (Item 3) and
is stamped in the gasket where shown (Item 1) [Figure valve stem seals (Item 4) [Figure 70-90-24].
70-90-23].
Figure 70-90-25
Gasket Class and Average Piston Step
Thickness Height
Class A 0,9 mm 0,24 - 0,33 mm
(0.0354 in) (0.0095 - 0.0130in)
Class B 1,0 mm 0,33 - 0,43 mm
(0.0394 in) (0.0130 - 0.0169 in)
Class C 1,1 mm 0,43 - 0,52 mm
(0.0433 in) (0.0169 - 0.0205 in)
P114036
Remove the valves (Item 1) [Figure 70-90-25] from the

block.

Cylinder Head Inspection
Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
70-90-8.)
Thoroughly clean the cylinder head surface.
Figure 70-90-26
1 P115981
Put the straight edge on the cylinder head’s four sides

and two diagonal as shown in figure [Figure 70-90-27].
2
The maximum distortion of the head surface is ± 0,05
mm in 100 mm (± 0.002 inches in 4.0 inches), If the
measurement exceeds the specification, replace the
cylinder head.
P115982
Repeat the procedure on the intake and exhaust surface
of the head.
Put a straight edge (Item 1) [Figure 70-90-26] on the
cylinder head.
NOTE: Do not put the straight edge across

combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-90-26] between

the straight edge and the surface of the cylinder head.

Cylinder Head Top Clearance
Thoroughly clean the cylinder head surface.
Figure 70-90-28
1
1
P-85173
1
Remove the solder and measure it [Figure 70-90-29].
1
Top Clearance
P114045 1,69 - 2,52 mm
Intake Valve
(0.0665 - 0.0992 in)
1,54 - 2,33 mm
Place four pieces of 3 mm (0.118 in) solder on the piston Exhaust Valve
(0.0606 - 0.0917 in)
where shown (Item 1) [Figure 70-90-28].
Turn the piston to B.D.C.
Install the cylinder head and bolts. Torque the bolts in the
correct sequence.
Rotate the crankshaft.

CYLINDER HEAD (CONT'D) Valve Stem Height
Valve Step Height Figure 70-90-31
Figure 70-90-30
P115984
P115985
Measure the valve stem height from the valve to the
cylinder head as shown [Figure 70-90-31].
Measure the valve at four points as shown [Figure 70-
90-30]. Valve Stem Height
20,8 - 21,3 mm
Valve Step Height Intake Valve
(0.8189 - 0.8386 in)
0,6 - 0,9 mm 20,8 - 21,3 mm
Intake Valve Exhaust Valve
(0.0236 - 0.0354 in) (0.8189 - 0.8386 in)
0,6 - 0,9 mm
Exhaust Valve
(0.0236 - 0.0354 in)

CYLINDER HEAD (CONT’D) Valve
Valve Guide Figure 70-90-33
Figure 70-90-32
P114056
P114042
Measure the overall length of the valve [Figure 70-90-
33].
Measure the valve guide (Item 1) [Figure 70-90-32]
inside diameter at three different depths. Valve Length
Intake Valve 108,3 mm (4.2638 in)
7,0 - 7,015 mm
Valve Guide ID Exhaust Valve 110,3 mm (4.3425 in)
(0.2756 - 0.2762 in)
Measure the outside diameter of the valve stem [Figure
Measure the valve guide length.
70-90-33].
43,4 - 43,6 mm
Valve Guide Length 6,97 ± 0,007 mm
(1,7087 - 1,7165 in) Valve Stem O.D.
(0.2744 ± 0.0003 in)

CYLINDER HEAD (CONT’D)
Valve Spring
Figure 70-90-34
B-3680
Measure the length of the valve spring. If the

measurement is less than the allowable limit, replace the
spring [Figure 70-90-34].
Free Length 55.23 mm (2.1744 in)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-90-34].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 1,8 mm (0.0708 in)

CYLINDER HEAD (CONT'D) Figure 70-90-37
Rocker Arm Shaft Disassembly And Assembly
Figure 70-90-35
1 1
P114011
2
Remove the mount (Item 1) [Figure 70-90-37]. Continue
P114009 to remove the rocker arms, springs and mounts.
Figure 70-90-38
Remove the bolt (Item 1) and mount (Item 2) [Figure 70-
90-35].
Figure 70-90-36
P114012
1
Remove the bolt (Item 1) [Figure 70-90-38] and the

P114010 mount from the shaft.
Remove the rocker arm (Item 1), spring (Item 2) and

rocker arm (Item 3) [Figure 70-90-36].

CYLINDER HEAD (CONT'D) Push Rod Inspection
Rocker Arm Shaft Inspection Figure 70-90-41
Figure 70-90-39
1
1 P-76926
P114054
Place the push rod on V blocks and measure the
alignment [Figure 70-90-41].
Inspect the wear points (Item 1) [Figure 70-90-39] for
wear and damage. Push Rod Alignment 0,5 mm (0.0207 in)
Measure the ID of the rocker arms (Item 2) [Figure 70-
90-39].
Rocker Arm ID 16,03 mm (0.6311 in)
Figure 70-90-40
P114055
Inspect the shaft (Item 1) [Figure 70-90-40] for wear and

damage.
Measure the OD of the shaft.
Rocker Arm Shaft OD 16,15 mm (0.6358 in)

CRANKSHAFT AND PISTONS Figure 70-100-2
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 70-90-5.) 1
Remove the top edge from the cylinder bore with a ridge 2
reamer.
Remove the oil pan and oil pump strainer. (See Oil Pan
Figure 70-100-1
P112954
Remove the cap (Item 1) and bearing (Item 2) [Figure

70-100-2].
1 Figure 70-100-3
P112953
Remove the connecting rod bolts (Item 1) [Figure 70-

100-1].
Installation: Tighten the bolts to an initial torque of 29,4

N•m (21.7 ft-lb). Tighten the bolts an additional 90°. P112955
NOTE: The rod bolts are a one time use bolt. Use new
bolts when installing the connecting rods. Remove the piston / connecting rod (Item 1) [Figure 70-
100-3] from the cylinder block.
NOTE: Install the piston / connecting rod assembly in

to the bore it was removed from.
Repeat the procedure to remove the remaining piston /

connecting rod assemblies.

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-6
Piston And Connecting Rod Inspection
Figure 70-100-4
1
2
2
P114005
1 Remove the connecting rod (Item 1) [Figure 70-100-6]

P114003 from the piston.
Installation: The mark (Item 2) on the piston and

Remove the bearings (Item 1) [Figure 70-100-4] from the connecting rod must be on the same side. When
rod and cap. installing the piston in the cylinder block, the marks (Item
2) [Figure 70-100-6] go the flywheel side of the engine.
NOTE: The yellow code 1,497 - 1,502 mm (0.0589 -
0.0591 in) bearing is the only service bearing Figure 70-100-7
available.
1
The rod and cap are a fracture design. The cap can only
fit the rod in one direction and is not interchangeable with
other rods.
Figure 70-100-5
1 1 1
P114007
Remove the rings (Item 1) [Figure 70-100-7].
P114004
Remove the snap ring (Item 1) and wrist pin (Item 2)

[Figure 70-100-5].

Piston And Connecting Rod Inspection (Cont’d)
Figure 70-100-8
1
P114052
Remove the carbon from the ring grooves. Measure the

P114008 clearance between the ring and groove with a feeler
gauge [Figure 70-100-10].
Installation: Install the rings with the R (Item 1) [Figure Top Ring 0,083 - 0,137 mm
70-100-8] towards the top of the piston. Install the rings (0.0033 - 0.0054 in)
with the ring gap 120° apart.
Second Ring 0,070 - 0,110 mm
(0.0028 - 0.0043 in)
Figure 70-100-9
Oil Ring 0,03 - 0,07 mm
(0.0012 - 0.0028 in)
P114053
Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
70-100-9].
Top Ring Gap 0,2 - 0,4 mm

(0.0079 - 0.0157 in)
Second Ring End Gap 0,55 - 0,70 mm
(0.0217 - 0.0276 in)
Oil Ring End Gap 0,2 - 0,4 mm
(0.0079 - 0.0157 in)

Timing Wheel Removal And Installation
Figure 70-100-11
2 1
P121018
Remove the bolts (Item 1) and the front oil seal holder
P121016 (Item 2) [Figure 70-100-13].
Installation: Apply Loctite® 5902 to the assembly

Remove the bolt (Item 1) and crankshaft pulley (Item 2) surface of the front seal holder.
[Figure 70-100-11].
Installation: Apply Loctite® 587 to the crankshaft pulley
bolt. Figure 70-100-14
Installation: Tighten the bolt to 255 N•m (188 ft-lb)

torque.
1
Figure 70-100-12
2
3
2
P121019
Use front seal installer (7031369) (Item 1) to install a new

front oil seal (Item 2) into the front oil seal holder (Item 3)
P121017 [Figure 70-100-14].
Remove the front oil seal (Item 1) from the front oil seal
holder (Item 2) [Figure 70-100-12].

CRANKSHAFT AND PISTONS (CONT’D)
Timing Wheel Removal And Installation (Cont’d)
Figure 70-100-15
P121023
Remove the bolt (Item 1) and the crank position sensor

(Item 2) [Figure 70-100-15].
Figure 70-100-16
2
P121024
Remove the key (Item 1) and the timing wheel (Item 2)

[Figure 70-100-16].

Crankshaft Removal And Installation
Figure 70-100-17
1
2 1
P112957A
1
Remove the crankcase (Item 1) [Figure 70-100-19].
P112956A
Installation: Apply Loctite® 5902 on the sealing edge of
the crankcase.
Remove the main bearing bolts (Item 1) and crankcase
bolts (Item 2) [Figure 70-100-17]. Figure 70-100-20
Figure 70-100-18
1
26 22 18 14 11 15 19 23
8 4 1 5 9
7 3 2 6 10
25 21 17 13 12 16 20 24
P112958A
P114438
Remove the crankshaft (Item 1) [Figure 70-100-20].
Installation: Tighten the main bearing bolts (Item 1 - 10)

[Figure 70-100-18] to an initial torque of 54 N•m (40 ft-lb)
torque in the order shown. After the initial torque, tighten
the main bearing bolts an additional 90°. Tighten the
main bearing bolts a second time by an additional 90°.
Tighten the crankcase bolts (Item 11 - 26) 22 N•m (16 ft-

lb) torque in the order shown.

Crankshaft Removal And Installation (Cont’d)
Figure 70-100-21
1 1
P114024
Remove the bolts / check valves (Item 1) [Figure 70-100-

P114018A 23] and remove the oilers.

Remove the crankshaft bearings (Item 1) [Figure 70-
100-21]. Figure 70-100-24
Installation: Install the bearing with the groove in the

cylinder block. The non-grooved bearing is installed in the
crankcase.
Figure 70-100-22
1
2
1
P114026
Remove the bolt / check valve assembly (Item 1) from the

oiler (Item 2) [Figure 70-100-24].
1
B114019
Remove the thrust bearings (Item 1) [Figure 70-100-22].

Cylinder Block Inspection
Figure 70-100-25
P115977
Measure the cylinder block bore [Figure 70-100-27].

P115974
Figure 70-100-28
With the bearings and crankcase installed, measure the

main journal bearings [Figure 70-100-25].
Figure 70-100-26
P-37163
Measure the bore at three different depths and at two

points 90° apart [Figure 70-100-28].
P115976A
Cylinder Block Bore 97,990 - 98,010 mm
(3.8579 - 3.8587 in)
Measure each bearing at three different points [Figure
70-100-26]. For detailed cylinder block dimensions: (See Engine
Component Class on Page 70-100-11.)
Main Journal Bearing I.D. 79 - 79,021 mm
(3.1102 - 3.1111 in)
For detailed cylinder block dimensions: (See Engine

Component Class on Page 70-100-11.)

Cylinder Block Inspection (Cont’d)
Figure 70-100-29
P115979
Measure the three camshaft bearings [Figure 70-100-

29].
Figure 70-100-30
P115980A
Measure the bearings in three different locations [Figure

70-100-30].
Cylinder Block Camshaft 45 - 45.025 mm

Bore (1.7716 - 1.7726 in)

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Inspection
Crankshaft Inspection Figure 70-100-33
Figure 70-100-31
P121030
P121022
Measure the I.D. of the connecting rod small end bore.
Measure the O.D. of the piston pin and the I.D. of the
Place the crankshaft on a set of V blocks. Set a dial
piston pin bore [Figure 70-100-33].
indicator on a main bearing journal. Spin the crankshaft
to determine the crankshaft warpage [Figure 70-100-31].
Connecting Rod Small 36,025 - 36,038 mm
End Bore (1.4183 - 1.4188 in)
Crankshaft Warpage
Piston Pin O.D. 35,995- 36,000 mm
Number 3 Main Journal 0,05 mm (0.0020 in)
(1.4171 - 1.4173 in)
Number 2 & 4 Main Journal 0,05 mm (0.0020 in)
Piston Pin Bore 36,008 - 36,014 mm
(1.4176 - 1.4179 in)
Figure 70-100-32
Figure 70-100-34
P121020
P121032
Measure the crankshaft main journals and rod journals
[Figure 70-100-32].
Measure the I.D. of the connecting rod large end bore
Main Journal Diameter 74,955 - 74,970 mm [Figure 70-100-34]. Measure the bore in three different
(2.9510 - 2.9516 in) locations.
Rod Journal Diameter 62,955 - 62,970 mm Connecting Rod Large 66,000 - 66,015 mm
(2.4785 - 2.4791 in) End Bore (2.5984 - 2.5990 in)
For detailed crankshaft dimensions: (See Engine For detailed connecting rod dimensions: (See Engine
Component Class on Page 70-100-11.) Component Class on Page 70-100-11.)

CRANKSHAFT AND PISTONS (CONT’D) The connecting rod bearings are available as a service
part in one class and are coded with yellow markings.
Engine Component Class
Connecting Rod Bearing 1,497 - 1,502 mm
The pistons, connecting rods, connecting rod bearings, (0.0590 - 0.0591 in)
crankshaft, crankshaft bearings and cylinder block are
available in different classes. The class is determined by Figure 70-100-37
the size of the components and is engraved or color
coded on the component.
Figure 70-100-35
1
2
1
P114051B
The crankshaft serial number (Item 1) and main journal

P114059 diameter class (Item 2) [Figure 70-100-37] is engraved
on the flywheel end of the crankshaft.
The piston is engraved with “A” or “B” (Item 1) [Figure Crankshaft Main Journal Diameter
70-100-35].
Class A 74,955 - 74,960 mm
(2.9510 - 2.9512 in)
Class A 97,920 - 97,930 mm
(3.8551 - 3.8555 in) Class B 74,960 - 74,965 mm
(2,9512 - 2.9514 in)
Class B 97,930 - 97,940 mm
(3.8555 - 3.8559 in) Class C 74,965 - 74,970 mm
(2.9514 - 2.9516 in)
Figure 70-100-36
Crankshaft Bearing Thickness / Color
Blue 1,995 - 2,000 mm
(0.0785 - 0.0787 in)
1 Yellow 2,000 - 2,005 mm
(0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm
(0.0789 - 0.0791 in)
P114058
The connecting rod is engraved on the cap (Item 1)

[Figure 70-100-36]. This letter / number must be used to
order replacement rod assemblies.

Engine Component Class (Cont’d)
Figure 70-100-38
P114060
The cylinder block bearing bore class (Item 1) [Figure

70-100-38] is engraved on the flange of the crankcase.
Cylinder Block Main Journal Diameter

Class A 79,000 - 79,007 mm
(2.9134 - 2.9137 in)
Class B 79,007 - 79,014 mm
(2.9137 - 2.9139 in)
Class C 79,014 - 79,021 mm
(2.9139 - 2.9142 in)
When replacing crankshaft bearings, use the chart

below.
Cylinder Block Crankshaft Main Journal

Main Journal Diameter
Diameter Class A Class B Class C
Class A Yellow Blue Blue
Bearing Bearing Bearing
Class B Yellow Yellow Blue
Class C Red Red Yellow

CAMSHAFT Figure 70-110-3
Remove the flywheel housing. (See Housing Removal 1

Remove the rocker arms and push rods. (See Rocker

Arm Shaft Disassembly And Assembly on Page 70-90-
14.)
Remove the oil pan. (See Oil Pan Removal And

NOTE: Before removing the camshaft, measure the

camshaft end play. (See Inspecting on Page P114023
70-110-2.)
Figure 70-110-1 Remove the valve tappets (Item 1) [Figure 70-110-3].
Figure 70-110-4
1
1
P121000
P115979A
Remove the bolts (Item 1) [Figure 70-110-1].
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque. Remove the cam bearings (Item 1) [Figure 70-110-4].
Figure 70-110-2 Installation: Install the cam bearings with the holes in
the bearing lined up with the oil passage in the cylinder
block.
1
P121001
Remove the camshaft (Item 1) [Figure 70-110-2].

CAMSHAFT (CONT’D) Figure 70-110-7
Inspecting
Figure 70-110-5
P121006
Measure the three camshaft journals. Measure each

P121007 journal in two different areas 90° apart [Figure 70-110-
7].
Measure the gap between the thrust washer and the gear Camshaft Journal 44,95 - 44,966 mm
[Figure 70-110-5]. (1.7697 - 1.7703 in)
Thrust washer to 0,1 - 0,2 mm Figure 70-110-8

gear clearance (0.0039 - 0.0079 in)
Figure 70-110-6
1 2
P121008
P121005 Place the camshaft on V Blocks. Set up a dial indicator

as shown [Figure 70-110-8].
Remove the gear (Item 1), thrust washer (Item 2), and Rotate the camshaft and record the warpage of the
key (Item 3) [Figure 70-110-6]. camshaft.
Installation: Heat the camshaft gear to 170 - 190°C (338 Camshaft warpage 0,01 mm
- 374°F) and press the gear on to the camshaft. (0.0004 in)

CAMSHAFT (CONT’D)
Inspecting (Cont’d)
Figure 70-110-9
P121000
With the camshaft (Item 1) [Figure 70-110-9] installed,

use a dial indicator to measure camshaft end play.
Camshaft end play 0,1 - 0,2 mm

(0.0039 - 0.0079 in)

GEARCASE Gear End Play
Gear Backlash Figure 70-120-2
Remove the flywheel housing. (See Housing Removal 2

Figure 70-120-1
3
4
1
2 1
P121037
3
Using a dial indicator, measure the end play of the
crankshaft gear (Item 1), camshaft gear (Item 2) and idle
P121035 gear (Item 3) [Figure 70-120-2].
Crankshaft gear end play 0,10 - 0,31 mm

Using a dial indicator, measure the backlash between the (0.0039 - 0.0122 in)
fuel injection pump gear (Item 1) to idle gear (Item 2), idle
gear to crankshaft gear (Item 3), idle gear to camshaft Camshaft gear end play 0,10 - 0,20 mm
(Item 4) [Figure 70-120-1], and crankshaft gear to oil (0.0039 - 0.0079 in)
pump gear. Idle gear end play 0,10 - 0,20 mm
(0.0039 - 0.0079 in)
Idle gear to crankshaft 0,087 - 0,202 mm
gear (0.0034 - 0.008 in)
Crankshaft gear to oil 0,066 - 0,247 mm
pump gear (0.0026 - 0.0097 in)
Idle gear to camshaft gear 0,087 - 0,213 mm
(0.0034 - 0.0084 in)
Fuel injection pump gear 0,081 - 0,196 mm
to idle gear (0.0032 - 0.0077 in)

GEARCASE (CONT’D) Figure 70-120-5
Gear Timing
1
Remove the flywheel housing. (See Housing Removal
Figure 70-120-3
4
1
2
2 P121035B
Idle gear (Item 1) to camshaft gear (Item 2) [Figure 70-

3 120-5].
Figure 70-120-6
P121035
The fuel injection pump gear (Item 1), idle gear (Item 2),
2
crankshaft gear (Item 3), and camshaft gear (Item 4)
[Figure 70-120-3] have timing marks. Align the marks
when assembling the gears. 1
NOTE: The fuel injection pump timing is not critical,

and if replacing the pump without removing
the timing cover, the marks do not need to be
aligned.
Figure 70-120-4
P121035C
2
Idle gear (Item 1) to crankshaft gear (Item 2) [Figure 70-
1 120-6].
P121035A
Fuel injection pump (Item 1) to idle gear (Item 2) [Figure

70-120-4].

GEARCASE (CONT’D) Idle Gear Inspection
Idle Gear Removal And Installation Figure 70-120-8
Figure 70-120-7
1 2
3
2 P114057
P121011
Measure the inside diameter of the idle gear (Item 1)
[Figure 70-120-8] at four different points, on either side
Remove the bolts (Item 1), idle gear shaft (Item 2) of the bearing lubrication channel.
[Figure 70-120-7] and the idle gear (Item 3).
Idle Gear I.D. 64,0 - 64,019 mm
Installation: Tighten the bolts to 43 N•m (32 ft-lb) torque. (2.5197 - 2.5204 in)
Measure the outside diameter of the idle gear shaft (Item

2) [Figure 70-120-8] at four different points on either side
of the lubrication port.
Idle Gear Shaft O.D. 59,921 - 59,940 mm

(2.3591 - 2.3598 in)

TURBOCHARGER Removal And Installation
Description Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.)
The turbocharger is located between the exhaust and
intake manifolds. It is driven by hot exhaust gases and Remove the DOC assembly. (See Removal And
supplies air at more than atmospheric pressure to the Installation on Page 70-40-1.)
intake. Lubrication for the turbocharger is supplied with
pressurized oil from the main engine oil galley. The Remove both side access covers. (See on Page 10-120-
location of the turbocharger is between the engine and 2.).
the blower housing.
Remove the fan duct panels. (See Removal And
Figure 70-130-1 Installation on Page 50-200-1.)
1 Figure 70-130-2
P121062 1
P121139
The oil is delivered to the turbocharger through a tubeline
(Item 1) and returns to the engine block through a drain
line (Item 2) [Figure 70-130-1]. Remove the nuts (Item 1) and the exhaust pipe (Item 2)
[Figure 70-130-2].
The turbocharger internal components are not
serviceable. Installation: Tighten the nuts (Item 1) [Figure 70-130-2]

TURBOCHARGER (CONT’D) Figure 70-130-5
Figure 70-130-3
1 1
1 3
2
2
P121141
Remove the bolts (Item 1), reposition the clamp (Item 2)

P115926A and remove the drain tube assembly (Item 3) [Figure 70-
130-5].
Loosen the hose clamp (Item 1) [Figure 70-130-3]. Plug the drain port on the turbocharger.
Remove the hose and plug the turbocharger inlet.
Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
Remove the hoses (Item 2) [Figure 70-130-3]. torque.
Figure 70-130-4 Figure 70-130-6

1
2
1
1 1
P121140 P121142
Remove the oil tube line bolts (Item 1) and the oil tube Remove the three nuts (Item 1) [Figure 70-130-6].
Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque.
Plug the inlet port on the turbocharger.
NOTE: Do not lift the turbocharger by actuator. The
Installation: Tighten the bolt to 19,6 N•m (14.5 ft-lb) actuator may be damaged because of the
torque. weight of the turbocharger.
NOTE: The oil delivery tube and copper washers are Installation: Inject new oil into the oil inlet and spin
single use parts and should be replaced the turbine shaft to lubricate the bearings.
whenever the oil delivery tube and copper
washers are removed. Remove the turbocharger and gasket.

TURBOCHARGER (CONT’D)
Testing
Turn the compressor wheel gently with a finger and check

for contact.
If the wheel does not turn smoothly, check the axial and
radial clearance.
If the compressor / turbine wheel and housing is

damaged, replace the turbocharger assembly.
Figure 70-130-7
P-76099
Move the compressor / turbine wheel (Item 1) [Figure

70-130-7] (up and down, right and left).
If the compressor / turbine wheel contacts the housing,

replace the turbocharger assembly.

FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-140-2
NOTE: Engine removed for photo clarity.

1
30-60-2.)
Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation (Earlier Models) on Page
30-60-4.)
Figure 70-140-1
P114378A
1 The ring gear (Item 1) [Figure 70-140-2] on the flywheel

is an interference fit. Heat the ring gear enough to
2 expand it and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth

fit.
Clean the new ring gear and heat it to a maximum

P115950 temperature of 220°C (428°F).
NOTE: The lead chamfer on ring gear tooth must face

Remove the bolts (Item 1) [Figure 70-140-1] from the the starter.
flywheel.
Fit the ring gear over the flywheel. Make sure the gear is
Remove the flywheel from the engine crankshaft. seated properly.
Installation: Apply engine oil to the bolts and tighten to

67,8 N•m (50 ft-lb) torque plus 45° of added rotation in a
crisscross pattern.
Installation: There is an alignment pin (Item 2) [Figure

70-140-1] that is used to install the flywheel in the proper
position for timing purposes.

FLYWHEEL AND HOUSING (CONT’D) Figure 70-140-4
Housing Removal And Installation

30-60-2.) 1
Remove the hydrostatic pump. (See Removal And

3
Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation (Earlier Models) on Page
30-60-4.)
2
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-140-1.) P121047
Remove the starter. (See Removal And Installation on Remove the rear oil seal (Item 1) and remove the
Page 60-40-1.) flywheel housing bolts (Item 2) [Figure 70-140-4].
Figure 70-140-3 Remove the flywheel housing (Item 3) [Figure 70-140-4].
Installation: Apply Loctite® 5902 to the assembly

surface of the flywheel housing and tighten the mounting
bolts to 22 N•m (16 ft-lb) torque.
1
Figure 70-140-5
2
4
1 1
2
P121046
Remove the mounting bolts (Item 1) and engine mount

(Item 2) [Figure 70-140-3].
3
P121014A
NOTE: Use rear oil seal assembly jig (7031370) to

install seal.
Install the rear oil seal (Item 1) to the rear oil seal
assembly jig guide (Item 2) [Figure 70-140-5].
Install the rear oil seal assembly jig guide (Item 2) to the
crankshaft (Item 4) [Figure 70-140-5].
Install the rear oil seal assembly jig holder (Item 3) to the
rear oil seal assembly jig guide (Item 2) [Figure 70-140-
5].
Tighten the center bolt on the rear oil seal assembly jig
holder to install the rear seal (Item 1) [Figure 70-140-5].

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) system circulates some of the exhaust gas from the engine to the intake side, cools the
gas and then delivers the cooled gas to the engine for re combustion in order to reduce NOx emission.
To reduce NOx emission from the engine, EGR circulates the exhaust gas of which oxygen concentration is very little to
the intake system. As a result, low temperature combustion occurs in the engine and the NOx emission is reduced.
The EGR cooler is used to reduce NOx emission and enhance engine combustion efficiency by reducing temperature of
high-temperature exhaust gas.
Figure 70-150-1
7
2
5 6
8
10
9
P115965
The air from the air filter (Item 1) is routed to the compressor side (Item 2) of the turbocharger. The compressed air then
flows through the inter cooler (Item 3) to the intake manifold (Item 5) and combustion chamber. Some of the exhaust gas
(Item 6) flows through the EGR valve (Item 7), through the EGR cooler (Item 4) and mixes with the air from the inter cooler
(Item 3). The remaining exhaust gas flows through the turbine (Item 8) side of the turbocharger, through the muffler (DOC)
(Item 9) and out the muffler tail pipe (Item 10) [Figure 70-150-1].

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-150-3
(CONT'D)
1 1
WARNING
AVOID BURNS 3
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests. 2
Allow the engine to cool before servicing.

W-2716-0208 P121141
Allow the engine to cool before working on the EGR Remove the bolts (Item 1), reposition the clamp (Item 2)
system. and remove the drain tube assembly (Item 3) [Figure 70-
150-3].
Installation: When reassembling replace with new
gaskets. Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
torque.
Figure 70-150-2
Figure 70-150-4
1
2 2
1
1
2 1
1 3
1
P121140
P115966
Remove the oil tube line bolts (Item 1) and the oil tube
Remove the bolts (Item 1) and disconnect the EGR pipes
(Item 2) [Figure 70-150-4].
Installation: Tighten the bolt to 19,6 N•m (14.5 ft-lb)
torque.
Remove the coolant hoses (Item 3) [Figure 70-150-4].
NOTE: The oil delivery tube and copper washers are
single use parts and should be replaced
whenever the oil delivery tube and copper
washers are removed.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-150-6
(CONT'D)
Figure 70-150-5
3
4
1
4 2
P115968
1
3 Remove the retaining bolts (Item 1) [Figure 70-150-6].
P115967 Remove the EGR valve (Item 2), the EGR cooler (Item 3)
and the gasket (Item 4) [Figure 70-150-6].
Remove the two retaining bolts (Item 1) [Figure 70-150- Installation: When reassembling replace with new
5] from the EGR mount. gaskets. Torque the bolts to 9,8 N•m (7.2 ft-lb).
Remove the three retaining bolts (Item 2) [Figure 70-

150-5].
Remove the coolant hose (Item 3) and the EGR valve


HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Air Conditioning Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-7
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-17
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schrader® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1


THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

EVAPORATOR / HEATER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R-134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
b-16691

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1
1
P114493A
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P121174 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2
1 1
P100889
Heater / Evaporator Unit: The heater / evaporator unit

(Item 1) [Figure 80-10-4] is located behind the loader
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower,
heat and A/C coils, thermostat and expansion valve.
P121216A
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-7
Components (Cont'd)
1
Figure 80-10-5
2
3
4
P-92638
1
Control Panel: The panel (Item 1) [Figure 80-10-7] has

P100878 three separate components.
Fan Switch: This is a four position rotary switch (Item 2)

Expansion Valve: The expansion valve (Item 1) [Figure [Figure 80-10-7]. When the fan switch is in the off
80-10-5] controls the amount of refrigerant entering the position the A/C will not engage, but the heat valve will
evaporator coil. operate, as it is controlled by the key switch.
Figure 80-10-6 A/C Switch: The rocker switch (Item 3) [Figure 80-10-7]
will be illuminated when the A/C is engaged.
2 Potentiometer: The potentiometer (Item 4) [Figure 80-

4 10-7] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
3 Figure 80-10-8
1
P101946
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-

10-6] cools and dehumidifies the air before it enters the
cab.
Thermostat: The thermostat (Item 2) [Figure 80-10-6]

controls the temperature of the evaporator coil.
P101968
Heater Coil: The heater coil (Item 3) [Figure 80-10-6]

supplies the warm air into the cab by passing air through Heater Valve: The heater valve (Item 1) [Figure 80-10-8]
the coil. is used to control the amount of engine coolant that flows
to the heater coil.
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-6] is used to push air through the heater and
evaporator coils and into the cab.

Components (Cont'd)
Figure 80-10-9
P114492A
Pressure Switch: The pressure switch (Item 1) [Figure

80-10-9] will disengage the compressor clutch at high
pressure readings over 2647,6 kPa (2647 bar) (384 psi)
on the high side, or at very low pressure of 193,1 kPa
(193 bar) (28 psi) or less on the high side, which
indicates loss of refrigerant.

Safety Equipment WARNING

Figure 80-10-10
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -6°C (21.6°F)
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-11] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-11
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
P16399 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-10] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Recirculation Filter
Filters Figure 80-20-2

Fresh Air Filters
Figure 80-20-1
4 1
P100755
2
The recirculation filter is located behind the operator’s
3 seat inside the operator cab. The filter cover is held in
position with three clips. Pull the cover at each end (Item
1) [Figure 80-20-2] to remove.
P-90489B P-90492A
Rinse the filter with water or use a vacuum cleaner to
clean. Do not use solvents.
The fresh air filters are located behind the side windows
outside the operator cab. (Right side shown) Remove the Line up the clips on the filter cover with the slots provided
retaining screw (Item 3) and the filter cover (Item 2) and push the cover into position.
[Figure 80-20-1]. (Lift arms shown raised for visual
clarity.)
NOTE: Loosen the upper filter cover bolt (Item 1)

[Figure 80-20-1] to allow removal and
installation of the cover if equipped with the
High-Efficiency Particulate Air (HEPA) filter
kit.
Shake the filter (Item 4) [Figure 80-20-1] or use low

pressure air to remove dirt. This procedure can be done
several times before replacement is required. Install the
filter, the filter cover, and the retaining screw.

REGULAR MAINTENANCE (CONT’D) Figure 80-20-5
Belt Adjustment
The air conditioning belt has a spring loaded idler that

constantly maintains the correct belt tension.This belt
does not require periodic adjustment.
Belt Replacement 1
Figure 80-20-3
P121903
Loosen the fuel filter clamps (Item 1) [Figure 80-20-5].
Remove the fuel filter assembly from the clamps and

1
move clear of the air conditioning compressor belt shield.
2
Figure 80-20-6
P121466
Remove the alternator belt shield mounting nuts and 2

bolts (Item 1) [Figure 80-20-3].
Remove the alternator belt shield (Item 2) [Figure 80-20-

3].
Figure 80-20-4
P121080
Remove the air conditioning compressor belt shield

mounting bolts and nut (Item 2) [Figure 80-20-6].
Remove the air conditioning compressor belt shield (Item

1 1) [Figure 80-20-6].
P121337

20-4] from the fuel filter.

Belt Replacement (Cont’d)
Figure 80-20-7
NA9657
Install new belt using the routing diagram [Figure 80-20-

P121079
8] and remove breaker bar.
NOTE: Verify the belt is properly aligned on each

Insert breaker bar into the hole provided in the idler pulley.
pulley (Item 1) [Figure 80-20-7] and push down to
release belt tension. Remove the belt from the pulleys. Install air conditioning compressor belt shield and
mounting bolts and nut [Figure 80-20-6].
Inspect the pulleys for wear.
Install fuel filter assembly into clamps and tighten clamps
[Figure 80-20-5].
Connect the electrical connector (Item 1) [Figure 80-20-

4] to the fuel filter.
Install the alternator belt shield, mounting bolts, and nuts

[Figure 80-20-3].
Condenser
The condenser should be cleaned with the hydraulic fluid

cooler and the radiator.
Air Conditioning Lubrication
Run the air conditioning for about 5 minutes every week

to lubricate the internal components.

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Air Conditioning Evaporator / Heater Coil

1
on Page 10-30-2.)
Figure 80-20-9
2
1
P109544
2 Clean the plenum drains (Item 1) [Figure 80-20-11] to

ensure they are not plugged by debris.
Inspect the cover seal (Item 2) [Figure 80-20-11] for

breaks and tears. Ensure the seal is firmly attached all
around the cover.
P100756
Figure 80-20-12
Unhook the cover latches (Item 2) and remove the cover

(Item 1) [Figure 80-20-9].
2
Figure 80-20-10
P109411
2
NOTE: The bosses (Item 1) fit inside the core
supports (Item 2) [Figure 80-20-12] when the
cover is installed. Deformity of the cover
P100757
indicates they are out of position.
Use low pressure air or water to remove debris from the

heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-10].

Air Conditioning Evaporator / Heater Coil (Cont’d)
NOTE: Improper cover installation can damage the

seal, which may lead to HVAC component
failure. Perform the following steps in the
order given to prevent cover seal damage.
Figure 80-20-13 1
P100756
3. Fasten the two remaining latches (Item 1) [Figure 80-

20-15].
NOTE: Perform a thorough visual inspection to

ensure that the cover and the cover seal are
not deformed. The cover should seal tightly
P109546
all around without any gaps.

1. Hold the cover in place and fasten two latches (Item 3.)
1) [Figure 80-20-13].
Figure 80-20-14
1 2 3
P109543A P109545
2. Push the cover up in three places (Items 1, 2, and 3)

until the slots snap into place on the tabs. This slot
(Inset) [Figure 80-20-14] is correctly fastened.

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch malfunc- Check power into and out of the fan switch. Replace Fan Switch.
tion.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly Repair or adjust.
connected and seals are not damaged.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive / drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation / thermostat
components. thermostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 rpm are:
High pressure side pressure: 1447,9 - 1827,1 kPa (210 - 265 psi) (14,5 - 18,3 bar)
Low pressure side pressure: 103,4 - 227,5 kPa (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures Replace compressor.
sor. equalize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostat’s tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver / drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
P100890

Troubleshooting Tree (Cont’d)
p100892

Troubleshooting Tree (Cont’d)
P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP TEMP TEMP TEMP
kPa BAR PSIG kPa BAR PSIG
°C °F °C °F
-8,8 16 108,2 1,08 15.69 33,9 93 759,8 7,60 110.20
-7,8 18 117,5 1,17 17.04 34,4 94 773 7,73 112.10
-6,7 20 127,1 1,27 18.43 35 95 786,7 7,87 114.10
-5,6 22 137 1,37 19.87 37,8 100 857,1 8,57 124.30
-4,4 24 147,2 1,47 21.35 38,9 102 886 8,86 128.50
-3,3 26 157,8 1,58 22.88 40 104 916,3 9,16 132.90
-2,2 28 168,7 1,69 24.47 41,1 106 946,7 9,47 137.30
-1,1 30 180 1,80 26.10 42,2 108 978,4 9,78 141.90
0 32 191,6 1,92 27.79 43,3 110 1010.1 10,10 146.50
1,1 34 203,5 2,04 29.52 44,4 112 1043,2 10,43 151.30
2,2 36 216 2,16 31.32 45,6 114 1076,3 10,76 156.10
3,3 38 228,7 2,29 33.17 46,7 116 1110,7 11,11 161.10
4,4 40 241,8 2,42 35.07 47,8 118 1145,2 11,45 166.10
5,6 42 255,3 2,55 37.03 48,9 120 1181,1 11,81 171.30
6,7 44 269,3 2,69 39.05 50 122 1217,6 12,18 176.60
7,2 45 276,4 2,76 40.09 51,1 124 1254,8 12,55 182.00
10 50 313,6 3,14 45.48 52,2 126 1292,8 12,93 187.50
12,8 55 353,5 3,54 51.27 53,3 128 1331,4 13,31 193.10
15,6 60 396,3 3,96 57.47 54,4 130 1371,4 13,71 198.90
18,3 65 442 4,42 64.10 57,2 135 1473,4 14,73 213.70
21,1 70 490,8 4,91 71.19 60 140 1581,7 15,82 229.40
23,9 75 543 5,43 78.75 62,8 145 1694,7 16,95 245.80
26,7 80 598,5 5,99 86.80 65,6 150 1813,3 18,13 263.00
29,4 85 657,8 6,58 95.40 68,3 155 1938,1 19,38 281.10
32,2 90 719,8 7,20 104.40 71,1 160 2069,1 20,69 300.10
32,8 91 733 7,33 106.30 73,9 165 2207,1 22,07 320.10
33,3 92 746,1 7,46 108.20 76,7 170 2349,7 23,50 340.80

Temperature / Pressure Chart (Cont’d)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 4.5 - 5.5°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature = 90°F

90°F
+40°F
130°F condenser temperature = 200 psig
Conditions and pressures will vary from system to system.

TROUBLESHOOTING (CONT'D) The louver temperature should be between 7.2 - 11.7°C
(45 - 53°F) depending on the amount of humidity in the
Poor A/C Performance air and ambient temperature.
Start the loader, lock the park brake, and engage the A/C If louver temperature is too high. (See Troubleshooting
system with the blower fan on High. Run the loader at full Tree on Page 80-30-4.)
rpm for approximately 15 minutes, with the loader cab
door closed. Inspect the blower for proper operation, or noise, and
replace if necessary. (See Removal And Installation on
Figure 80-30-1 Page 80-130-1.)
Inspect the A/C condenser for dirt or mud and clean if

necessary. (See Removal And Installation on Page 80-
60-1.)
1
Inspect the A/C evaporator coil for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
110-1.)
Inspect the engine coolant to see if it is bypassing the

heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-17.)
P-90356B
Figure 80-30-2
N-22411
Measure the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].

HVAC Repair And Leaks
Figure 80-30-3
P121243
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT’D) Open the rear door (tailgate).
Electrical System Figure 80-30-6
Check to see if the compressor clutch is engaging.
With an operator in the loader seat and the cab door 1

open, turn the loader key switch to RUN, without starting
the loader.
Figure 80-30-4
P121246
2 Locate the loader harness and the compressor clutch

1 wire (Item 1) [Figure 80-30-6].
Disconnect the loader harness (Item 1) [Figure 80-30-6]

from the compressor clutch wire.
P-92638
Figure 80-30-7
Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON
position. 1
The compressor clutch should make a click sound, which

indicates the clutch is engaging.
Figure 80-30-5
P121247
1 With a multimeter, test the resistance to the compressor

clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor

clutch.
P107514B
If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.

TROUBLESHOOTING (CONT’D) Figure 80-30-10
Electrical System (Cont’d)
Figure 80-30-8
P121245
1
Using a multimeter test the loader wiring harness (Item 1)
P121247 [Figure 80-30-10] for voltage.
The voltage should be battery voltage.

With a multimeter, test the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, inspect the
harness for broken wires.
The voltage reading should be battery voltage.
Figure 80-30-11
If there is no power at the clutch, inspect the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.

Figure 80-30-9
P121245
If there is voltage at the harness, test the resistance at

the pressure switch (Item 1) [Figure 80-30-11].
1
If there is no resistance value, check for low refrigerant
level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
P121244
If a resistance value is seen, the pressure switch is good.

Locate the loader harness and the pressure switch wire
(Item 1) [Figure 80-30-9]. Reconnect the loader harness to the pressure switch.
Disconnect the loader harness (Item 1) from the pressure

switch wire (Item 2) [Figure 80-30-9].

Figure 80-30-12
1 P-90363A
Disconnect the blower wiring connector (Item 1) [Figure

P100951A 80-30-14] from the loader wiring harness.
Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
1
2 P-90362A
1
Test the loader harness (Item 1) [Figure 80-30-15] for
P-90362A voltage. The voltage should be battery voltage.
Test the loader harness (Item 1) [Figure 80-30-13] for If there is no voltage at the wiring harness, inspect the
voltage. The voltage should be battery voltage. harness for broken wires.
If there is no voltage at the wiring harness, inspect the If there is voltage at the wiring harness, test the
harness for broken wires. resistance to the blower at the blower wiring connector
(Item 2) [Figure 80-30-15].
If there is voltage at the wiring harness, inspect the
thermostat (Item 2) [Figure 80-30-13] for resistance. If there is no resistance value replace the blower. (See
The resistance value of the thermostat should be 10 ohm
at 20°C (68°F). If there is a resistance value inspect the climate controls
at the control panel inside the loader cab.
If there is no resistance value, replace the thermostat.
If there is a resistance value, inspect the blower.

Figure 80-30-16 C
H
B
1 M
N-22288
If there is voltage at the wiring harness, test the blower

P-90364 switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame
[Figure 80-30-18].
Figure 80-30-17
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the

blower switch.
If the above resistance tests are good, test the A/C

P-90365 switch.
Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.
Test the loader harness for voltage. The voltage should

be battery voltage.
If there is no voltage at the wiring harness, inspect the


TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Electrical System (Cont’d) If a resistance value is found, test the potentiometer.
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does

not work, test the potentiometer.
1
Figure 80-30-21
1
P-90367
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.
Test the harness for voltage. The voltage should be

P-90366
battery voltage.
If there is no voltage at the wiring harness, inspect the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Figure 80-30-20 Test the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be battery voltage.
If there is no voltage at the wiring harness, inspect the

1
2
N-22289
If there is voltage at the wiring harness, test the A/C

switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no

continuity between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

continuity between terminal (Item 1) and terminal (Item 2)
[Figure 80-30-20].

Electrical System (Cont'd)
Figure 80-30-22
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0K
ohm.
If there is voltage at the wiring harness, test the Test the resistance between the wire terminal C and wire
potentiometer [Figure 80-30-22] for resistance. terminal B frame [Figure 80-30-24] should be around
10K ohm.
The resistance should be 10K ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
P-90368
To test the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Raise the lift arms and install an approved lift arm
Figure 80-30-25
Figure 80-30-27
2 3
1
1
P-90369
P-90364A
To test the resistance of the white wire, turn the Push the A/C switch (Item 1) to the OFF position, turn the
potentiometer control (Item 1) [Figure 80-30-25] blower switch (Item 2) to position 1, then turn the
clockwise to the full Heater position. temperature control (Item 3) [Figure 80-30-27]
counterclockwise to the full A/C position, with the loader
Figure 80-30-26 key switch OFF.

C 7217666 on Page 10-61-1.)
A
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
B
N-22290
Test the resistance between the wire terminal A and wire

terminal B frame [Figure 80-30-26] should be around
10K ohm. 1
Test the resistance between the wire terminal C and wire

terminal B frame [Figure 80-30-26] should be around 0K
ohm.
P-90371A
If the resistance is not found replace the potentiometer.
Measure the heater hose (Item 1) [Figure 80-30-28] for

temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replaced.

Heater Valve Not Opening Or Closing

Figure 80-30-29
P100896
NOTE: The HVAC assembly is removed for photo

2 3 clarity.
1
Place the Remote Start Tool on the left fender of the
P-90364A loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
Push the A/C switch (Item 1) to the OFF position, turn the starting the loader. The heater valve should rotate. Place
blower switch (Item 2) to position 1 and turn the a mark on the loader shaft.
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader key switch OFF. Turn the remote start key to the OFF position and remove
the Remote Start Tool from fender.
Lower operator cab.
TOOL KIT - MEL1563 on Page 10-60-1.) or (See Turn the temperature control (Item 3) [Figure 80-30-29]
REMOTE START TOOL (SERVICE TOOL) KIT - to the High Heater position, with the loader key switch
7217666 on Page 10-61-1.) OFF.
Raise the operator cab.
Place the Remote Start Tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-30], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
If it does not rotate, test the potentiometer for proper

function. (See Electrical System on Page 80-30-11.)
Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)

SYSTEM CHARGING AND RECLAMATION Raise the lift arms and install an approved lift arm
Refrigerant Identification
Connect the Refrigerant Identifier to the low pressure

WARNING hose.
Connect the Refrigerant Identifier to its power source.

Follow the steps displayed on the refrigerant identifier
screen.
gas.
W-2371-0611
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
Figure 80-40-1 sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
1
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.
N-23024
NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-3
Reclamation And Charging With Recovery / Charging

Unit

Figure 80-40-2
N-22291
IMPORTANT: Only trained technicians should

perform the reclaiming and recharging.
WARNING
P100895
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
Locate the low pressure port (Item 1), and high pressure blindness if it contacts the eyes and may cause
port (Item 2) [Figure 80-40-2]. serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
WARNING • NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of R-134a to the system must be done by a
refrigerant can cause severe injuries to eyes. In competent refrigeration dealer who has the proper
contact with a flame, R-134a refrigerant gives a toxic equipment, knowledge, and experience to service
gas. refrigeration equipment.
W-2371-0611 W-2373-0611
Use an approved recovery / charging unit [Figure 80-40-

3] to evacuate the system.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Unit (Cont'd)
Figure 80-40-4
N-22292
Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P100385
NOTE: For the correct quantity of refrigerant (See
Capacities on Page SPEC-10-5.).
Figure 80-40-5
Figure 80-40-7
1
2
P100950
N-22381
Connect the reclaimer to the loader A/C charge ports

[Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 1) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 2) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.

COMPRESSOR Figure 80-50-3
NOTE: If compressor is being removed for engine

removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt 2
and reposition the compressor.
Evacuate the A/C system. (See Reclamation And

1
2.) 1
Open the rear door.
Figure 80-50-1
P121274
Remove the bolts (Item 1) and the compressor shield

1 (Item 2) [Figure 80-50-3].
Figure 80-50-4
P121246 2
Disconnect the loader harness (Item 1) [Figure 80-50-1]

from the compressor clutch wire.
1
Figure 80-50-2
P121090A
Remove the nuts and bolts (Item 1) and the alternator

shield (Item 2) [Figure 80-50-4].
1 2
P121273
Disconnect the water in fuel sensor (Item 1) and remove

the bolts (Item 2) [Figure 80-50-2].
Reposition the fuel filter.

COMPRESSOR (CONT'D) Figure 80-50-6
Figure 80-50-5
2
3
1
1
P121276
2
Remove the compressor hoses (Item 1) [Figure 80-50-6]
from the compressor.
P121275
Cap and plug the compressor hoses and the fittings with
Insert a breaker bar (Item 1) into the idler pulley (Item the proper A/C caps and plugs.
2)[Figure 80-50-5]. Push down on the breaker bar and
remove the belt. NOTE: Always replace O-rings and lube with
fittings.
WARNING Installation: Tighten the compressor hose (Item 2) to 46
N•m (34 ft-lb) torque and (Item 3) [Figure 80-50-6] to 30
In the event of a leak, wear safety goggles. Escaping N•m (22 ft-lb) torque.
contact with a flame, R-134a refrigerant gives a toxic Figure 80-50-7
gas.
W-2371-0611
P121278A
Remove the compressor mounting bolts (Item 1) [Figure

80-50-7] top and bottom (top shown).
Remove the compressor from the loader.

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See Reclamation And Charging With
Oil Recovery / Charging Unit on Page 80-40-2.)
Figure 80-50-8 Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200

1 rpm.
Remove the compressor from the loader. (See Removal

P121174
The compressor (Item 1) [Figure 80-50-8] is factory filled

with 115 - 155 cc's of PAG 46 oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check

or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
• When ever the evaporator, condenser or receiver /

drier is replaced.
• Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser

or receiver / drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 46 oil should be used, and never

mix R-12 and R-134a Oils.
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

COMPRESSOR (CONT'D) Figure 80-50-11
Oil Check
Figure 80-50-9
1
1
P121272
Add the same amount of new compressor oil that was

P121272 removed through the suction side connector (Item 1)
[Figure 80-50-11].
Drain the oil through the connectors (Item 1) [Figure 80- NOTE: The suction port on the compressor is marked
50-9]. with an SUC and is the larger port on the
compressor.
Figure 80-50-10
P121174
NOTE: After draining the oil, extract the remaining oil

through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
10] several times by hand.
Measure the drained oil in a measuring cylinder.
Inspect the oil for contamination, dirt, metal shavings, or

varnish color.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

CONDENSER Figure 80-60-2


1.)
Remove the refrigerant from the A/C system. (See

Unit on Page 80-40-2.)
P114505
WARNING Unhook the two rubber straps (Item 1) [Figure 80-60-2].
Figure 80-60-3
gas.
W-2371-0611
1
Figure 80-60-1
1
1
P121217A
Raise the air conditioning condenser (Item 1) [Figure 80-

60-3].
NOTE: The air conditioning condenser fits into two

P121216A slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains
Remove the two hoses (Item 1) [Figure 80-60-1]. connected to the brackets when raising and
lowering.
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.

fittings.
Installation: Tighten the hoses (Item 1) [Figure 80-60-1]


CONDENSER (CONT’D)
Figure 80-60-4
1
2
P121248
Remove the clips (Item 1) [Figure 80-60-4] and lift the

condenser out of the machine.
Installation: Ensure the air condenser is installed into

the two slotted brackets (Item 2) [Figure 80-60-4] (left
side shown).
Ensure the clips (Item 1) are properly installed over the

two slotted brackets (Item 2) [Figure 80-60-4] (left side
shown).
Figure 80-60-5
P114505
Fasten the two rubber straps (Item 1) [Figure 80-60-5]

(right side shown).

RECEIVER / DRIER Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Receiver / Drier Removal And Installation
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
WARNING NOTE: Always replace O-rings and lube with

fittings.
NOTE: When replacing a receiver / drier in an A/C
system 30 cc of PAG 46 oil must be added to
W-2059-0598
the system when recharging.
Figure 80-70-2
1.)

WARNING 1

gas. P115342
W-2371-0611
Note the flow direction on the receiver / drier (Item 1)

Figure 80-70-1 [Figure 80-70-2] for proper installation.
P114493
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.

RECEIVER / DRIER (CONT’D)
Receiver / Drier Removal And Installation (Cont’d)
Figure 80-70-3
P114491
Loosen the two clamps (Item 1) and remove the receiver /

drier (Item 2) [Figure 80-70-3].
Figure 80-70-4
P114490
Remove the two mount bolts (Item 1) from the receiver /

drier bracket (Item 2) [Figure 80-70-4].

RECEIVER / DRIER (CONT’D) Figure 80-70-6
Pressure Switch Removal And Installation
Figure 80-70-5 1
P114492
Remove the pressure switch (Item 1) [Figure 80-70-6]

from the receiver / drier.
Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
70-5] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0611

RECEIVER / DRIER (CONT’D)
Schrader® Valve Removal And Installation
Figure 80-70-7
P115343
The Schrader® valve (Item 1) [Figure 80-70-7] is located

in the receiver / drier under the pressure switch.

Remove the pressure switch.
With a Schrader® valve removal tool, remove the valve

from the hose.

EVAPORATOR / HEATER UNIT Figure 80-80-3


1 2
2
2.)
Figure 80-80-1
P100900A
1
NOTE: Support the evaporator / heater unit before
removing the mounting hardware.
Remove the two bolts (Item 1) and two nuts (Item 2)

1 [Figure 80-80-3].
Figure 80-80-4
1
3
3
P100879A
Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1]. 1
2
Figure 80-80-2
P100899
1
1 Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Cap and plug the hoses and the expansion valve fittings

P100879A damage O-rings when installing the hose
fittings.
NOTE: Cap the heater hoses and the heater valve Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)
with plugs to prevent coolant loss from the torque.
system.
Remove the two bolts (Item 2) and two nuts (Item 3)
Remove the two hoses (Item 1) [Figure 80-80-2]. [Figure 80-80-4].
Remove the two nuts (Item 3) [Figure 80-80-4].
Remove evaporator / heater unit from the loader.

THERMOSTAT The EDT has the following protection built in:
Description 1. Over temperature
The Electronic De-icing Thermostat (EDT) is a micro 2. Over current from clutch output
controller based module that measures evaporator coil
temperature and cycles the compressor clutch to 3. Voltage (Above and below operational limits or
maintain a constant evaporator pressure. Onboard circuit reverse voltage)
protection and diagnostics are also built into the module.
4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before
startup to protect the compressor clutch. 5. Temperature sensor open and short detection
The EDT will turn the clutch on when the evaporator coil
DETECTION
temperature is above 2°C (35.6°F). If the EDT does not MALFUNCTION STATUS LED
INTERVAL
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator Temperature Continuous 1x per second
temperature is below -2°C (28.4°F), the EDT will turn off sensor open or
the clutch and status LED. short detection
Clutch circuit At A/C startup 2x per second
Figure 80-90-1 open, short or
over current
Compressor Continuous 3x per second
clutch short to
ground
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

THERMOSTAT (CONT’D) Figure 80-90-4
Raise the lift arms and install an approved lift arm 1

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P100893
Figure 80-90-2
Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-4].
2
P100889
Undo the four latches (Item 1) and remove the cover

(Item 2) [Figure 80-90-2].
Installation: (See Installing on Page 80-150-1.)
Figure 80-90-3
P100894
Remove the thermostat probe (Item 1) [Figure 80-90-3]

from the A/C evaporator coil.

EXPANSION VALVE Figure 80-100-2
Raise the lift arms and install an approved lift arm 2


1
2.)
WARNING P100756
In the event of a leak, wear safety goggles. Escaping Unhook the four latches (Item 1) and remove the cover
refrigerant can cause severe injuries to eyes. In (Item 2) [Figure 80-100-2].
gas. Installation: (See Installing on Page 80-150-1.)
W-2371-0611
Figure 80-100-3
Figure 80-100-1
1
1
1
P101948
P103082
NOTE: The evaporator / heater unit is removed for

Remove the two A/C hoses (Item 1) [Figure 80-100-1] photo clarity.
from the expansion valve.
Remove the two evaporator fittings (Item 1) [Figure 80-
Cap and plug the hoses and the expansion valve fittings 100-3] from the expansion valve.
Installation: Tighten the two evaporator fittings to 30
NOTE: Always replace O-rings and lube with N•m (22 ft-lb) torque.
damage O-rings when installing the hose Remove the two mount bolts (Item 2) [Figure 80-100-3].
fittings.
Remove the expansion valve from the loader.
Installation: Tighten the two A/C hose fittings to 30 N•m
(22 ft-lb) torque. Cap and plug the evaporator tubelines (Item 1) [Figure
80-100-3] and the expansion valve fittings with the proper
A/C caps and plugs.

EXPANSION VALVE (CONT'D)
Figure 80-100-4
N-22085
The expansion valve [Figure 80-100-4] is replaced as a

complete unit.

EVAPORATOR COIL Figure 80-110-2


2.)
1
WARNING P101948
In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
gas. Disconnect the two evaporator fittings (Item 1) [Figure
W-2371-0611
80-110-2] from the expansion valve.
Figure 80-110-1 Cap and plug the evaporator tubelines (Item 1) [Figure
80-110-2] and the expansion valve fittings with the proper
A/C caps and plugs.
2
fittings.
Installation: Tighten the two evaporator fittings to 29,8

1
Figure 80-110-3
P100756
Unhook the four latches (Item 1) and remove the cover 2 2

(Item 2) [Figure 80-110-1].
3
P100757
Remove the thermostat probe (Item 1) [Figure 80-110-3]

from the evaporator coil.
Remove the two retaining clips (Item 2) [Figure 80-110-

3] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil (Item 3) [Figure 80-110-3].

EVAPORATOR COIL (CONT'D)
Figure 80-110-4
P-90424
Inspect the evaporator coil [Figure 80-110-4] for leaks,

and replace as needed.
Clean with low pressure water or air.

HEATER COIL Figure 80-120-3
Remove the evaporator coil (if necessary). (See Removal

1
Remove the heater valve. (See Removal And Installation
on Page 80-140-1.)
NOTE: The evaporator / heater unit is removed for

photo clarity.
Figure 80-120-1
P101947
2
Remove the retainer clips (Item 1) [Figure 80-120-3]

from both sides.
1
Figure 80-120-4
P100756
1
Unhook the four latches (Item 1) and remove the cover
(Item 2) [Figure 80-120-1].
Figure 80-120-2 P100946
P100944

HEATER COIL (CONT'D)
Figure 80-120-5
P100947
Remove the heater coil from the unit.
Figure 80-120-6
P100945
The heater coil [Figure 80-120-6] can be cleaned with

low pressure air or water.

BLOWER FAN Disassembly And Assembly
Remove the evaporator / heater unit. (See Removal And

Remove the heater coil. (See Removal And Installation

on Page 80-120-1.)
Figure 80-130-1
1 1
P-90458
1
1
Remove the eight screws (Item 1) [Figure 80-130-2]
2 from the blower wheel cover.
Figure 80-130-3
P100888
1
Remove the blower fan (Item 2) [Figure 80-130-1] from

the evaporator / heater unit.
2
P-90465
Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].
Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

BLOWER FAN (CONT'D) Figure 80-130-6
Figure 80-130-4
P-90463
1 Inspect the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
NOTE: Mark the wires for proper installation.
Remove the two wires (Item 1) [Figure 80-130-4] from

the blower motor.
Figure 80-130-5
1 1
P-90461
1
Remove the blower wheel outside clamp (Item 1) [Figure
80-130-7] from the blower wheel.
P100887
Remove the two screws (Item 1) [Figure 80-130-5] from

the resistor.
Remove the blower motor from the blower housing.

BLOWER FAN (CONT'D)
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-
8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.

HEATER VALVE Figure 80-140-2

2
1
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly.
Remove any tie straps that hold the heater hoses.
NOTE: The evaporator / heater unit is shown

removed for photo clarity. P100948
Figure 80-140-1
system.
1
Remove the heater hose clamp (Item 1) [Figure 80-140-
2].
Remove the heater hose from the heater valve.

2].
Remove the heater hose from the heater coil.
P101961
Disconnect the loader wiring harness (Item 1) [Figure

80-140-1] from the heater valve.

HEATER VALVE (CONT’D)
Figure 80-140-3
1
2
P100949

system.

3].
Remove the heater valve (Item 3) [Figure 80-140-3] from

the evaporator / heater unit.

EVAPORATOR / HEATER COVER Installing
Removing NOTE: The evaporator / heater unit is shown

removed for photo clarity.
support device. (See Installing on Page 10-20-2.) Figure 80-150-2

2 2
Figure 80-150-1
1 1
1
P109411
The tabs (Item 1) must be nested inside the core

P100756 supports (Item 2) [Figure 80-150-2] when positioning the
cover on the HVAC body.
Unhook cover latches (Item 1) and remove the cover Figure 80-150-3
(Item 2) [Figure 80-150-1].
P109396
NOTE: DO NOT hook the tabs (Item 1) [Figure 80-150-

3] until later. Damage to the seal can occur
allowing water to enter the housing causing
premature internal component failure.

EVAPORATOR / HEATER COVER (CONT’D) Figure 80-150-6
Installing (Cont’d)
Figure 80-150-4 1
P109398
2 2
Repeat procedure for other side of cover (Item 1) until

P109397 remaining tabs (Item 2) [Figure 80-150-6] are snapped
into place.
Position the cover (Item 1) and hook the two latches (Item Figure 80-150-7
2) [Figure 80-150-4].
Figure 80-150-5
2 1 1
P109400
P109398 Hook the two remaining latches (Item 1) [Figure 80-150-

7].
Push the corner of the cover (Item 1) until the tab (Item 2) Lower the operator cab. (See Lowering on Page 10-30-
[Figure 80-150-5] snaps into place. 3.)
Remove the lift arm support device and lower the lift
arms. (See Removing on Page 10-20-3.)

SPECIFICATIONS
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
TECHINCAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Loader Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic / Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1

Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Mainframe And Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-8
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-9
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-14
Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s)
are provided for comparison purposes only and are subject to change without notice. Specification(s) for your
individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions,
and other factors.
SPEC-01 S770 Service Manual

SPEC-02 S770 Service Manual
LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 74 inch Construction and Industrial bucket and may
vary with other bucket types.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
1770 mm 2179 mm
(69.7 in) (85.8 in)
1832 mm
(72.1 in)
1880 mm
1507 mm (74 in)
(59.3 in)
98°
37°
4232 mm
(166.6 in)
800 mm
(31.5 in)
3353 mm
(132 in)
2649 mm
2065 mm (104.3 in)
(81.3 in)
25.1°
31.9°
1227 mm
207 mm
(48.3 in)
(8.1 in)
2903 mm
(114.3 in)
3597 mm
(141.6 in) NA9520
Changes of structure or weight distribution of the loader can cause changes in control and steering response,
and can cause failure of the loader parts.
SPEC-10-1 S770 Service Manual

LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity 1520 kg (3350 lb)

with 200 Pound Frame Mounted
1588 kg (3500 lb)
Counterweight Kit
1610 kg (3550 lb)
Counterweight Kit
1656 kg (3650 lb)
Counterweight Kit
Tipping Load 3039 kg (6700 lb)
Operating Weight 4225 kg (9314 lb)
Breakout Force – Lift 3160 kg (6966 lb)
Breakout Force – Tilt 3098 kg (6831 lb)
Travel Speed:
– Single Speed Loader 0 – 11,4 km/h (0 – 7.1 mph)
– Two-Speed Loader (Option):
Low Range 0 – 11,4 km/h (0 – 7.1 mph)
High Range 0 – 19,8 km/h (0 – 12.3 mph)
Engine
Make / Model Bobcat Engine / 3,4L Bobcat Engine Tier 4

Fuel / Cooling Diesel / Liquid
Horsepower:
– ISO 9249 EEC / SAE J1349 Net 65,8 kW (88.2 hp) @ 2400 rpm
– ISO 14396 Gross 68,7 kW (92.1 hp) @ 2400 rpm
– SAE J1995 Gross 69,6 kW (93.3 hp) @ 2400 rpm
– Rated Power 68,6 kW (92.0 hp) @ 2400 rpm
Torque:
– ISO 9249 EEC / SAE J1349 Net 332,3 N•m (245.1 ft-lb) @ 1600 rpm
– ISO 14396 Gross 350,3 N•m (258.4 ft-lb) @ 1600 rpm
– SAE J1995 Gross 354,9 N•m (261.7 ft-lb) @ 1600 rpm
– Rated Torque 349,9 N•m (258.1 ft-lb) @ 1600 rpm
Low Idle rpm 1050
High Idle rpm 2400
Number of Cylinders 4
Displacement 3409 cm3 (208.0 in3)
Bore / Stroke 98 mm / 113 mm (3.86 in / 4.45 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel – Compression
Air Induction Turbocharged and Charged Air Cooled
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Air intake heater automatically activated as needed in RUN position

Drive System
Main Drive Fully hydrostatic, 4-wheel drive

Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
Transmission
hydrostatic motors
Prestressed #120 HSOC endless roller chain (no master link) and sprockets in
Final Drive sealed chaincase with oil lubrication (Chains do not require periodic adjustments)
Two chains per side with no idler sprocket
Axle Size 68,6 mm (2.70 in), heat treated
Wheel Bolts Eight – 9/16 in wheel bolts fixed to axle hubs
Controls
Direction and speed controlled by two hand operated steering levers or optional
Machine Steering
joystick(s)
Loader Hydraulics:
Controlled by separate foot pedals or optional Advanced Control System (ACS)
– Lift and Tilt
or optional Selectable Joystick Controls (SJC)
– Front Auxiliary Controlled by electrical switch on Right Hand steering lever or joystick
– Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Hand operated speed control, additional foot operated speed control pedal with
Engine SJC option; key-type start switch or optional Keyless Start Panel or optional
Deluxe Instrumentation Panel and function error shutdown
Two independent hydrostatic systems controlled by two hand operated steering
Service Brake
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Mechanical disc activated by manually operated switch on left instrument panel
Spring applied pressure release multi-disc brake activated by manually operated
Parking Brake (Two-Speed Option)
switch on left instrument panel

Hydraulic System
Pump Type Engine driven, gear type

Pump Capacity – Standard-Flow 87,1 L/min (23.0 U.S. gpm)
Pump Capacity – High-Flow (Option) 138,5 L/min (36.6 U.S. gpm)
System Relief at Quick Couplers 23,8 – 24,5 MPa (238 – 245 bar) (3450 – 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, spin-on element
Double-acting; lift cylinders have cushioning feature on lower, tilt cylinders have
Hydraulic Cylinders:
cushioning feature on dump and rollback
Lift Cylinder (2):
Bore Diameter 82,6 mm (3.25 in)
Rod Diameter 50,8 mm (2.00 in)
Stroke 662,7 mm (26.09 in)
Tilt Cylinder (2):
Bore Diameter 76,2 mm (3.00 in)
Rod Diameter 38,1 mm (1.50 in)
Stroke 349,0 mm (13.74 in)
3-Spool, open center, manually operated with spring detent for lift float;
Control Valve – Standard
Electrically controlled auxiliary spool
3-Spool, open center with electric actuator controlled lift with float and tilt;
Control Valve – ACS and SJC
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses, and fittings
BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 – (Two – 2.5 U.S. gal)
Fluid Type
6903118 – (5 U.S. gal)
6903119 – (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 4.8 seconds
Lower Lift Arms 3.4 seconds
Bucket Dump 2.3 seconds
Bucket Rollback 1.7 seconds

Electrical System
Alternator Belt driven, 120 amperes, open frame

12 volt, 1000 cold cranking amperes @ -18°C (0°F),
Battery
186 minute reserve capacity @ 25 amperes
Starter 12 volt, gear type, 2,7 kW (3.62 hp)
Gauges:
Engine Coolant Temperature and Fuel Level
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, Diesel Exhaust Fluid (DEF) / AdBlue®, and
General Warning
Indicators:
Diesel Exhaust Fluid (DEF) / AdBlue® Level, BICS™ Functions, Two-Speed, 3-
Point Restraint, and Turn Signals
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Instrumentation Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown, Lift
and Tilt Compensation Setting, Steering Drift Compensation Setting, and Drive
Response Setting
Other:
Audible Alarm, Lights, and Option / Accessory Switches
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Engine Coolant Temperature, Engine Oil
Pressure, System Voltage, Hydraulic Fluid Temperature, and Hydrostatic Charge
Pressure
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multiple-Language Display, Help Screens, Diagnostic Capability, and
Engine / Hydraulic Systems Shutdown Function
Capacities
Fuel 90,5 L (23.9 U.S. gal)

Engine Oil with Filter Change 12,6 L (13.3 qt)
Engine Cooling System with Heater 14,4 L (3.8 U.S. gal)
Engine Cooling System without
13,6 L (3.6 U.S. gal)
Heater
Hydraulic / Hydrostatic Reservoir 9,5 L (2.5 U.S. gal)
Hydraulic / Hydrostatic System 36,0 L (9.5 U.S. gal)
Chaincase Reservoir 41,6 L (11.0 U.S. gal)
Diesel Exhaust Fluid (DEF) /
17,4 L (4.6 U.S. gal)
AdBlue®
Air Conditioning Refrigerant (R-134a) 0,9 kg (2.0 lb)

Tires
Heavy Duty (Standard) 12.00 – 16.5, 12 Ply Rating

Heavy Duty Offset (Option) 12.00 – 16.5, 12 Ply Rating
Heavy Duty Poly Fill (Option) 12.00 – 16.5, 12 Ply Rating
Severe Duty (Option) 12.00 – 16.5, 12 Ply Rating
Severe Duty Poly Fill (Option) 12.00 – 16.5, 12 Ply Rating
Solidflex (Option) 33 x 6 x 11
Super Float (Option) 33 x 15.50 – 16.5, 12 Ply Rating
Inflate tires to MAXIMUM pressure shown on the sidewall of the tire; DO NOT mix
Recommended Pressure
brands of tires used on the same loader

TECHINCAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Oil Pressure at Low Idle 147 - 294 kPa (1,47 - 2,94 bar) (21 - 43 psi)
Engine Oil Pressure at High Idle 294 - 539 kPa (2,94 - 5,39 bar) (43 - 78 psi)
Firing Order 1-3-4-2
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Valve Clearance (Cold) Intake 0,4 mm (0.016in)
Valve Clearance (Cold) Exhaust 0,45 mm (0.018 in)
NOTE: For additional engine specifications, (See Specifications on Page 70-10-2.)
Engine Torques
Engine Oil Drain Cap 54,2 N•m (40 ft-lb)

Fuel Injection Tubeline Nuts 27 - 31 N•m (20 - 23 ft-lb)
Fuel Injector Retaining Bolt 39 - 46 N•m (29 - 34 ft-lb)
Valve Cover Bolts 7,4 - 8,3 N•m (5.4 - 6.1 ft-lb)
Head Bolts 44,1 N•m (32.5 ft-lb)
Knock Sensor Bolts 22 N•m (16 ft-lb)
NOTE: For additional engine torques, (See Torque Values on Page 70-10-11.)
Cooling System
Coolant Type and Mix 47% Water and 53% Propylene Glycol
Radiator Cap Pressure 97 kPa (1 bar) (14 psi)
Thermostat Fully Open at 97°C (207°F)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 70-60-1.)

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)
Loader Torques
Bob-Tach Pivot Pin Retainer Bolt 446 - 453 N•m (330 - 335 ft-lb)
Lift Arm Pivot Pin Retainer Bolt 48 - 54 N•m (35 - 40 ft-lb)
Tilt Cylinder Pivot Pin Retainer Bolt 48 - 54 N•m (35 - 40 ft-lb)
Control Valve Mounting Bolts 125 - 135 N•m (90 - 100 ft-lb)
Hydraulic Pump Mounting Bolts 88 - 95 N•m (65 - 70 ft-lb)
Hydrostatic Motor Mounting Bolts 123 - 137 N•m (91 - 110 ft-lb)
Hydrostatic Pump Pulley Nut 257 - 325 N•m (190 - 240 ft-lb)
Main Frame Mounting Bolts 542 - 583 N•m (400 - 430 ft-lb)
Wheel Nuts (Installing) 217 N•m (160 ft-lb)
Wheel Nuts (Checking) 190 N•m (140 ft-lb)
NOTE: Additional loader torques can be found in the relevant section of this manual.
Hydraulic / Hydrostatic System
Pump Capacity at High Idle

- Standard Flow 87,1 L/min (23.0 U.S. gpm)
- High Flow 138,5 L/min (36.6 U.S. gpm)
- Charge 51,1 L/min (13.5 U.S. gpm)
Charge Pressure at High Idle Fluid Manual 2689 - 3378 kPa (26,8 - 33,8 bar) (390 - 490 psi)
Temp at 60°C (140°F): SJC 2860 - 3550 kPa (28,6 - 35,5 bar) (415 - 515 psi)
Test Charge Pressure See Loader Service Manual
Maximum Cylinder Drift Allowed
33 mm (1.3 in)
Without Bucket in 10 Minutes
NOTE: For additional hydraulic / hydrostatic system information, (See HYDRAULIC SYSTEM INFORMATION on
Page 20-10-1.) and (See HYDROSTATIC SYSTEM INFORMATION on Page 30-10-1.)
Fuel Consumption
Engine Load Full - 100% High - 70% Medium - 50% Low - 30%
19,7 L 16,3 L 13,6 L 11,7 L
Fuel Consumption Rate Per Hour
(5.2 U.S. gal) (4.3 U.S. gal) (3.6 U.S. gal) (3.1 U.S. gal)
NOTE: The engine fuel consumption chart is to be used as a guideline only. The actual results may vary.
High - Continuous loading or digging or load / carrying cycles; little idling.

Medium - Average loading or load / carrying cycles; some idling.
Low - Light loading or carrying - not much digging or pushing; considerable idling.

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE grade 5 SAE grade 8
size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- N•m ft-lb N•m ft-lb N•m ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100
M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 2900 - 2600
NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-40-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the locknut and install the fitting. Tighten the locknut until
the washer is tight against the surface [Figure SPEC-40-
1].
Figure SPEC-40-2
O-ring Boss
Tightening Torque
x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” - 16 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.
Figure SPEC-40-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
P-85926
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-40-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-40-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

SPECIFICATIONS
Specifications WARNING
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.

CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart

SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing loaders.
Remote Start Tools
TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool S70, S100, T110 This tool has been replaced by
S450 - S850 the new remote start tool
T450 - T870 7003031, see below. MEL1563
A770 includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness S70, S100, T110 Used with MEL1563 to connect
S450 - S850 remote start tool to machine.
T450 - T870
MEL1566 Service Tool Harness S70, S100, T110 Used with MEL1563 to connect
Communicator S450 - S850 remote start tool to PC.
T450 - T870
A770
7217666 Remote Start Tool S70, S100, T110 This tool replaced the original
KIT S450 - S850 remote start tool kit MEL1563
(Was 7003031) T450 - T870 and 7003031. Kit 7217666
A770 includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.
7022042 Remote Start Tool This tool replaces remote start

tool 6689778 and 7003030.
(Was 7003030)
(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to loader.
6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.
6689745 BOSS Service Tool Included with 7003031 but only

Harness used on early model loaders
equipped with BOSS.
7152935 Service Tool Harness Loaders with the Used to connect the 7 pin
7 pin attachment attachment harness to remote
harness. start tool.
See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-0818

SERVICE TOOLS REQUIRED (CONT’D)
Hydraulic Tools
TOOL PART MODELS

NUMBER USED ON
MEL1744 Hydraulic Tester S70, S100 Hydraulic tester MEL1744, MEL10003
(Flow Meter) T110 or TWX-RFIK200-S-6 can be used for
S450 - S850 hydraulic testing.
T450 - T870
A770
MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK200-S-6
(Flow Meter) are no longer available, order
MEL1744.
TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)
MEL1074 O-Ring Seal Hook
MEL1075 Adjustable Gland Includes MEL1075-1 and MEL1075-2

NUt Wrench
MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders.
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders.
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2
MEL1396-2 Piston Ring

Compressor
MEL1418 Cylinder Hone = S510 - S850

2.00 in T550 - T870
OEM6275 Cylinder Hone =
2.75 - 3.00 in
3.00 - 3.50 in
3.50 - 4.00 in
ST LDR-0818

Hydraulic Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL1033 Rod Seal Installation S70, S100
Tool T110
S450 - S850
T450 - T870
A770
MEL10006 Hydraulic Test Kit This test kit includes various adapters
and couplers that are used when
testing hydraulic functions. MEL10006
Includes: MEL10006-1 thru
MEL10006-7
MEL1278 Detent Tool S70, S100

T110
S450 - S850
T450 - T870
MEL1285 Detent Spring Tool S70, S100
T110
S450 - S850
T450 - T870
A770
MEL1355-2 Pressure Gauge, S450 - S850
1000 psi T450 - T870
MEL1355-3 Pressure Gauge, A770
5000 psi
MEL1723 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.
MEL1173A Hydraulic Test Kit S70 This test kit includes various adapters
and couplers that are used when
testing hydraulic functions.
MEL1173A Includes: MEL1173-1 thru
MEL1173-17
TWX-4004 42mm Thinwall S450 - S850 Used to remove and install 42mm
Socket T450 - T870 couplers on the front auxiliary coupler
A770 block.
7313845 50mm Coupler S450 - S850 Used to remove and install 50mm
Was 7299828 Wrench T450 - T870 couplers on the front auxiliary coupler
A770 block.
7246786 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.
ST LDR-0818

Hydraulic Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
7342781 Lift Cylinder Piston S450
Nut Socket T450
ST LDR-0818

Mainframe And Drive Tools
TOOL PART MODELS

NUMBER USED ON
MEL1399 Seal Driver Tool S450
MEL1525 Seal Driver Tool S70
MEL1242 Power Ram S100

S450 - S850
MEL1202 Axle Bearing Service S70, S100 MEL1202 Includes:

Set S450 - S770 MEL1202-1 thru MEL1202-13
MEL1714 Axle Seal Installation S850

Tool
6675936 Bleed Tool T110 - T870 Machines with two track tension
(MEL1560) fittings.
7277225 Bleed Tool T110 - T870 Machines with one track tension
fittings.
MEL1246 Chain Link Tool S450 - S850

A770
MEL1604 Seal Driver A770
MEL1269 Chain Breaker S450 - S595
MEL1364 Chain Link Tool S450 - S595
MEL1685 Pivot Point Tapered S630 - S850

Reamer T630 - T870
MEL1734 Pivot Point Tapered S450 - S595

Reamer T450 - T595
MEL1605 Bearing Race A770

Installer
ST LDR-0818

Mainframe And Drive Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL1730 Bearing Race S850
Remover
MEL1731 Bearing Race S850

Installer
MEL1606 Seal Installer A770
MEL1420 Carrier Seal S510 - S595

installation Tool
MEL1612 Bearing Removal T550 - T595

Tool
MEL1562 Bearing Installation T630 - T870

Tool
MEL1431 Seal Driver Tool S630 - S770

A770
MEL1407 Seal Driver Tool S630 - S770
7313844 Cab Isolator Tool S450 - S850

T450 - T870
A770
7343587 Drive Motor Seal MCR5T &

Installer MCR6T Drive
Motors
ST LDR-0818

Mainframe And Drive Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
7343588 Drive Motor Seal MCR10T
Installer Drive Motors
7343752 Skid Steer Loader S630-S850

Drive Shaft Seal M-Series
Protector Loaders
ST LDR-0818

Electrical Tools
TOOL PART MODELS

NUMBER USED ON
MEL1609 Wheel Speed S630 - S850
T630 - T870
A770
MEL1428 Sensor Tester S70,S100

T110
S450 - S850
T450 - T870
A770
MEL1567 Seat Bar Adapter S70, S100

T110
S450 - S850
T450 - T870
A770
7313846 Injector Signal Tester S450 - S850 Used to test injector signal on Bobcat
Was 7299829 T450 - T870 1.8L, 2.4L and 3.4L engines.
A770
7299830 Injector Signal Tester S750 - S850 Used to test injector signal on Kubota
T750 - T870 iT4 engines.
A770
ST LDR-0818

Engine Tools
TOOL PART MODELS

NUMBER USED ON
7024161 Diagmaster Kit S750 - S850 Includes:
(iT4 engine only) T750 - T870 DST-i (Diagmaster Service Tool)
A770 Vehicle cable (7024272)
USB cable (7024271)
Diagmaster Diagnostic Software.
MEL10630 Engine Compression S70,S100 Includes: MEL1352, MEL1433,

Test Kit T110 MEL1489, MEL1546, MEL1551,
S450 - S650, MEL1594, MEL1594,
T450 - T650 MEL10630-1 - MEL10630-11 and
MEL10630-14
MEL1655 Compression S450 - S650, Used in glow plug port for testing
Adapter T550 - T650 compression, NOT included with
MEL10630. Kubota V2607 and V3307
engines.
MEL1614 Compression S750 - S850 Used in injector port for testing
Adapter T750 - T870 compression, NOT included with
A770 MEL10630. Kubota V3300 and V3800
engines.
MEL1656 Fuel Injection Pump
Degree Restoring
Tool
MEL1657 Timing Gear Puller

Tool
7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool

Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357)
7031370 Rear Main Seal Bobcat 1.8L Used for installing rear main seal.
Installer & 2.4L
Engine
Models Tier 4
7031369 Front Seal Installer T4 Bobcat Used for installing front seal.
Engine
Applications
ST LDR-0818

Engine Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
7031371 Valve Spring T4 Bobcat Used for compressing valve springs.
Compressor Engine
Applications
MEL1733 Pivot Bushing S510 - S850 Use to install pivot bushing into
Installer T550 - T870 flywheel housing.
4200 Injector Nozzle S70, S100

Tester T110
S450 - S850
T550 - T870
A770
4201 Injector Nozzle
Tester Adapter Kit
MEL1173-1 Pressure Gauge S450 - S850

10000 psi T550 - T870
MEL1637 Governor Connecting S750 - S850

Rod Tool T750 - T870
A770
MEL1667 Governor Connecting S510 - S590,

Rod Tool S750 - S850
T550, T590,
T750 - T870
MEL1660 Crankshaft S510 - S650,
Replacement Tool T550 - T650
MEL1237 Fuel Line Adapter S450 - S550

T450 - T590
MEL1724 Crankshaft Position S750 - S850 For checking crankshaft sensor on

Sensor Measuring T750 - T870 IT4 Kubota engine.
Tool A770
ST LDR-0818

TOOL PART MODELS

NUMBER USED ON
MEL1725 Compression S750 - S850 Used in injector port. For checking
Adapter T750 - T870 compression on IT4 Kubota engine.
A770
MEL1666 Camshaft Gear S510 - S550 Kubota V2607, V3007 and V3307
Puller T550 - T590 engines.
MEL1653-1 Engine Removal Tool S450 - S850,

T450 - T870,
A770
MEL1653-2 Engine Removal Tool S750 - S850, T3 Kubota V3800 Engines.

T750 - T870,
A770
MEL1653-3 Engine Removal Tool S450 - S530, Kubota V2203 and V2403 Engines
T450 and universal lift adapter.
MEL1653-4 Engine Removal Tool S550 - S590, Kubota V2607 Engines.

T550 - T590
MEL1653-5 Engine Removal Tool S630, S650, Kubota V3307 Engines.

T630, T650
MEL1653-6 Engine Removal Tool S750 - S850 iT4 Kubota V3800 Engines.
T750 - T870,
A770
MEL1653-7 Engine Removal Tool S740 - S850 Included with MEL1653-1

Handle T740 - T870
A770
ST LDR-0818

TOOL PART MODELS

NUMBER USED ON
7111805 Mount S750 - S850 Used with MEL1653-2
(Was MEL1686) (Engine Removal T750 - T870
Tool) A770
MEL1653-8 Engine Removal Tool S740 - S850 Used with MEL1653-1

T740 - T870
A770
MEL1653-9 Engine Removal Tool S510 - S595, 2.4L Bobcat Engine Tier 4.
S630, S650,
T550 - T595,
T630, T650
MEL1653-11 Engine Removal Tool S750 - S850, 3.4L Bobcat Engine Tier 4 with SCR.
T750 - T870,
A770
MEL 1653-12 Engine Removal Tool S740, T740 3.4L Bobcat Engine Tier 4 without
SCR.
MEL1712 Push Button Starter S450 - S850,

Switch T450 - T870,
A770
MEL1270 Fuel Line Removal S70
Tool
MEL1271 Delivery Valve

Removal Tool
MEL1485 Injector Removal

Socket
MEL1616 Radiator Tank Test

Adapter
MEL1642 Radiator Cap Test

Adapter
ST LDR-0818

TOOL PART MODELS

NUMBER USED ON
7277084 Urea (DEF/AdBlue®) Bobcat 3.4L Includes: Filter Disassembly Tool,
Filter Service Kit Engine Filter and Equalizer.
Models Tier 4
SCR
Equipped
7299827 Compression Bobcat 3.4L Used in injector port for checking
Adapter Engine compression.
Models Tier 4
7313843 Compression Bobcat 1.8L Used in glow plug port for checking
Adapter & 2.4L compression.
Engine
Models Tier 4
7268212 Valve Lash Adjusting All Bobcat
Wrench Engine
Models
7255632 Valve Stem Seal Tool
MEL1742 Seal Installer S450 Drive motor seal installer.
MEL1607 Snap Ring Installer
7332314 Turbo and Oil Sensor All Bobcat 7332314 includes: 7332313 - Oil
Block Adapter Kit Engine Sensor Block Adapter and 7332298 -
Models Turbo Oil Adapter.
installer Engine
Models Tier 4
Guide Engine
Models Tier 4
7357425 Dust Cover Installer Bobcat 3.4L Used for installing Dust Cover.
Engine
Models Tier 4
ST LDR-0818

HVAC Tools
TOOL PART MODELS

NUMBER USED ON
MEL1581 HVAC Recover, S450 - S850 MEL1581 is no longer available,
Recycling, T450 - T870 order MEL1735 or MEL1736
Recharging Machine A770
MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine
MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine
MEL1592 HVAC Refrigerant

Identification Tool
MEL1595 AC Compressor S630 - S850

Pulley Puller T630 - T870
ST LDR-0818

ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) (SJC) . . . . 50-131-1 CONTROL PEDALS AND LINKAGES (ACS)
ACCESS PANEL (INSIDE) . . . . . . . . . 50-130-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-101-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-50-1 CONTROL PEDALS AND LINKAGES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-1
AIR CONDITIONING SYSTEM FLOW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1 CONTROL SYSTEM (ACS) . . . . . . . .60-130-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 CONVERSIONS . . . . . . . . . . . . . . .SPEC-60-1
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-160-1 CRANKSHAFT AND PISTONS . . . . .70-100-1
AUTOMATIC RIDE CONTROL . . . . . . 20-140-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-90-1
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14
BOBCAT CONTROLLER (SJC) (DRIVE) DIAGNOSTIC SERVICE CODES . . . . .60-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 DIESEL EXHAUST FLUID (DEF) / ADBLUE®
BOBCAT CONTROLLERS (GATEWAY AND SYSTEM . . . . . . . . . . . . . . . . . . . . . . .10-101-1
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 DIESEL OXIDATION CATALYST (DOC)
BOBCAT INTERLOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-40-1
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 DOSING CONTROL UNIT (DCU) . . . .60-73-1
BOB-TACH (HAND LEVER) . . . . . . . . 10-140-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-80-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-60-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 DRIVE COMPONENTS . . . . . . . . . . . .40-20-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-141-1 ELECTRICAL / HYDRAULIC CONTROLS
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 (ACS) . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
BRAKE (SINGLE SPEED) . . . . . . . . . . 40-10-1 ELECTRICAL / HYDRAULIC CONTROLS
(SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . 40-11-1
ELECTRICAL / HYDRAULIC CONTROLS
BUCKET POSITION VALVE . . . . . . . . 20-100-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-150-1 ELECTRICAL SYSTEM INFORMATION
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
CAMSHAFT AND CRANKSHAFT POSITION EMERGENCY EXIT . . . . . . . . . . . . . .10-200-1
SENSOR . . . . . . . . . . . . . . . . . . . . . . 60-230-1 ENGINE AIR CLEANER . . . . . . . . . . . .10-80-1
CAMSHAFT . . . . . . . . . . . . . . . . . . . . 70-110-1 ENGINE COMPARTMENT TEMPERATURE
CHAINCASE . . . . . . . . . . . . . . . . . . . . 40-30-1 SENSOR . . . . . . . . . . . . . . . . . . . . . .60-240-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-40-1 ENGINE CONTROL UNIT (ECU) . . . . .60-80-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1 ENGINE COOLING SYSTEM . . . . . . .70-60-1
CONTROL HANDLE / LEVER (ACS) ENGINE COVER . . . . . . . . . . . . . . . . .50-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1
CONTROL HANDLE / LEVER (SJC) ENGINE LUBRICATION SYSTEM . . .10-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1
ENGINE SPEED CONTROL (FOOT)
CONTROL HANDLE / LEVER . . . . . . 50-120-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-21-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-111-1 ENGINE SPEED CONTROL (HAND)
CONTROL PANEL SETUP . . . . . . . . 60-180-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1
CONTROL PANEL . . . . . . . . . . . . . . . 50-110-1 EVAPORATOR / HEATER COVER . . .80-150-1
EVAPORATOR / HEATER UNIT . . . . . .80-80-1
INDEX-01 S770 Service Manual

EVAPORATOR COIL . . . . . . . . . . . . .80-110-1 INSTRUMENT PANELS . . . . . . . . . . . 60-50-1
EXHAUST GAS RECIRCULATION (EGR) LEFT SIDE LOWER PANEL . . . . . . . 50-170-1
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-150-1 LIFT ARM BYPASS CONTROL VALVE
EXPANSION VALVE . . . . . . . . . . . . . .80-100-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
FAN DUCT PANELS . . . . . . . . . . . . . .50-200-1 LIFT ARM SUPPORT DEVICE . . . . . . 10-20-1
FINAL DRIVE TRANSMISSION LIFT ARMS . . . . . . . . . . . . . . . . . . . . . 50-50-1
(CHAINCASE) . . . . . . . . . . . . . . . . . .10-130-1 LIFTING AND BLOCKING THE LOADER
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
FLYWHEEL AND HOUSING . . . . . . .70-140-1 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7 LOADER IDENTIFICATION . . . . . . . . . . . 1-15
FRONT AUXILIARY HYDRAULIC COUPLER LOADER SPECIFICATIONS . . . . .SPEC-10-1
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1 LOADER STORAGE AND RETURN TO
FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1 SERVICE . . . . . . . . . . . . . . . . . . . . . 10-180-1
FUEL SYSTEM . . . . . . . . . . . . . . . . .10-100-1 LUBRICATING THE LOADER . . . . . 10-150-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . .70-80-1 LUBRICATION SYSTEM . . . . . . . . . . 70-70-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-90-1 MAIN RELIEF VALVE . . . . . . . . . . . . . 20-30-1
GEARCASE . . . . . . . . . . . . . . . . . . . .70-120-1 MAINTENANCE CLOCK . . . . . . . . . 60-200-1
HEADLINER . . . . . . . . . . . . . . . . . . . .50-190-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . 1-1
HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1 OIL COOLER . . . . . . . . . . . . . . . . . . . 20-90-1
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1 OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
HYDRAULIC / HYDROSTATIC FILTERS OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 OPERATOR SEAT (SUSPENSION)
HYDRAULIC / HYDROSTATIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-50-1 OPERATOR SEAT . . . . . . . . . . . . . . . 50-30-1
HYDRAULIC / HYDROSTATIC SYSTEM PASSWORD SETUP (DELUXE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 INSTRUMENTATION PANEL) . . . . . . 60-190-1
HYDRAULIC CONNECTION PASSWORD SETUP (KEYLESS START
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1 PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
HYDRAULIC CONTROL VALVE (ACS) OR PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-170-1
(SJC) . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
REAR AUXILIARY DIVERTER VALVE
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
REAR DOOR (TAILGATE) . . . . . . . . . 50-80-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1
REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1
RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1
REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1 REMOTE START TOOL (SERVICE TOOL) KIT
- 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDROSTATIC DRIVE MOTOR (TWO-
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 REMOTE START TOOL KIT - MEL1563
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1
RIGHT SIDE LOWER PANEL . . . . . . 50-180-1
HYDROSTATIC MOTOR CARRIER (SJC)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
HYDROSTATIC MOTOR CARRIER . . .30-30-1 SEAT BAR SENSOR . . . . . . . . . . . . 60-110-1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-51-1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-210-1
HYDROSTATIC SYSTEM INFORMATION SELECTIVE CATALYTIC REDUCTION (SCR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
SERVICE PC (LAPTOP COMPUTER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . 10-70-1
SERVICE TOOLS REQUIRED . . . . SPEC-70-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING DRIFT COMPENSATION
(OPERATOR MODE) . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION
(SERVICE MODE) . . . . . . . . . . . . . . . 60-171-1
STOPPING THE ENGINE AND LEAVING THE
LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
TECHINCAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
TELEMATICS . . . . . . . . . . . . . . . . . . . 60-250-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . 80-90-1
TIRE MAINTENANCE . . . . . . . . . . . . 10-160-1
TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TOWING THE LOADER . . . . . . . . . . . . 10-50-1
TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
TRANSPORTING THE LOADER ON A
TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . 80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-130-1
TWO-SPEED / BRAKE VALVE . . . . . . 30-70-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-140-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-142-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-141-1

Bobcat®, the Bobcat logo and the colors of the Bobcat machine are registered trademarks of
Bobcat Company in the United States and various other countries.

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Service Manual

Compact Track Loader

CORRECT CORRECT CORRECT

P-90216 NA1694 NA1693

WRONG WRONG WRONG

NA1674 NA1695 NA1680

NA1682 NA1683 B-6589

1-1 S770 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC TOC-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

1-3 S770 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-5 S770 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach® wedges and

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

6. Machine signs (decals) must 14. Check all machine fluid

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

1-7 S770 Service Manual

22. Check for any field

1-8 S770 Service Manual

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

1-9 S770 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

1-10 S770 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

1-11 S770 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Know where fire extinguishers and first aid kits are

1-12 S770 Service Manual

Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number (Item 1) [Figure 3] is located

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

Module 1 - Model / Engine

Explanation of loader Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

2. The five digit Production Sequence Number identifies

1-13 S770 Service Manual