A300 6901756 enUS SM

Service
Manual
Dealer Copy -- Not for Resale

S/N 521111001 & Above
S/N 521211001 & Above
BOBCAT SKID-STEER LOADER

With ALL WHEEL STEER (AWS)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6901756 ( ) Printed in U.S.A. © Bobcat Company 2010
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
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
B-10731a B-16261 B-16264

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

B-16272 B-16260 B-16263
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
B-16271 B-16270 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.
MSW14-0409
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ALPHABETICAL INDEX
AWS CONTROLLER .............................................. 60-01 HEATER COIL .........................................................80-01

AIR CLEANER .................................................... 70-01 HEATER / AC FAN ..................................................80-01
AIR CLEANER SERVICE ....................................... 10-01 HEATER VALVE ......................................................80-01
AIR CONDITIONING SERVICE.............................. 80-01 HUB .........................................................................40-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 HYDRAULIC CONNECTION SPECS ...............SPEC-01
ALTERNATOR ........................................................ 60-01 HYDRAULIC FLUID RESERVOIR ......................... 20-01
HYDRAULIC FLUID SPECIFICATIONS ....... SPEC-01
BASIC TROUBLESHOOTING ................................ 80-01 HYDRAULIC / HYDROSTATIC FILTER ..................20-01
BATTERY................................................................ 60-01 HYDRAULIC / HYDROSTATIC SYSTEM ................10-01
BICS™ SYSTEM .................................................... 60-01 HYDRAULIC PUMP ................................................20-01
BOBCAT 2001 CONTROLLER ............................... 60-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
BOBCAT INTERLOCK HYDROSTATIC MOTOR ..................................... 30-01
CONTROL SYSTEM (BICS™) ......................... 60-01 HYDROSTATIC MOTOR CARRIER ........................30-01
BOB-TACH ............................................... 10-01, 50-01 HYDROSTATIC PUMP ........................................ 30-01
BRAKE .................................................................... 40-01 HYDROSTATIC SYSTEM INFORMATION ..........30-01
BUCKET POSITION VALVE ................................ 20-01 INSIDE ACESS PANEL ...........................................50-01
INSTRUMENT PANEL............................................ 60-01
CHAINCASE ........................................................... 40-01
CHARGE PRESSURE ............................................ 30-01 LIFT ARMS ..............................................................50-01
CONTROL .............................................................. 50-01 LIFT ARM BYPASS CONTROL VALVE .............. 20-01
CONTROL PANEL .................................................. 50-01 LIFT ARM SUPPORT DEVICE ........................... 10-01
CONVERSIONS ............................................ SPEC-01 LIFT AND TILT ACTUATOR CALIBRATION ...........60-01

COOLING FAN ....................................................... 70-01 LIFTING AND BLOCKING THE LOADER.............. 10-01
COMPONENTS ...................................................... 80-01 LIGHTS ................................................................60-01
COMPRESSOR ...................................................... 80-01 LOADER SPECIFICATIONS (A300) ................. SPEC-01
CONDENSER ......................................................... 80-01 LOADER TORQUES ......................................... SPEC-01
CYLINDER (LIFT) ................................................... 20-01 LUBRICATING THE LOADER.................................10-01
CYLINDER (POWER BOB-TACH).......................... 20-01
CYLINDER (STEERING) ........................................ 20-01 MAIN RELIEF VALVE ..............................................20-01
CYLINDER (TILT) ................................................... 20-01 MUFFLER................................................................70-01
DIAGNOSTICS SERVICE CODES ......................60-01 OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

DRIVE BELT ........................................................... 30-01 OPERATOR CAB .........................................10-01, 50-01
DRIVE COMPONENTS .......................................... 40-01 OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
ELECTRICAL / HYDRAULIC CONTROLS
REFERENCE ........................................................ 60-01 POWER BOB-TACH .................................10-01, 50-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 POWER BOB-TACH BLOCK...................................20-01
ENGINE ................................................................. 70-01 PRESSURE RELIEF VALVE ...................................80-01
ENGINE COMPONENTS AND TESTS .................. 70-01 PRESSURE SWITCH..............................................80-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 RADIATOR ..............................................................70-01
ENGINE SPECIFICATIONS ...........................SPEC-01 REAR AUXILIARY DIVERTER................................20-01
ENGINE SPEED CONTROL .................................. 70-01 REAR DOOR .......................................................50-01
EVAPORATOR........................................................ 80-01 REAR GRILL .......................................................50-01
EVAPORATOR / HEATER UNIT ............................. 80-01 RECEIVER / DRIER ................................................80-01
EXPANSION VALVE ............................................... 80-01 RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
FAN GEARBOX ...................................................... 10-01 REMOTE START .................................................10-01
FINAL DRIVE TRANSMISSION (CHAINCASE) ..10-01
FLYWHEEL AND HOUSING ................................70-01 SAFETY ..................................................................80-01
FUEL SYSTEM ....................................................... 10-01 SEAT BAR ...............................................................50-01
FUEL TANK............................................................. 50-01 SEAT BAR SENSOR ...............................................60-01
SELECT VALVE.......................................................20-01
GENERAL AIR CONDITIONING SERVICE PC (LAPTOP COMPUTER) ................... 60-01
SERVICE GUIDELINES........................................ 80-01 SERVICE SCHEDULE ........................................... 10-01
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ALPHABETICAL INDEX (CONT’D)
SPARK ARRESTOR MUFFLER .............................10-01

SPEED SENSOR ................................................... 60-01
STARTER ............................................................... 60-01
STEERING BLOCK ................................................ 40-01
STEERING SOLENOID.......................................... 60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE / PRESSURE ...............................80-01

THERMOSTAT.........................................................80-01
TIRE MAINTENANCE ............................................ 10-01
TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER.............10-01
TROUBLESHOOTING.............................................70-01
WHEEL POSITION SENSORS .............................. 60-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

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

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
BOBCAT LOADER INDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAINFRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
SYSTEM &
MAINFRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
SPECIFICATIONS
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

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

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

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

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

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

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

the work lights.
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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
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.
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A300 Bobcat Loader

IV Service Manual
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at

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

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

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

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
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.).
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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

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

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

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

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

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

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

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

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

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

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1008 SM
A300 Bobcat Loader
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SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-24798
Figure 3

N-19358
The loader serial number plate is located on the outside

of the loader frame [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
P-24799
Model 1.-Model / Engine Model 2.-Production
Combination Sequence (Series)
The engine serial number is located on the valve cover at
1. The four digit Model / Engine Combination Module the right side of the engine [Figure 3]. There is also an
number identifies the model number and engine extra S/N tag attached to the engine [Figure 4]
combination.
2. The five digit Production Sequence Number identifies

the order which the loader is produced.
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DELIVERY REPORT
Figure 4
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure

5].
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BOBCAT LOADER INDENTIFICATION
▼ FRONT LIGHTS OPERATOR SEAT

with SEAT BELT
GRAB HANDLES
STEERING LEVER
▼REAR AUXILIARY
QUICK COUPLERS
TILT CYLINDER
+ BUCKET ▼FRONT AUXILIARY

QUICK COUPLERS
BUCKET STEPS STEPS

● OPERATOR CAB
LIFT CYLINDER (ROPS & FOPS)
SEAT BAR
LIFT ARM
REAR GRILL
LIFT ARM
SUPPORT DEVICE
▼REAR
LIGHT
REAR DOOR
▼ TAIL LIGHT
* TIRES B-16375
B-16374
▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES - Flotation tires ▼ are shown. The Bobcat loader is factory equipped with standard tires.
+ BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator
cab as shown. Extra insulated cab is available as an option (Reduced noise level).
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 DRIVE
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1

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

ELECTRICAL
Replacing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 SYSTEM &
ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Fuel Lift Pump Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 SERVICE
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1 SPECIFICATIONS

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Steering Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 10-120-2
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing The Lift Arm Support Device. . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Procedure For Loader With Attachments Control Harness 10-60-2
Procedure For Loader W/O Attachments Control Harness 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
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LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-31290
Lift the rear of the loader and install jackstands [Figure

B-7023A 10-10-2].
Figure 10-10-3
WARNING

AVOID INJURY OR DEATH
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
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807 P-31677
Read the Removal & Installation, Disassembly & Lift the front of the loader and put jackstands under the
Assembly, etc. completely to become familiar with the axle tubes [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tires.
WARNING
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
A300 Bobcat Loader

10-10-1 Service Manual
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LIFT ARM SUPPORT DEVICE
Installing The Lift Arm Support Device

DANGER
Figure 10-20-1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
1 can cause lift arms to drop.
• Keep out of this area when lift arms are raised
P-31244
unless supported by an approved lift arm
P-31290
support. Replace if damaged.
D-1009-0409
WARNING Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-1].
Never work on a machine with the lift arms up unless Remove the lift arm support device (Item 1) [Figure 10-
the lift arms are secured by an approved lift arm 20-1] from the storage position.
support device. Failure to use an approved lift arm The operator must stay in the operator seat with the seat
support device can allow the lift arms or attachment belt fastened and the seat bar lowered, until the lift arm
to fall and cause injury or death. support device is installed.
W-2059-0598
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
WARNING
Repair the support device if damaged or if parts are
missing. Using a damaged support device or with
missing parts can cause lift arms or boom to fall P-10136
causing serious injury or death.
W-2271-1007
P-31264
Have a second person install the lift arm support device

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

cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
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LIFT ARM SUPPORT DEVICE (CONT’D)
Installing The Lift Arm Support Device (Cont’d)
Figure 10-20-3
P-31265
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-

20-3].
Removing The Lift Arm Support Device
The operator must be in the operator's seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, raise the lift arms all the way up.
Have a second person remove the lift arm support

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

secure with clamping knobs.
Remove the jackstands.
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OPERATOR CAB Figure 10-30-2
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS / FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.
Level I - Protection from falling bricks, small concrete P-31288 P-31289

blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Loosen the nut (both sides) at the front corner of the
operator cab [Figure 10-30-2].
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Remove the nuts and plates [Figure 10-30-2] (both
or forestry. sides).

Raising The Operator Cab Figure 10-30-3
Figure 10-30-1
P-31267
P-31290
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
Always stop the engine before raising or lowering the mechanism engages [Figure 10-30-3].
cab.
Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing The Lift
Arm Support Device on Page 10-20-1.)
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
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OPERATOR CAB (CONT’D) Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Raising The Operator Cab (Cont’d)
Release the latching mechanism (Inset) [Figure 10-30-4]
Advanced Hand Control Only and pull the cab all the way down.
Figure 10-30-5
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
WARNING P-31288 P-31289

Never modify operator cab by welding, grinding, Install the plates and nuts [Figure 10-30-5] (both sides).
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to Tighten the nuts to 40 - 50 ft.-lb. (54 - 68 N•m) torque.
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or Emergency Exit
death.
W-2069-0200 Figure 10-30-6
Lowering The Operator Cab

Figure 10-30-4
N-19386
The front opening on the operator cab and rear window

N-20120 P-31268 provide exits.
REAR WINDOW (If Equipped)

Always stop the engine before raising or lowering the
cab. Pull on the tag on the top of the rear window to remove
NOTE: Make sure the seat bar is fully raised or the rubber cord [Figure 10-30-6].
lowered when lowering the cab. Always use
the grab handles to lower the cab.
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OPERATOR CAB (CONT’D) Figure 10-30-9
Emergency Exit (Cont’d)
Figure 10-30-7
P-28359
Push the window out with your foot [Figure 10-30-9] at

P-31269 any corner of the window.
Exit through the front door.

Push the rear window out of the rear of the operator cab.

Exit through the rear of the operator cab [Figure 10-30-
7].
Figure 10-30-8
N-20171
FRONT DOOR (If Equipped)
NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].
NOTE: When the special applications kit is installed,

the front door cannot be used for an
emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
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TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
Figure 10-40-1
P-31228A P-31230A
P-31914
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 6595014 P-31826
break and cause personal injury.
W-2058-0807
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
• Lower the bucket or attachment to the floor.
Be sure the transport and towing vehicles are of
adequate size and capacity (See Performance on Page • Stop the engine.
SPEC-10-2.)
• Engage the parking brake.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader • Install chains at the front and rear loader tie down
to prevent the front end of the trailer from raising up. positions (Inset) [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.
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TOWING THE LOADER The parts from the list below are required to complete the
towing tool needed in this procedure [Figure 10-50-1]:
Procedure
1 - 2 ft. Common Drain Hose (Item 1)
1 - 6678026 - Check Relief Valve (500 PSI) (Item 2)
DANGER 10K-5 - Tee Fitting (Item 3)
13K-5 - Swivel fitting (Item 4)
1 - 6661753 - Coupler, Male (Item 5)
1 - MEL1218 - Coupler, Female (Item 6)
2 - 36K-5 - Caps (Item 7)
Connect the drain hose (Item 1) [Figure 10-50-1] to the

check valve (Item 2) [Figure 10-50-1].
Connect the tee fitting (Item 3) [Figure 10-50-1], check

P-90328 valve (Item 2) [Figure 10-50-1], and the coupler (Item 5)
[Figure 10-50-1] to the swivel fitting (Item 4) [Figure 10-
AVOID DEATH 50-1].
tubeline, hose, fitting, component or a part failure Figure 10-50-2
can cause lift arms to drop.

D-1009-0409
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 P-34378
to fall and cause injury or death.
W-2059-0598
Disconnect the two hoses (Item 1) [Figure 10-50-2] from
the parking brake solenoid valve that goes to the right
Figure 10-50-1 and left brake housing on the hydrostatic motors.
3
6
2
1
7
P-34159
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
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TOWING THE LOADER (CONT’D) Figure 10-50-4
Procedure (Cont’d)
Figure 10-50-3
2 P-34380
3
Operate the Port-a-Power to 350 - 400 PSI (2413 - 2758

P-34379 kPa) to release the brakes [Figure 10-50-4].
Connect the two hoses (Item 1) [Figure 10-50-3] to the Lower the cab and tow the loader.
tee fitting of the towing tool.
Release the Port-a-Power pressure to apply the brakes.

Connect the Port-a-Power (with an attached gauge
pressure, 600 PSI (4137 kPa) or larger) to the quick Remove the towing tool from the brake hoses.
coupler (Item 2) [Figure 10-50-3] on the towing tool.
Install the two hydraulic hoses to the parking brake
Route the drain hose (Item 3) [Figure 10-50-3] into a solenoid valve.
bucket.
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REMOTE START Figure 10-60-2
Procedure For Loader W/O Attachments Control

Harness
Figure 10-60-1
1
1
P-28365
Remove the cap (Item 1) [Figure 10-60-2] from the

loader harness.
P13841
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-60-2].
The tool listed will be need to do the following procedure:

Figure 10-60-3
MEL1563 - Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-1] 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 2
linkage.
Lift and block the loader. (See Procedure on Page 10-10-

1.) 1
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)
P-28366
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Connect the remote start tool to the engine harness
Open the rear door of the loader. connector (Item 1) [Figure 10-60-3].
The connector (Item 2) [Figure 10-60-3] from the remote

start harness is not used in the remote start procedure
and should remain capped.
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Kit will not operate.
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REMOTE START (CONT’D) Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Procedure For Loader W/O Attachments Control
Harness (Cont’d) Open the rear door of the loader.
Figure 10-60-5
WARNING
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
1
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
P-28362
Procedure For Loader With Attachments Control

Harness Figure 10-60-6

Figure 10-60-4
1
1
P-28364
P13841
Disconnect the attachment control harness (Item 1)
[Figure 10-60-5] & [Figure 10-60-6] from the loader
The tool listed will be need to do the following procedure: harness (Item 2) [Figure 10-60-6].
MEL1563 - Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-4] 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.

1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)
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REMOTE START (CONT’D) Procedure
Procedure for Loader With Attachments Control Figure 10-60-8

Harness (Cont’d)
Figure 10-60-7
1
3 2
P13842
1
P-28363 The remote start tool (Item 1) [Figure 10-60-8] has three
rocker switches.
Connect the remote start tool (Item 1) [Figure 10-60-7] to Figure 10-60-9

the loader harness connector (Item 2) [Figure 10-60-6].
The connector (Item 3) [Figure 10-60-7] on the remote

start harness is not used in the remote start procedure
and should remain capped.
2
NOTE: The key switch on the right-hand side 1
3
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
N-19541
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the The traction lock switch (Item 1) [Figure 10-60-9] is used
to turn traction lock on or off. Push the switch to the
loader can still be started from the operator panel override position. The switch will illuminate to indicate
inside the cab. Placing the key switch of the remote traction lock OVERRIDE, in this position the wheels are
start tool in the run position disconnects the able to turn.
operator panel key switch from the start circuit. If the
service technician will be working the engine area it The maximum flow / variable flow switch (Item 2) [Figure
is important to remove the operator panel keys. 10-60-9] is used to activate the auxiliary hydraulics.
W-2357-0899
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-9]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
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REMOTE START (CONT’D)
NOTE: With the engine running; pushing and holding

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

■ ■ ■ ▼
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000 3000
Engine Oil Check the oil level and add oil as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cyl., Bob-Tach Pivot Lubricate with multi-purpose lithium based grease.
Pins, Wedges and Steering Cyl.
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Manual.

Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Fuel Filter Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating / cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Add oil as needed.
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105 - 115 ft.-lb. (142 - 156 N•m)
torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine / Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Condition Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS™)
Fuel Filter Replace filter element.
Steering King Pins Lubricate with multi-purpose lithium based grease.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ●Replace the filter element.
Engine Oil and Filter ^Replace oil and filter. Use CD or better grade oil and Bobcat filter. ❍
Steering Filter ^Replace filter.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves #Adjust the engine valves.
Wheel Bearings & Outer Axle Repack the wheel bearings. Grease internal splines in hub yolk.
Splines
Engine Timing Belt ▼Replace the timing belt and belt tensioner assy.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic / hydrostatic filter element at first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Valve Clearance Adjustment on Page
70-70-27.)
■ Or every 12 months.
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AIR CLEANER SERVICE If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER /
Replacing Filter Element CODE DISPLAY (Item 2) [Figure 10-80-2].
Figure 10-80-1 Figure 10-80-3
B-16300
P-31251
B-15552
B-15553
OUTER FILTER

It is important to change the air filter element only when Disengage the clamps (Item 1) [Figure 10-80-3] and
the Air Cleaner Icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Replacing Filter Element
(Cont'd) on Page 10-80-2.)
Figure 10-80-2
P-31252
1
Remove the outer filter element (Item 1) [Figure 10-80-
4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
B-15551 Install a new outer element.
Install the dust cover and fasten the clamps.

Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
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AIR CLEANER SERVICE (CONT’D) Install the new inner element.
Replacing Filter Element (Cont'd) Install the dust cover and fasten the clamps (Item 1)
[Figure 10-80-6].
Figure 10-80-5
P-31253
INNER FILTER

Only replace the inner filter element under the following
conditions:
• Replace the inner filter element every third time the

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

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Figure 10-80-6
P-31251
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ENGINE COOLING SYSTEM Figure 10-90-2
Cleaning Cooling System
Figure 10-90-1
P-31260
Remove the cotter pin (Item 1) [Figure 10-90-2] (both

P-31259 sides) from the oil cooler.
Figure 10-90-3
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.

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 P-31261
Remove the rear grill. (See Removal And Installation on Raise the oil cooler [Figure 10-90-3].
Page 50-60-1.)
Use air pressure or water pressure to clean the top of the
Use air pressure or water pressure to clean the top of the engine oil cooler.
oil cooler [Figure 10-90-1].
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ENGINE COOLING SYSTEM (CONT’D
Cleaning Cooling System (Cont’d)
Figure 10-90-4
Access
Cover
P-31691
NOTE: The access cover (both sides) must be in

place to ensure proper air flow through the oil

cooler which will ensure correct cooling for
the engine / hydraulic system [Figure 10-90-4].
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FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
The following is one suggested blending guideline which

should prevent fuel gelling problems:
Temp. F° (C°) No. 2 No. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15526
We recommend an operator contact their fuel supplier for
local recommendations.
Use a clean, approved safety container to add fuel of the
Filling The Fuel Tank correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap [Figure 10-100-1].

WARNING

Fuel Filter
Figure 10-100-3
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1
2
1
P-31256
1
(See SERVICE SCHEDULE on Page 10-70-1.) for the

recommended service interval when to remove the water
from the fuel filter.
P-31254
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to drain any water from the
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. filter.

recommended service interval when to replace the fuel
filter.
To replace the fuel filter element, use a filter wrench to

remove the filter element (Item 2) [Figure 10-100-3].
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FUEL SYSTEM (CONT’D) Fuel Lift Pump Strainer
Fuel Filter (Cont’d) Figure 10-100-6
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.
Removing Air From The Fuel System
Figure 10-100-4
1

P-24722
P-31256
After replacing the fuel filter element or when the fuel

tank has run out of fuel, the air must be removed from the
fuel system prior to starting the engine. P-31257
Loosen the air vent plug (Item 1) [Figure 10-100-4] at the

top of the fuel filter. Loosen the bolt and remove the cover and strainer (Item
1) [Figure 10-100-6].
Figure 10-100-5
Clean the strainer with clean diesel fuel.
Install the strainer and cover and tighten bolt.
P-31258
Operate the hand pump (priming bulb) (Item 1) [Figure

10-100-5] until the fuel flows from the air vent plug with
out air bubbles.
Tighten the air vent plug.
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ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil Figure 10-110-2
Figure 10-110-1
N-19328
P-31258
service interval for replacing the engine oil and filter.
Check the engine oil level every day.
Run the engine until it is at operating temperature. Stop

Before starting the engine for the work shift, open the the engine.
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]. Open the rear door. Remove the drain plug (Item 1)
[Figure 10-110-2]. Drain the oil into container.
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service

Classification of CD, CE or better. (See Oil Chart below.)
Oil Chart
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CD, CF4,CG4)
*Can be used ONLY when available with appropriate diesel rating.
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ENGINE LUBRICATION SYSTEM Figure 10-110-4
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
2
P-31258
Remove the filler cap (Item 2) [Figure 10-110-4].

P-31297
Put 10 qt. (9,5 L) of oil in the engine.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
WARNING

oil as needed if it is not at the top mark on the dipstick.

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
Remove the oil filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain plug.
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HYDRAULIC / HYDROSTATIC SYSTEM Figure 10-120-3
Checking And Adding Fluid
Figure 10-120-1
Sight
Gauge
P-4613
P-30011
NOTE: Before installing the fill cap, make sure the

P-31692 rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
Use only recommended fluid in the hydraulic system. Figure 10-120-4

(See Specifications on Page SPEC-60-1.)

To check the reservoir, use the following procedure:
Put the Bobcat loader on a level surface. Lower the lift

arms and tilt the Bob-Tach fully back. Stop the engine.
Check the fluid level at the sight gauge [Figure 10-120-

1]. The fluid level must show in the sight gauge.
Figure 10-120-2 1
P-31281
Hydraulic / Hydrostatic Filter Replacement

1
correct service interval.

on Page 10-30-1.)
P-31692 Use a filter wrench to remove the filter element (Items 1)

[Figure 10-120-4].
If fluid is needed, remove the fill cap (Item 1) [Figure 10- Clean the surface of the filter housing where the element
120-2]. seal contacts the housing. Put clean oil on the rubber
seal of the filter elements.
Add the fluid as needed to bring the level to the center of
the sight gauge. Install and hand tighten the filter elements.
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Disconnect the hoses from the hydrostatic motor case
drain filter (Item 1) [Figure 10-120-6].
Replacing Hydraulic Fluid
Remove the case drain filter and clean thoroughly with
Figure 10-120-5 clean solvent.
Install the case drain filter and tighten the hoses.
Install the plug in the reservoir drain hose and tighten.

Install the motor cover.
Add the correct fluid to the reservoir until the fluid level is
at the sight gauge. (See Checking And Adding Fluid on
1 Page 10-120-1.)
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.
P-31286
Steering Filter Replacement

service interval. Figure 10-120-7

Replace the fluid if it becomes contaminated or after
major repair.
Also clean the hydrostatic motor case drain filter

thoroughly after a major repair.

on Page 10-30-1.)
1
Remove the left hydrostatic motor cover.
Pull the reservoir drain hose (Item 1) [Figure 10-120-5]

out the motor cover hole. Remove the plug and drain the
fluid into a container.
P-26700
Replace the filter element. (See Hydraulic/Hydrostatic

Filter Replacement on Page 10-120-1.) Raise the lift arms and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on
Figure 10-120-6
Page 10-20-1.)

on Page 10-30-1.)
1
Remove the filter mount bracket bolt (Item 1) [Figure 10-
120-7]
P-31672
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Steering Filter Replacement (Cont’d)
Figure 10-120-8
P-26701
Disconnect the inlet hose (Item 1) [Figure 10-120-8]

from the gear pump to the filter.

Disconnect the outlet hose (Item 2) [Figure 10-120-8]
from the filter to the steering valve.
Remove the filter mount clamp (Item 3) [Figure 10-120-

8].
Discard the filter and install a new filter.
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FINAL DRIVE TRANSMISSION (CHAINCASE) Replacing The Oil
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-1616
P-31287
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and drain plug at the rear of the chaincase.
chains and uses the same type of oil as the hydraulic /

hydrostatic system. (See Specifications on Page SPEC- Figure 10-130-3
60-1.)
To check the chaincase oil level, use the following

procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.
1
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug. P-1619
Remove the drain plug (Item 1) [Figure 10-130-3] and

drain the oil into a container.
Check the drain plug and replace if necessary.
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FAN GEARBOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P7616

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.
When checking the gearbox lube level, make sure the

level does not go above the center line of the shaft in the
gearbox [Figure 10-140-1]. Use SAE 90W gear lube if
the level is low.
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BOB-TACH Figure 10-150-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Wedge Must Contact
Lower Edge Of Hole
In the Attachment
Figure 10-150-1 B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
If the wedge does not contact the lower edge of the hole
P-21234
[Figure 10-150-2] and [Figure 10-150-3], the

1 attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
P-31693
Move the Bob-Tach levers to engage the wedges [Figure

10-150-1]. The levers and wedges must move freely.
The wedges must extend through the holes in the

attachment mounting frame (Inset) [Figure 10-150-1].
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

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

1 Page 10-70-1 and See LUBRICATING THE LOADER on
Page 10-160-1)
P-31237
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POWER BOB-TACH Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
B-15177
Wedges Must Contact

Lower Edge Of Hole
In The Attachment
P-31237
If the wedge does not contact the lower edge of the hole
B-15891C (Item 1) [Figure 10-151-3], the attachment will be loose
and can come off the Bob-Tach.
Push and hold the BOB-TACH “WEDGES UP” switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and

hold the BOB-TACH “WEDGES DOWN” switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
P-31233 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1 and See LUBRICATING THE LOADER on
Page 10-160-1)
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LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1 3
P-31301
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3].

P-31299
Figure 10-160-4
Lubricate the loader as specified (See SERVICE

SCHEDULE on Page 10-70-1.) for the best performance

of the loader.
Record the operating hours each time you lubricate the

Bobcat loader.
4
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1]. P-31302
Figure 10-160-2
4. Lift Arm Link Pivot (Both Sides) [Figure 10-160-4].
Figure 10-160-5
2
P-31300
P-31305
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-
2].
5. Base End Tilt Cylinder (Both Sides) [Figure 10-160-
5].
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LUBRICATION OF THE LOADER (CONT’D) Figure 10-160-8
Procedure (Cont'd)
Figure 10-160-6
P-31308
8. Bob-Tach Wedge (Both Sides) [[Figure 10-160-8]

P-31306
Figure 10-160-9
6. Rod End Tilt Cylinder (Both Sides) [Figure 10-160-6].

Figure 10-160-7
9
P-31304
7
9. Control Link (Both Sides) [Figure 10-160-9].

P-31307
Figure 10-160-10
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-7].
10
P-31303
10. Control Link (Both Sides) [Figure 10-160-10].
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LUBRICATION OF THE LOADER (CONT’D)
Procedure (Cont'd)
Figure 10-160-11
11
12
P-24819
11. Steering King Pins (All Wheels) [Figure 10-160-11].

12. Steering Cylinder (All Wheels) [Figure 10-160-11].
Pivot Pins
Figure 10-160-12
P-31309
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-12].
Check that the lock nuts are tightened to 18 - 20 ft.-lb. (24

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

using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
P-24816 lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
(See SERVICE SCHEDULE on Page 10-70-1.) for the pressure frequently to avoid over inflation.
service interval to check the wheel nuts [Figure 10-170-

1].
When installing wheel nuts, tighten to 160 ft.-lb. (217

N•m) torque. WARNING
When checking wheel nuts, tighten to 140 ft.-lb. (190
N•m) torque.
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
Tire Rotation
explosion which can result in injury or death.
W-2078-1007
Figure 10-170-2
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
B-9976
Check the tires regularly for wear, damage and pressure.

(See Tires on Page SPEC-10-4.)
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 SAFETY &
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-90-1 MAINTENANCE
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5 SYSTEM
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2

ELECTRICAL
SYSTEM &
CYLINDER (STEERING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1 ANALYSIS
Removal (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
ENGINE
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SERVICE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Base Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 SPECIFICATIONS
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . 20-120-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-40-1
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . 20-40-7
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Auxiliary Electric Solenoid Disassembly And Assembly . . . . . . . . . 20-40-22
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-30-21
BICS™ Valve Check Valve Removal And Installation . . . . . . . . . . . . 20-40-9
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation . . . 20-40-9
BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . 20-40-10
BICS™ Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve Soleniod Removal And Installation . . . . . . . . . . . . . . 20-40-11
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Lift And Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . 20-40-20
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Checking The Output Of The Auxiliary Pump . . . . . . . . . . . . . . . . . . 20-60- 1
Checking The Output Of The Steering Pump . . . . . . . . . . . . . . . . . . 20-60- 2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60- 7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60- 3
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
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HYDRAULIC SYSTEM (CONT’D)
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . 20-50-1

Additional Inspection For Loaders W/Advanced Hand Controls 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Checking The Main Relief Valve At Front Auxiliary Hydraulics . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
POWER BOB-TACH BLOCK (EARLY MODELS) . . . . . . . . . . . . . 20-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
POWER BOB-TACH BLOCK (LATER MODELS) . . . . . . . . . . . . . 20-111-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1

REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) . . . . . 20-100-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
REAR AUXILIARY DIVERTER (LATER MODELS). . . . . . . . . . . . 20-101-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-8
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-8
A300 Bobcat Loader

67 of 772
A300 Bobcat Loader

68 of 772
HYDRAULIC/HYDROSTATIC SCHEMATIC
A300 (S/N 521111001 - 521111292)

Printable Version Click Here
(PRINTED MAY 2004)

V-0144legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
55 PUSH BUTTON SOLENOID ACTIVATED
19 RELIEF VALVE - MAIN: VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS DIRECTIONAL CONTROL VALVE -
3250-3350 PSI (224-231 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) BRAKE
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC CONTROL VALVE - MAKE-UP
4000 PSI (276 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - SOLENOID ACTIVATED DIRECTIONAL
39 58 FILTER (BRAKE)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
7 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) AUXILIARY ("SV1")
CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Dealer Copy --40NotPILOT ACTIVATED DIRECTIONAL CONTROL
for Resale DRIVE MOTOR
VALVE VALVE - FOR REAR AUXILIARY - NORMALLY
CLOSED ("P1" and "F1") 60 PUMP SERVO
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - AUXILIARY 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 62 FILTER - STEERING (10 MICRON)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
SPOOL 44 FILTER - CASE DRAIN (Attachment) PROPORTIONAL FLOW CONTROL
PRESSURE: 5000 PSI (345 Bar)
45 VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP 64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 46 TWO-STAGE RELIEF 0-2000 PSI (0-138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69 / 138 Bar) 65 STEERING CYLINDER
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - 270 PSI (18,6 BaR)
13 PILOT ACTIVATED DIRECTIONAL 29 CONTROL VALVE (TWO COIL)
CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (83 Bar) 67 PRESSURE CONTROL PILOT
VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 49 RESTRICTOR - 0.015 inch (0,381 mm) 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,35 L/min.) at High Engine Idle 68
50 PRESSURE COMPENSATED FLOW DISPLACEMENT CONTROL SPOOL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE CONTROL
DIRECTIONAL CONTROL VALVE - 69 FRONT AUXILIARY MANUAL
51 RELIEF VALVE - PORT:
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: PRESSURE BLEED-OFF VALVE
4000 PSI (276 Bar)
200 PSI (13,8 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION NOTE: Unless otherwise specified
CONTROL VALVE - BLEED OFF REAR VALVE (ON/OFF) springs have NO significant
AUXILIARY ("SV2") pressure value.
Printed in U.S.A. V-0144legend (4-28-04)
69 of 772
A300 (S/N 521111001 - 521111292) DIVERTER VALVE (OPTIONAL)
38
(PRINTED MAY 2004)
V-0144
39
HYDROSTATIC M2 M1 PILOT
PUMP
Printable Version Click Here 26 26
TWO SPEED DRIVE MOTOR
INTEGRATED QUICK STEERING VALVE

40 36 COUPLER BLOCK 65 65
28 63 63
CHARGE M3 MALE MALE F1 D1 69
31 32 INLET
MALE
29
M4 34 MALE
45 (REAR QUICK
M COUPLERS)
60 CASE 66 66
5
DRAIN FEMALE
33 35 37 69
F2 D2
59 68 FEMALE FEMALE
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
65
65
64
X1 X2
P T
X2 X1
44
Control
Module 67
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
68 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
28
Dealer Copy -- Not for Resale HYDRAULIC CONTROL VAVLE 10
BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
61
TWO SPEED VALVE OUTLET 23 TILT CYLINDER
B 22
55 INLET BICS CONTROL VALVE
58 48
47
46
58 50

A B 12
DR 51 TILT
56 9 49
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
PP 18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS

VALVE
15
Printed in U.S.A.
V-0144 (4-28-04)
70 of 772
A300 (S/N 521111293 - 521111550)

(PRINTED MAY 2004)
V-0575legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
55 PUSH BUTTON SOLENOID ACTIVATED
19 RELIEF VALVE - MAIN: VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS DIRECTIONAL CONTROL VALVE -
3250-3350 PSI (224-231 Bar) OPEN ("D1" and "P1")
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
4000 PSI (276 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - SOLENOID ACTIVATED DIRECTIONAL
39 58 FILTER (BRAKE)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
3500 PSI (241 Bar) AUXILIARY ("SV1")
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Dealer Copy --40NotPILOT ACTIVATED DIRECTIONAL CONTROL
for Resale DRIVE MOTOR
VALVE VALVE - FOR REAR AUXILIARY - NORMALLY
CLOSED ("P1" and "F1") 60 PUMP SERVO
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY (Removed at
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH S/N 521111295 And Above) 63 SOLENOID ACTIVATED
SPOOL PRESSURE: 5000 PSI (345 Bar) PROPORTIONAL FLOW CONTROL
44 FILTER - CASE DRAIN (Attachment) VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
45 VARIABLE CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED PRESSURE
SPOOL BIDIRECTIONAL HYDROSTATIC PUMP
28 RELIEF VALVE - CHARGE: 0-2000 PSI (0-138 Bar)
120 degrees F. (53 degrees C.)Fluid 46 TWO-STAGE RELIEF 65 STEERING CYLINDER
12 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle 1000/2000 PSI (69 / 138 Bar)
66 CHECK VALVE - 270 PSI (18,6 Bar)
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL CONTROL VALVE (TWO COIL) 67 PRESSURE CONTROL PILOT
12.0 GPM (45,4 L/min.) at High Engine Idle
48 RELIEF VALVE - 1200 PSI (83 Bar) VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,35 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm)
68 DISPLACEMENT CONTROL SPOOL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
DIRECTIONAL CONTROL VALVE - CONTROL 69 FRONT AUXILIARY MANUAL
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: PRESSURE BLEED-OFF VALVE
51 RELIEF VALVE - PORT:
200 PSI (13,8 Bar) 4000 PSI (276 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE - BLEED OFF REAR CONTROL VALVE - BUCKET POSITION springs have NO significant
AUXILIARY ("SV2") VALVE (ON/OFF) pressure value.
71 of 772
A300 (S/N 521111293 - 521111550) DIVERTER VALVE (OPTIONAL)
38
(PRINTED MAY 2004)
V-0575
39
HYDROSTATIC M2 M1 PILOT
PUMP

40 36 COUPLER BLOCK 65 65
28 63 63
CHARGE M3 MALE MALE F1 D1 69
31 32 INLET
MALE
29
M4 34 MALE
45 (REAR QUICK
M COUPLERS)
60 CASE 66 66
5
DRAIN FEMALE
33 35 37 69
F2 D2
59 68 FEMALE FEMALE
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
65
65
64
X1 X2
P T
X2 X1
44
Control
Module 67
(EDC)
62
PUMP
3
68 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
28
BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
61
TWO SPEED VALVE OUTLET 23 TILT CYLINDER
B 22
58 48
47
46
58 50

A B 12
DR 51 TILT
56 9 49
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
PP 18
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS

VALVE
15
Printed in U.S.A.
V-0575 (4-28-04)
72 of 772
A300 (S/N 521111551 - 521111762)

(PRINTED MAY 2004)
V-0577legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 SOLENOID ACTIVATED DIRECTIONAL 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) CONTROL VALVE - ROD BIDIRECTIONAL HYDROSTATIC
MOTOR
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 LOAD SHUTTLE VALVE - BLEED OFF
FILTER - CASE DRAIN (90 Micron) 54 HYDRAULIC BRAKE - SPRING APPLIED -
18 LOAD CHECK VALVE - LIFT AND TILT PRESSURE TO RELEASE
3 36 SOLENOID ACTIVATED DIRECTIONAL
FILTER - HYDRAULIC (CANISTER)
CONTROL VALVE (TWO COIL) 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224-231 Bar) BRAKE
CONTROL VALVE - FOR REAR AUXILIARY
at Front Quick Couplers
20 RELIEF VALVE - PORT: 38 ORIFICE WITH 0.140 RESTRICTION
POWERED BOB-TACH 4000 PSI (276 Bar)
39 RELIEF VALVE - 3300 PSI (22753 KPA) 57 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 40 ORIFICE WITH 0.031 RESTRICTION 58 FILTER (BRAKE)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
3500 PSI (241 Bar) 41 CHECK VALVE - BICS CONTROL VALVE
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Dealer Copy -- Not for Resale DRIVE MOTOR
VALVE 42 LIFT ARM BY-PASS RESTRICTOR
60 PUMP SERVO
9 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY 43 FRONT AUXILIARY MANUAL 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC PRESSURE BLEED-OFF VALVE
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 44 FILTER - CASE DRAIN (Attachment) 62 FILTER - STEERING (10 MICRON)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
45 VARIABLE CAPACITY DISPLACEMENT
SPOOL PRESSURE: 5000 PSI (345 Bar) PROPORTIONAL FLOW CONTROL
BIDIRECTIONAL HYDROSTATIC PUMP
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING 46 TWO-STAGE RELIEF
CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 1000/2000 PSI (69 / 138 Bar)
0-2000 PSI (0-138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 47 SOLENOID ACTIVATED DIRECTIONAL 65 STEERING CYLINDER
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle CONTROL VALVE (TWO COIL)
66 CHECK VALVE - 270 PSI (18,6 Bar)
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP 48 RELIEF VALVE - 1200 PSI (83 Bar)
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle 67 PRESSURE CONTROL PILOT
VALVE - 2 COILS
30 49 RESTRICTOR - 0.015 inch (0,381 mm)
14 SOLENOID ACTIVATED DIRECTIONAL HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,35 L/min.) at High Engine Idle 68
50 PRESSURE COMPENSATED FLOW DISPLACEMENT CONTROL SPOOL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE CONTROL
DIRECTIONAL CONTROL VALVE -
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
200 PSI (13,8 Bar) 4000 PSI (276 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE - BASE CONTROL VALVE - BUCKET POSITION springs have NO significant
VALVE (ON/OFF) pressure value.
73 of 772
(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC COUPLERS) MALE
A300 (S/N 521111551 - 521111762)

(PRINTED MAY 2004) BASE ROD REAR AUX VALVE (OPTIONAL)
V-0577
HYDROSTATIC M2 M1
PUMP
TWO SPEED DRIVE MOTOR 33 34
35 INTEGRATED QUICK STEERING VALVE

36
COUPLER BLOCK 65 65
28 38 63 63
CHARGE M3
31 INLET 43
32 MALE
29 40
39
M4 37 MALE
45
M
60 CASE 66 66
5
DRAIN FEMALE
43
POUT PIN T
59 68
54
53 Control
Module 66 66
(EDC) 67 63
9 63
65
65
64
X1 X2
P T
X2 X1
44
Control
Module 67
(EDC)
62
PUMP
3
68 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
28
BOB-TACH 43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
61
TWO SPEED VALVE TILT
OUTLET 23 CYLINDERS
B 22
58 48
47
46
58 50

A B 12
DR TILT
56 9 49 PP 51
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
18
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS

VALVE
15
Printed in U.S.A.
V-0577 (4-30-04)
74 of 772
A300 (S/N 521111763 AND ABOVE)

(PRINTED MAY 2004)
V-0576legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 SOLENOID ACTIVATED DIRECTIONAL 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) CONTROL VALVE - ROD BIDIRECTIONAL HYDROSTATIC
MOTOR
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 LOAD SHUTTLE VALVE - BLEED OFF
FILTER - CASE DRAIN (90 Micron) 54 HYDRAULIC BRAKE - SPRING APPLIED -
18 LOAD CHECK VALVE - LIFT AND TILT 36 PRESSURE TO RELEASE
3 FILTER - HYDRAULIC (CANISTER) SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
3250-3350 PSI (224-231 Bar) 37 PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE - FOR REAR AUXILIARY
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 38 ORIFICE WITH 0.140 RESTRICTION CONTROL VALVE - MAKE-UP
POWERED BOB-TACH 4000 PSI (276 Bar)
39 RELIEF VALVE - 3300 PSI (22753 KPA) 57 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 40 ORIFICE WITH 0.031 RESTRICTION 58 FILTER (BRAKE)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
7 41 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) CHECK VALVE - BICS CONTROL VALVE
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Dealer Copy -- Not for Resale DRIVE MOTOR
VALVE 42 LIFT ARM BY-PASS RESTRICTOR
60 PUMP SERVO
9 FIXED CAPACITY DISPLACEMENT 43 RESTRICTION - 0.089 inch 2,26 mm)
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 13.0 GPM (49,2 L/min.) at High Engine Idle
44 FILTER - CASE DRAIN (Attachment)
CONTROL VALVE - FLOW CONTROL 26 45 VARIABLE CAPACITY DISPLACEMENT 63 SOLENOID ACTIVATED
RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP PROPORTIONAL FLOW CONTROL
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 46 RELIEF VALVE - 2000 PSI (138 Bar) 64 SOLENOID ACTIVATED PRESSURE
SPOOL 28 RELIEF VALVE - CHARGE: 47 SOLENOID ACTIVATED DIRECTIONAL 0-2000 PSI (0-138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) 65 STEERING CYLINDER
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle
48 RELIEF VALVE - 1200 PSI (83 Bar) 66 CHECK VALVE - 270 PSI (18,6 Bar)
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle 67 PRESSURE CONTROL PILOT
49 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,35 L/min.) at igh Engine Idle 50 CHECK VALVE - With 300 PSI (20,7 Bar) Spring
And With 0.016 inch (0,40 mm) Orifice 68 DISPLACEMENT CONTROL SPOOL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - 51 RELIEF VALVE - PORT: 69 FRONT AUXILIARY MANUAL
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: 4000 PSI (276 Bar) PRESSURE BLEED-OFF VALVE
200 PSI (13,8 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL 70 RESTRICTION - 0.025 inch 0,6 mm)
33 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
NOTE: Unless otherwise specified springs have
CONTROL VALVE - BASE VALVE (ON/OFF)
NO significant pressure value.
75 of 772
(REAR QUICK
MALE
A300 (S/N 521111763 AND ABOVE) COUPLERS)
(PRINTED MAY 2004)

V-0576
HYDROSTATIC M2 M1 BASE ROD REAR AUX VALVE (OPTIONAL)
Printable Version Click Here PUMP
26
26

33 34
COUPLER BLOCK 65 65
28 63 63
CHARGE M3 35
36 D1 69
31 32 INLET
MALE
38
29
M4 40 MALE
45 39
M
60 CASE 37 66 66
5
DRAIN FEMALE
69
59 68
POUT PIN T
54
53 Control
Module 66 66
(EDC) 67 63
9 63
65
65
64
X1 X2
P T
X2 X1
44
Control
Module 67
(EDC)
62
PUMP
3
68 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
28
CASE
DRAIN 11
M2 M1 27
24 24
25 B
A B
30
OUTLET AUXILIARY
BOB-TACH SPOOL
INLET CYLINDER
61
TWO SPEED VALVE (OPTIONAL)
OUTLET 23 TILT CYLINDER
B HYDRAULIC 22
58 POWERED
BOB-TACH
(OPTIONAL)
49
58 DR
A B 12
51 TILT
56 9
CYLINDER
48 46 SPOOL
50
P2
70 21
54 53 47 43
C
PP 18
P1 P2 17
5 13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS

VALVE
15
Printed in U.S.A.
V-0576 (4-30-04)
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HYDRAULIC SYSTEM INFORMATION
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HYDRAULIC SYSTEM INFORMATION (CONT’D)
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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 the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4

The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
Bypass valve stuck. 12
Bypass valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Specifications on Page SPEC-60-1.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.
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Tighten Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
For Tightening Torques For Hydraulic Fittings, Tubelines

Etc., (See HYDRAULIC CONNECTION
SPECIFICATIONS on Page SPEC-50-1.)
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CYLINDER (LIFT) Install a cap (Item 1) [Figure 20-20-2] in the hose and
tighten.
Checking
Engage the parking brake. Lower the seat bar. Start the
Figure 20-20-1 engine and move the right joystick forward.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2]. Remove the lift cylinder for
repair. Repeat the procedure to check the other lift
cylinder.
Removal And Installation
Figure 20-20-3
1
P-31363
Lower the lift arms. Stop the engine. Raise the seat bar. 1

WARNING
P-31363
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury Disconnect both hydraulic hoses from the cylinder (Item
and possible death if proper medical treatment by a 1) [Figure 20-20-3]. Cap and plug the fittings and hoses.
physician familiar with this injury is not received
immediately. Figure 20-20-4
W-2145-0290
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.
Figure 20-20-2 1
1
2
P-31365
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-4] from the retaining pin on the rod end of the lift
cylinder.
Installation: Tighten the retainer bolt and nut to 18 - 20

P-31364 ft.-lb. (24 - 27 N•m) torque.
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CYLINDER (LIFT) (CONT’D) Figure 20-20-7
Removal And Installation (Cont'd)
Figure 20-20-5
1
P-31368
1
Install a slide hammer (Item 1) [Figure 20-20-7] and

P-31366 remove the base end pivot pin.
Remove the lift cylinder.

Install a slide hammer (Item 1) [Figure 20-20-5] and
remove the retaining pin from the rod end of the cylinder.

Figure 20-20-6 WARNING
explosion or fire.
1 W-2103-0508
P-31367
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-6] from the pivot pin at the base end of the lift cylinder.

ft.-lb. (24 - 27 N•m) torque.
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CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Case 9. Spacer
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. O-ring 13. Seal
6. Nut 14. Plug
7. Seal 15. O-ring
8. O-ring 16. Tubeline
7 4

14 15
TS-1060a
1
13
16
3
11
10
12
14 15
TS-1060b PE1519A
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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 20-20-8 P-48038
1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

20-10] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-10] on

the piston head, becomes damaged, the
complete piston head must be replaced.

Figure 20-20-11
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-8] from the cylinder case.
2
Figure 20-20-9
4
3 P-48039
2
1 Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-11] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-9].
CYLINDER (LIFT) (CONT’D) Disassembly (Cont'd)
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Figure 20-20-12 Assembly
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool

1 MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Figure 20-20-14
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-12] from

the cylinder head.
Figure 20-20-13

P7424
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

1
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during

installation.
P-48042
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-14].
Remove the rod seal (Item 1) [Figure 20-20-13] from the
cylinder head. Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Assembly (Cont'd)
Figure 20-20-15
1
2
P7425
Install the rod seal in the head [Figure 20-20-17].

P-48038
Figure 20-20-18
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-15] on the cylinder piston.

2
Figure 20-20-16
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 18].
Install the rod seal on the rod seal tool [Figure 20-20-16].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-16] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-16].
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CYLINDER (LIFT) (CONT’D)
Assembly (Cont'd)
Figure 20-20-19
1
2 3
P-48036
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-19].
Tighten the nut (Item 4) [Figure 20-20-19] to 600 ft.-lb.

(814 N•m) torque.
Figure 20-20-20
P-48035
Put the base end of the hydraulic cylinder in a vise.
Using a spanner wrench, tighten the head (Item 1)

[Figure 20-20-20] until the head is flush with the end of
the cylinder tube assembly.
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CYLINDER (TILT) Install a cap (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Checking
Figure 20-21-1 engine and move the right joystick toward the operator. If
there is leakage from the open port on the cylinder (Item
2) [Figure 20-21-2], remove the tilt cylinder for repair.
Repeat procedure to check the other tilt cylinder.
Figure 20-21-3
P-31369
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. 1

WARNING P-31371
Hydraulic fluid escaping under pressure can have Remove the attachment from the Bob-Tach. Roll the Bob-
sufficient force to enter a person’s body by Tach forward
penetrating the skin. This can cause serious injury Stop the engine. Raise the seat bar.
and possible death if proper medical treatment by a
physician familiar with this injury is not received Remove the retainer bolt and nut (Item 1) [Figure 20-21-
immediately. 3] from the rod end pivot pin.
W-2145-0290
Installation: Tighten the retainer nut to 18 - 20 ft.-lb. (24 -
Disconnect the hose (Item 1) [Figure 20-21-1] which 27 N•m) torque.
goes to the base end of the tilt cylinder.
Figure 20-21-4
Figure 20-21-2
1
2
1
P-31372
P-31370
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

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CYLINDER (TILT) (CONT’D) Figure 20-21-7
Figure 20-21-5
1
P-31374
Remove the base end pivot bolt and washer (Item 1)

P-31369 [Figure 20-21-7].
Figure 20-21-8
Disconnect the two hydraulic hoses (Items 1 & 2) [Figure
20-21-5] from the tilt cylinder.

Cap the hoses and plug the fittings on the cylinder.
Figure 20-21-6
P-31375
Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-8].
P-31373
Remove the retainer nut (Item 1) [Figure 20-21-6] from

the base end pivot pin.
Installation: Tighten the retainer nut to 190 ft.-lb. (257,6

N•m) torque.
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Base Pin Removal And Installation
Figure 20-21-9
P-31378
1
Check pivot pin and replace as needed [Figure 20-21-
P-31376 11].
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-9]. (See Removal And Installation on

Page 20-21-1.)
Figure 20-21-10
P-31377
Use a 7/8” (0.875 mm) shaft (Item 1) [Figure 20-21-10]

and a hammer to remove the tilt cylinder base pin from
the lift arms.
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CYLINDER (TILT) (CONT’D)
1. Case 9. O-ring
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. Bushing 13. Seal
6. Nut 14. Plug
7. O-ring 15. O-ring
8. Seal 16. Tubeline TS-1688b
12
9
1
15
10
14

16
11
15 6
3
14
2 13
4
8
TS-1688a PE1520A
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Disassembly
2
MEL1074 - O-ring Seal Hook 1

Spanner Wrench

cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-12 P-48073
Remove the seal (Item 1), and O-ring (Item 2) [Figure

20-21-14] from the piston.
1
Figure 20-21-15

2
P-48034
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-12] from the cylinder case.
Figure 20-21-13 P-48039
3 Remove the two O-rings (Item 1) and the back-up washer

2 (Item 2) [Figure 20-21-15] from the cylinder head.
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].
CYLINDER (TILT) (CONT’D) Disassembly (Cont'd)
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Figure 20-21-16 Assembly
Use the following tools to assemble the cylinder:

1 MEL1033 - Rod Seal Installation Tool
Spanner Wrench
Figure 20-21-18
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-16] from

the cylinder head.
Figure 20-21-17

P7424

1

installation.
P-48042
fits the piston [Figure 20-21-18].
Remove the rod seal (Item 1) [Figure 20-21-17] from the
cylinder head. Allow the seal to stretch for 30 seconds before installing it
on the piston.
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Assembly (Cont'd)
Figure 20-21-19
P7425

P-48073
Figure 20-21-22
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-19] on the cylinder piston.

2
Figure 20-21-20
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 20-21-
P-48043 P7427 22].
Install the rod seal on the rod seal tool [Figure 20-21-20].
NOTE: During installation the spring side of the seal

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

21-20].
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Assembly (Cont'd)
Figure 20-21-23
1
1
2
P-48070

P-48071
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-21-25] until the head is flush with the end of
NOTE: Clean and dry the threads before installing the the cylinder tube assembly.
nut. Install the new nut from the kit.

Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-23].
Tighten the nut (Item 3) [Figure 20-21-23] to 100 ft.-lb.

(136 N•m) torque.
Figure 20-21-24
P-48088 P-48089
Mark the end of the shaft and nut [Figure 20-21-24].

Tighten the nut an additional 135 degrees or 2-1/4 flats
[Figure 20-21-24].
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CYLINDER (POWER BOB-TACH) Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
Checking
Figure 20-22-3
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid 2
enters skin or eyes, get immediate medical attention 1
from a physician familiar with this injury.
W-2072-0807
P-31381
Figure 20-22-1
Install a plug in the hose (Item 1) [Figure 20-22-3] and
tighten.

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

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

(Item 2) [Figure 20-22-3], remove the lift cylinder for
repair.
P-31379
WARNING
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1]. AVOID INJURY OR DEATH
Figure 20-22-2 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
P-31380
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CYLINDER (POWER BOB-TACH) (CONT’D)
Figure 20-22-4
1 1
P-31379
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].

Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-31382
Remove the bolts and washers (Item 1) [Figure 20-22-

5].
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the cylinder from the lever pivots.
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1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2 3
4
5
6

7
8 9
10
11
12
13
B-16207
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CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-8
Disassembly 3 2 1
Figure 20-22-6
1 P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2)

P16293 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9

MEL1074 - O-ring Seal Hook
Spanner Wrench 4

2
1
cylinder.
Put the base end of the cylinder in a vise.

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

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

MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Spanner Wrench


installation.
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

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

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

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
22-13]. NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16
3
2 4
1
P7425
P16294

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

the piston. do not get grease on the threads. Install the
new nut (Item 4) [Figure 20-22-16].
Tighten the nut to 90 ft.-lb. (122 N•m) torque.
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Assembly (Cont'd)
Figure 20-22-17
P16293

Tighten the head using a spanner wrench [Figure 20-22-
17].
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CYLINDER (STEERING) Figure 20-23-3
Removal (Front)
Figure 20-23-1
P-24924
Remove the two retainer bolts (Item 1) [Figure 20-23-3]

P-24816 from wheel position sensor / steering cylinder cover.
Remove the wheel position sensor / steering cylinder

Lift and block the loader. (See Procedure on Page 10-10- cover from the loader.
1.)

Figure 20-23-4
Remove the tire / wheel assemble [Figure 20-23-1].
Figure 20-23-2
1
1
1
P-28215
P-26077 Remove the retainer bolt (Item 1) [Figure 20-23-4] from

the cylinder rod cover.
Remove the four bolts (Item 1) [Figure 20-23-2] from the Remove the cover from the loader.
hydrostatic motor cover.
Remove the hydrostatic motor cover.
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CYLINDER (STEERING (CONT’D)) Figure 20-23-7
Removal (Front) (Cont’d)
Figure 20-23-5
1
1
P-26075

P-28216 on Page 10-30-1.)
Remove the three mount bolts (Item 1) [Figure 20-23-7]

Remove the retainer bolt [Figure 20-23-5] (Item 1) from on the left foot rest.
the steering cylinder pin.

Remove the foot rest from the loader.
Figure 20-23-6
Figure 20-23-8
P-28217
P-26076
Remove the steering cylinder pin (Item 1) [Figure 20-23-

6]. Remove the two mount bolts (Item 1) [Figure 20-23-8]
from the access panel.
Remove the access panel from the loader.
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CYLINDER (STEERING) (CONT’D) Figure 20-23-11
Removal (Front) (Cont'd)
Figure 20-23-9
1
1
P-26080
Remove the rod end hydraulic hose (Item 1) [Figure 20-

P-26078 23-11], by going through the motor cover access hole.
Figure 20-23-12
Remove the bolt (Item 1) [Figure 20-23-9] from the base
end steering cylinder pin.

Figure 20-23-10 1
P-26081
Remove the base end cylinder pin (Item 1) [Figure 20-

P-26079 23-12].
Mark the hydraulic hoses for proper installation.
Remove the base end hydraulic hose (Item 1) [Figure

20-23-10].
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Removal (Front) (Cont'd)
Figure 20-23-13
2
P-28218
Remove the two retainer bolts (Item 1) [Figure 20-23-15]

P-26082 from wheel position sensor / steering cylinder cover.
Remove the six mount bolts (Item 2) [Figure 20-23-15]

Remove the steering cylinder, from the loader [Figure from the loader access cover.
20-23-13].

Removal (Rear) cover from the loader.
Figure 20-23-14 Figure 20-23-16
P-26083 P-26085
Lift and block the loader. (See Procedure on Page 10-10- Disconnect the wheel position sensor wire (Item 1)
1.) [Figure 20-23-16].
Remove the tire / wheel assembly [Figure 20-23-14].
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Removal (Rear) (Cont'd)
Figure 20-23-17
1
P-26089
Remove the bolt (Item 1) [Figure 20-23-19] from the rod

P-26086 end cylinder pin.
Figure 20-23-20
Push the harness connector (Item 1) [Figure 20-23-17]
through the access cover.

Remove the access cover from the loader.
Figure 20-23-18
1
P-26090
Remove the rod end cylinder pin (Item 1) [Figure 20-23-

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

the motor cover.
Remove the motor cover from the loader.
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Removal (Rear) (Cont’d)
Figure 20-23-21
P-26093
1
Remove the base end cylinder pin (Item 1) [Figure 20-
P-26091 23-23].
Figure 20-23-24

Remove the base and rod cylinder hoses (Item 1)
[Figure 20-23-21].
Figure 20-23-22
1
P-26094
Remove the steering cylinder from the loader [Figure 20-

23-24].
P-26092
Remove the retainer bolt (Item 1) [Figure 20-23-22] from

the base end cylinder pin.
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MAIN RELIEF VALVE
Checking The Main Relief Valve At Front Auxiliary

Hydraulics
WARNING
Figure 20-30-1 Put jackstands under the front axles and rear corners
W-2017-0286
Figure 20-30-2
1 2
P-31821
The tools listed will be needed to do the following

procedure:
MEL10003 - Hydraulic Tester

B-15551
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position, as the engine Start the engine and run at low engine idle RPM. Push
stops running, turn the key switch all the way to the left to the mode switch (Item 1) (on the instrument panel) two
release the hydraulic pressure at the front auxiliary quick times to engage the front auxiliary hydraulics, the light
couplers. (Item 2) [Figure 20-30-2] will come ON.

1.)
Connect the IN port of the hydraulic tester to the female

quick coupler on the loader [Figure 20-30-1].
Connect the OUT port of the hydraulic tester to the male

quick coupler on the loader [Figure 20-30-1].
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
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MAIN RELIEF VALVE (CONT’D) Raise the operator cab (See Raising The Operator Cab
on Page 10-30-1.)
Checking The Main Relief Valve At Front Auxiliary
Hydraulics (Cont’d)
Figure 20-30-3
IMPORTANT
Right damage the system.
Steering I-2003-0888
1 Lever
Control
The main relief valve (Item 1) [Figure 20-30-4] is located
at the lower front of the control valve.
Remove the right motor cover.
P-26697 Clean the area around the control valve.
Figure 20-30-5
Push the button (Item 1) [Figure 20-30-3] for fluid flow to

the quick couplers.
2
Watch the flow meter on the hydraulic tester to make
sure the flow is correct. Increase the engine speed to full
RPM.
There should be 20.0 GPM (75,8 L/min.) free flow. Turn

the restrictor control, on the tester, until the main relief 1
valve opens. The correct pressure for the main relief is
2950 - 3050 PSI (20340 - 21030 kPa).
If the relief pressure is not correct, stop the engine.

Adjust or replace the main relief valve. (See Checking
The Main Relief Valve At Front Auxiliary Hydraulics on
N-23264
Page 20-30-1.)
Removal and Installation Loosen and remove the main relief valve (Item 1)[Figure
20-30-5].
Figure 20-30-4
Installation: Tighten the main relief valve to 35 - 40 ft.-lb.
(47 - 54 N•m) torque.
N-20039
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MAIN RELIEF VALVE (CONT’D) Adjustment
Removal and Installation (Cont’d) Figure 20-30-7
Figure 20-30-6
N-23265
CD-15092
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 2) [Figure 20-30-5].
Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-6]. Turn the adjusting screw (Item 1) [Figure 20-30-7] in or

out until the pressure is correct. Turning screw in will
Clean the main relief valve in clean solvent. Use air increase pressure.
pressure to dry the valve.
NOTE: If the correct pressure can not be reached,
Install new O-rings and back-up washers. Install the main replace the main relief valve. Check the
relief valve and tighten [Figure 20-30-4]. Check the pressure setting of the new relief valve.
pressure again. (See Removal and Installation on Page
20-30-2.)
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A300 Bobcat Loader

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HYDRAULIC CONTROL VALVE Figure 20-40-2
Actuator Removal And Installation (In Loader)
WARNING
support device can allow the lift arms or attachment 1
W-2059-0598
P-34367
Figure 20-40-1
Unplug the actuator connectors (Item 1) [Figure 20-40-2]

1 from the loader harness.
Figure 20-40-3

1
N-23246
Raise the lift arms and install an approved lift arm support
Page 10-20-1.) P-34368
Stop the engine. Raise the seat bar.

Remove the two screws (Item 1) [Figure 20-40-3] from
Remove the access cover (Item 1) [Figure 20-40-1] from the actuator retainer.
the right side of the loader frame.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10,2 -
Mark the actuator wiring harness connectors for proper 11,3 N•m) torque.
installation.
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HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-6
Actuator Removal And Installation (In Loader)

(Cont’d)
1
Figure 20-40-4
P-26822
2 Check and replace the O-ring (Item 1) [Figure 20-40-6]

on the spacer.
P-34369
Figure 20-40-7
Pull the actuator (Item 1) [Figure 20-40-4] away from the

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

20-40-4] 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
1
Procedure on Page 60-160-1.)
Figure 20-40-5
P-26821
1
Check and replace the O-ring (Item 1) [Figure 20-40-7]
on the control valve housing.
P-26820
Remove the spacer (Item 1) [Figure 20-40-5].
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HYDRAULIC CONTROL VALVE (CONT’D) Stop the engine. Raise the seat bar.
Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Removal And
DANGER Installation on Page 20-80-1.)
Remove the actuators from the control valve. ((See

Actuator Removal And Installation (In Loader) on Page
20-40-1.)
Clean area around control valve.
Open rear door.
The fixed end main valve hose assembly (Item 1) [Figure

20-40-8] is connected to a fixed end fitting on the control
P-90328
valve. The hose is routed to the upright where the hose is
connected to a fitting that feeds the base end of both lift
AVOID DEATH cylinders. The hose can only be removed by first
• Disconnecting or loosening any hydraulic removing it from the tee fitting located at the rear of the
tubeline, hose, fitting, component or a part failure loader.
• Keep out of this area when lift arms are raised Cap and plug the hose and fitting.
support. Replace if damaged. Figure 20-40-9

D-1009-0409
WARNING 1

2
support device can allow the lift arms or attachment
W-2059-0598
P-34370
Figure 20-40-8
Remove lift arm bypass knob (Item 1) [Figure 20-40-9],

lock nut & rubber washer.
Disconnect the two tubelines (Item 2) [Figure 20-40-9]

from the lift arm bypass valve.
1
Cap and plug tubelines and fittings.
P-34118
device.
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Removal And Installation (Cont’d)
Figure 20-40-10 1
1 P-34371
Disconnect the wire harness connector (Item 1) [Figure

P-34120 20-40-12] from auxiliary valve solenoid.
Figure 20-40-13
At the right fender, remove the two mounting bolts and
nuts (Item 1) [Figure 20-40-10] from the lift arm bypass

mount.
Remove the lift arm bypass valve and tubelines from the
loader.
Figure 20-40-11 2
2
1
1
P-34124
Disconnect the harness connector (Item 1) [Figure 20-

40-13] from the BICS™ valve solenoid connector.
Disconnect the harness connector (Item 2) [Figure 20-

40-13] from the auxiliary valve solenoid.
P-34122
Disconnect the hose (Item 1) [Figure 20-40-11] that goes

from the control valve to the hydraulic cooler.
Disconnect the charge pressure sender (Item 2) [Figure

20-40-11] from the control valve.
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Figure 20-40-14
1
P-34128
Remove the two control valve mount bracket mount bolts

P-34126 (Item 1) [Figure 20-40-16].
Remove right side motor cover.

Loosen the fixed end main valve hose assembly (Item 1)
[Figure 20-40-14] from the control valve. Remove the right rear wheel / tire assembly from the

loader.
The hose can be removed from the control valve by
rotating the hose assembly. Remove the right side pump access cover.
Cap the hose and plug the fitting. Figure 20-40-17
Figure 20-40-15
1
1
P-34129
P-34127
At the right side motor cover access hose, remove the
two control valve mount bolts (Item 1) [Figure 20-40-17]
Install a chain hoist (Item 1) [Figure 20-40-15] to the from the mounting plate.
control valve, and support the control valve.
Remove the control valve mount bracket from the loader.
Loosen all the tubeline fittings connected to the control
valve.
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Figure 20-40-18
1 1
2
P-34366
Disconnect the tilt tubeline (Item 1) [Figure 20-40-20]

P-34130 from the control valve.
Cap and plug the tubeline and fitting.

Disconnect the case drain hose (Item 1) [Figure 20-40-
18] and cap the fitting and plug the hose. Figure 20-40-21

Disconnect the two auxiliary tubelines (Item 2) [Figure
20-40-18] from the control valve.
Figure 20-40-19
1
1
P-34133
With the chain hoist lift the control valve up and clear of
2 the tapelines [Figure 20-40-21].
P-34131
Disconnect the hydraulic hose (Item 1) [Figure 20-40-21]
that comes from the back of the gear pump to the bottom
Disconnect the tilt tubeline (Item 1) [Figure 20-40-19] of the control valve.
from the control valve.
Remove the control valve from the loader.
Disconnect the lift tubeline (Item 2) [Figure 20-40-19]
from the control valve.
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Actuator Removal And Installation (Out Of Loader)
Figure 20-40-22
1
N-19113
2
1
Use a drift pin and hammer to remove the actuator pin
N-19112 (Item 1) [Figure 20-40-23] from the actuator and the lift
or tilt spool.
Remove the two screws (Item 1) [Figure 20-40-22] on Figure 20-40-24

the actuator retainer.

Installation: Tighten the bolt and nut to 90 - 100 in.-lb.
(10,2 - 11,3 N•m) torque.
Pull the actuator (Item 2) [Figure 20-40-22] away from

the control valve.
4
2 3
1 N-19114
Remove the actuator (Item 1) [Figure 20-40-24].
Remove the O-ring (Item 2) [Figure 20-40-24].
Remove the spacer block (Item 3) [Figure 20-40-24].
Remove the O-ring (Item 4) [Figure 20-40-24].
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See
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BICS™ Valve Removal And Installation
Figure 20-40-25
1
1
1
1 2
P-28324
Replace the four large O-rings (Item 1) and small O-ring

P-28322 (Item 2) [Figure 20-40-27] from the top of the control
valve.
Loosen the six mounting bolts (Item 1) [Figure 20-40-25] Figure 20-40-28
from the BICS™ valve.

Remove the mounting bolts.
Figure 20-40-26
3 6
1 2
5
4
P-28322
Install the six mounting bolts.

The chart below lists the correct torque specifications
P-28323
and tightening sequence when reinstalling the BICS]
valve assembly to the hydraulic control valve. Thoroughly
Remove the BICS™ valve assembly [Figure 20-40-26] clean and dry bolts and threads in valve. Use liquid
from the top of the control valve. adhesive Loctite® #242.
Step Torque Sequence

1 110 - 130 in -lb.
(12,4 - 14,7 N•m)
2 190 - 210 in.-lb. 1,2,3,4,5 & 6
(21,5 - 23,7N•m)
3* 190 - 210 in.-lb.
(21,5 - 23,7N•m)
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for

every bolt or repeat step 3.
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BICS™ Valve Lift Arm Bypass Orifice Removal And

Installation
Figure 20-40-29
1
N-18685
Using a flat blade screw driver, remove the lift arm

bypass orifice (Item 1) [Figure 20-40-30] & [Figure 20-
P-28332 40-31].
Orifice size is 0.078 in.

Remove the fitting (Item 1) [Figure 20-40-29] from the

BICS™ valve. Clean and inspect the orifice. Replace as needed.
Figure 20-40-30 Reverse the removal procedure to install the lift arm
bypass orifice.
BICS™ Valve Check Valve Removal And Installation
Figure 20-40-32
1
1
P-28333
P-28334
Remove the check valve (Item 1) [Figure 20-40-32].
Installation: Tighten the check valve to 20 ft.-lb. (27

N•m) torque.
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HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve Lock Valve Removal And Installation
BICS™ Valve Check Valve Removal And Installation Figure 20-40-35

(Cont’d)
Figure 20-40-33
1
3
2
1
P-28335
N-18684 There are two lock valves on the BICS™ valve, lift lock
valve (Item 1) and tilt lock valve (Item 2) [Figure 20-40-
35].
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-33]. Figure 20-40-36
Install new O-rings (Item 1) [Figure 20-40-33] and back-

up ring (Item 2) [Figure 20-40-34] on the check valve.
Check valve (Item 3) [Figure 20-40-33] has a rating of 5 -

10 PSI.
Figure 20-40-34
P-28336
P-8956
Clean and inspect the screen (Item 1) [Figure 20-40-34]

on the end of the valve.
Reverse the removal procedure to install the BICS™

check valve.
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HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve Solenoid Removal And Installation
BICS™ Valve Lock Valve Removal And Installation Figure 20-40-39
Figure 20-40-37
2
1
P-28338
P-28337
Remove the nut (Item 1) [Figure 20-40-39] from the
solenoid cartridge.
Loosen and remove the lock valve(s) (Item 1) [Figure 20-
40-36] & [Figure 20-40-37] from the valve. Installation: Tighten the mounting nut to 53 in.-lb. (6

N•m) torque.
Installation: Tighten the lock valve(s) to 25 ft.-lb. (34
N•m) torque. Remove the coil (Item 2) [Figure 20-40-39].
Figure 20-40-38 Figure 20-40-40
1 1
2
2 N-18690 N-18693
Remove the O-rings (Item 1) and back-up rings (Item 2) Remove the O-rings (Item 1) [Figure 20-40-40] from
[Figure 20-40-38] from both the tilt and lift lock valves. both ends of the coil.
Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-38] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.
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HYDRAULIC CONTROL VALVE (CONT’D) Install new O-rings (Item 1) [Figure 20-40-40] & [Figure
20-40-42] and new back-up rings (Item 2) [Figure 20-40-
BICS™ Valve Solenoid Removal And Installation 42] on the stem.
(Cont’d)
BICS™ Valve Solenoid Testing
Figure 20-40-41
Figure 20-40-43
P-28340
P9175
Remove the solenoid stem (Item 1) [Figure 20-40-41].

Use an Ohm meter to measure coil resistance [Figure
Installation: Tighten the stem to 20 ft.-lb. (27 N•m) 20-40-43]
torque.
Coil wires do not have polarity.
Figure 20-40-42
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Correct resistance for the auxiliary, lift, and tilt lock coils
3
are 7-10 ohms
2
The other coils (BICS™, diverter, select valve) are 5-8
ohms
N-18694
Clean all parts in solvent and dry with compressed air.
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-42] from the stem.
Inspect all parts for wear and replace as needed.
NOTE: The screen (Item 3) [Figure 20-40-42] can be

cleaned with solvent. If it is torn or worn it
needs to be replaced
Use an Ohm meter to measure coil resistance [Figure

20-40-39].
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HYDRAULIC CONTROL VALVE (CONT’D)
Identification Chart
H1
Item A300 Loader H2
A1 Lift Cylinder Base End / Restrictor

A2 Tilt Cylinder Base End
H3
A3 Auxiliary Hydraulics C4
B1 Lift Cylinder Rod End B3 A3

G3 D3
B2 Tilt Cylinder Rod End C3
D2
B3 Auxiliary Hydraulics G2 B2 A2 E2
C1 Load Check Valve / Lift Function C2

F2 D1
B1 A1 E1
C2 Load Check Valve / Tilt Function
F1 C1
C3 Orificed Load Check Valve / Auxiliary Function MR
C4 Outlet Fluid Flowd1 TS-2136

D1 Lift Spool Detent
D2 Tilt Spool Detent

D3 Auxiliary Spool / Centering Spring
E1 Port Relief Valve - 4000 PSI
E2 Anti-Cavitation / Port Relief valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relieve Valve - 4000 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug / Port Relief (Optional) - 3500 PSI
H3 Auxiliary Electric solenoid
MR Main Relief Valve - 3300 PSI
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HYDRAULIC CONTROL VALVE (CONT’D)
Lift Base End Restrictor

IMPORTANT
Figure 20-40-44
1 damage the system.
I-2003-0888
Figure 20-40-46
N-21159
1
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation on

Page 20-40-8.)
Remove the restrictor (Item 1) [Figure 20-40-44] from

the lift section base end port.
P-28324
Load Check Valve

Mark each valve section, spool and related parts so that
Figure 20-40-45 they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
Loosen and remove the load check valve plugs (Item 1)

1 [Figure 20-40-46].
1
Installation: Always use new O-rings. Tighten the plugs
to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
2
P-28324
Remove the BICS™ valve assembly from the control

valve. (See Contents Page 20-01.)
Remove the four large O-rings (Item 1) and small O-ring

(Item 2) [Figure 20-40-45]. Always replace these O-rings
before installing the BICS™ valve assembly
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HYDRAULIC CONTROL VALVE (CONT’D) Main Relief Valve
Load Check Valve (Cont'd) Figure 20-40-49
Figure 20-40-47
1
2 3 P-28326
P-28325
Loosen the main relief valve (Item 1) [Figure 20-40-49].
Remove the spring (Item 1) and poppet (Item 2) from, the Figure 20-40-50
load check plug (Item 3) [Figure 20-40-47].

Figure 20-40-48
P-28327
N-20078 P-28324 Remove the main relief valve (Item 1) [Figure 20-40-50].
The auxiliary section (Item 1) may have a load check with

an orifice located in the center of the poppet (Item 2)
[Figure 20-40-48].
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Main Relief Valve (Cont'd)
Figure 20-40-51
1
2 3 4 5
B-06764
B 06764
1. Relief Valve
2. O-ring
3. Sleeve
N-19034
4. O-ring
5. Glide Ring
Loosen the port relief valve (Item 1) [Figure 20-40-52] &
P-28328 [Figure 20-40-53].
Installation: Always use new O-rings and back-up

Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
relief valve [Figure 20-40-51].

Figure 20-40-54
Installation: Always use new O-rings, sleeve, and glide
ring. TIghten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Port Relief Valve
Figure 20-40-52
N-18981
Remove the port relief valve (Item 1) [Figure 20-40-54].
N-19000
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Port Relief Valve (Cont’d)
Figure 20-40-55
2
1
1. O-ring
N-18980
2. Back-up Washer
3. O-ring
4. Relief Valve Remove the anti-cavitation / port relief valve (Item 1)
N-18844 [Figure 20-40-57] from the control valve for the tilt
section.
Remove the O-rings and back-up washer from the port Figure 20-40-58
relief valve [Figure 20-40-55].

Anti-Cavitation Valve / Port Relief Valve
Figure 20-40-56 1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-58] from the

anti-cavitation / port relief valve.
N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-40-

56].
Installation: Always use new O-rings and back-up

washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
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Anti-Cavitation Valve 1 2
3 4
Figure 20-40-59
E-01509
1. Anti-Cavitation Valve
2. O-ring
1
3. Back-up Washer
4. O-ring
P-28331
Remove the O-rings and back-up washer from the anti-

P-28329 cavitation valve [Figure 20-40-61].
Lift Spool Removal And Installation

Figure 20-40-60
Figure 20-40-62

1
N-19036A 1
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-40-

59] & [Figure 20-40-60] from the control valve. Remove the actuator (Item 1) [Figure 20-40-62] from the
control valve.
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Lift Spool Removal And Installation (Cont’d)
Figure 20-40-63
1
2 N-18983
Remove the spool assembly (Item 1) [Figure 20-40-65]

N-19114 and seal from the control valve.
Tilt Spool Removal And Installation

Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-63] from the lift spool. Figure 20-40-66

Figure 20-40-64
2
1
1 1
P-28320
N-19003
Remove the bolts (Item 1) to pull the actuator (Item 2)
[Figure 20-40-66] from the spacer.
Remove the screws (Item 1) [Figure 20-40-64] from the
cap.
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Tilt Spool Removal And Installation
Figure 20-40-67
N-18985
2
Remove the spool assembly (Item 1) [Figure 20-40-69]
2 1 P-28321 and seal from the control valve.
Assembly: Always use a new spool seal.

Remove the spacer (Item 1) and O-rings (Item 2) [Figure
20-40-67] from the tilt spool. Lift And Tilt Spool Disassembly And Assembly

Figure 20-40-68 Figure 20-40-70
1
1
N-19003 N-18942
Remove the screws (Item 1) [Figure 20-40-68] from the Put the linkage end of the spool in the vice [Figure 20-
end cap. 40-70].
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 - Install the spool tool [Figure 20-40-70] over the centering
11,3 N•m) torque. spring.
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Lift and Tilt Spool Disassembly and Assembly 2

(Cont’d)
1
Figure 20-40-71
1
1
N-18930 N-18943
Remove the spool seal(s) (Item 1) and the back-up

washer (Item 2) [Figure 20-40-73].
N-19014
Assembly: Always use a new spool seal.
Remove the bolt (Item 1) [Figure 20-40-71] holding the Auxiliary Spool Removal And Installation

centering spring to the spool.
Figure 20-40-74
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
Remove spring tool from the spring assembly.
Figure 20-40-72
2 1
3
1
4
N-19003
Remove the screws (Item 1) [Figure 20-40-74] from the

end cap (both sides).
N-18944A Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -

11,3 N•m) torque.
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-72].
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HYDRAULIC CONTROL VALVE (CONT’D) Auxiliary Electric Solenoid Disassembly And
Assembly
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-77
Figure 20-40-75
1 P-28341
N-18987
Remove the nut (Item 1) [Figure 20-40-77] from both

Remove the end cap, O-ring, springs and washer (both solenoids.
sides) [Figure 20-40-75].

Installation: Tighten the nut to 8 - 12 ft.-lb. (11 - 16 N•m)
Assembly: Always use a new spool seal. torque.
Figure 20-40-76 Figure 20-40-78
1
1
N-18988 P-28342
Remove the spool (Item 1) [Figure 20-40-76]. Remove the coil (Item 1) and the stem (Item 2) [Figure
20-40-78].
Assembly: Put grease on all the centering spring
component parts. Installation: Tighten the stem to 20 ft.-lb. (27 N•m)
torque.
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Auxiliary Electric Solenoid Disassembly And

Assembly (Cont’d)
Figure 20-40-79
P-28345
1
Remove the end cap and solenoid assembly (Item1).
Remove the O-ring, springs, and washer [Figure 20-40-
N-18795 81].
Port-Auxiliary Section Disassembly

Remove the O-rings (Item 1) [Figure 20-40-79] from the

stem. Figure 20-40-82
Figure 20-40-80
2 1
1
P-28343
P-28344
Remove the plug (Item 1) [Figure 20-40-82] or optional
port relief valve from the control valve.
Disconnect the tubeline (Item 1) and remove the screws
(Item 2) [Figure 20-40-80] from the end cap. NOTE: The optional port relief (Item 1) [Figure 20-40-
82] is 3500 PSI (24129 kPa).
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
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HYDRAULIC CONTROL VALVE (CONT’D) Check the rubber boots and retainers.
Port-Auxiliary Section Disassembly (Cont’d) Replace the parts as needed.
Figure 20-40-83 Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

Plug installation.
1
N-18800
Figure 20-40-84

Port Relief (Optional)
1 2
N-18843
Remove the O-rings (Item 1) [Figure 20-40-83] &

[Figure 20-40-84] and back-up ring (Item 2) [Figure 20-
40-83] & [Figure 20-40-84] from the plug.
Cleaning And Inspection
Clean all components with clean solvent and dry with

compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
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LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Inspecting
Figure 20-50-1
DANGER
P-90328
AVOID DEATH
P-31822
Raise the lift arms 6 feet (2 m) off the ground. Stop the support. Replace if damaged.
engine. Turn the Lift Arm Bypass Control Knob clockwise D-1009-0409

1/4 turn. Then pull up and hold the Lift Arm Bypass
Control Knob until the lift arms slowly lower.
Additional Inspection For Loaders W/ Advanced

Hand Controls WARNING
Sit in the operator's seat and fasten the Seat Belt. Lower Never work on a machine with the lift arms up unless
the Seat Bar, start the engine and press the green the lift arms are secured by an approved lift arm
PRESS TO OPERATE Button. support device. Failure to use an approved lift arm
Raise the lift arms about 6 feet (2 meters) off the ground. to fall and cause injury or death.
W-2059-0598
Turn the key OFF and wait for the engine to come to a
complete stop.
Turn the key ON. Press the green PRESS TO OPERATE
Page 10-20-1.)
Button, move the left hand control toward the operator.
The lift arms should not lower.
on Page 10-30-1.)
Move the right hand control away from the operator. The
bucket (or attachment) should not tilt forward.
Hold the bypass control knob (Item 1) [Figure 20-50-1]
and loosen the jam nut on the bypass valve shaft.
A300 Bobcat Loader

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LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-4
Figure 20-50-2
2
1
1
P13653
Remove the two bolts (Item 1) [Figure 20-50-4] to

P-31823 replace the bypass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm

Remove the bypass control knob. Remove the jam nut bypass valve in the loader.
(Item 1) [Figure 20-50-2] from the valve shaft.

Disassembly And Assembly
Remove the rubber washer (Item 2) [Figure 20-50-2].
Figure 20-50-5
Figure 20-50-3
2
1
1 2
P13656
P-34060
Remove the bypass valve (Item 1) [Figure 20-50-5] from

Disconnect the two hydraulic tubelines (Item 1) [Figure the valve block. Inspect the bypass valve for damage and
20-50-3] and cap and plug the lines. replace if necessary.
Remove the two mounting bolts (Item 2) [Figure 20-50- Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50
3]. N•m) torque.
Installation: Tighten the mounting bolts to 180 - 200 in.- Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
lb. (21 - 23 N•m) torque. the valve block for damage and replace if necessary.
Remove the lift arm bypass valve.
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HYDRAULIC PUMP Figure 20-60-2
Checking The Output Of The Auxiliary Pump

procedure:
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification before
the test is done.
Lift and block the loader. (See Procedure on Page 10-10- P-34062
1.)
Connect the INLET hose from the tester to the OUTLET
fitting on the pump. Connect the OUTLET hose from the
Page 10-20-1.)
tester to the OUTLET hose which was disconnected from
Raise the operator cab. (See Raising The Operator Cab the pump [Figure 20-60-2].
on Page 10-30-1.)
Start the engine and run at low idle RPM. Make sure the
Connect the remote start switch. (See REMOTE START

tester is connected correctly. If no flow is indicated on the
on Page 10-60-1.)
tester, the hoses are connected wrong. With the hoses
Figure 20-60-1 connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140° F (60° C) by turning the restrictor

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
1 Turn the restrictor down to system operating pressure.

DO NOT EXCEED SYSTEM RELIEF PRESSURE. (3300
PSI) The highest pressure flow must be at least 80% of
free flow.
HIGH PRESSURE FLOW (GPM)
%= X100
FREE FLOW (GPM)
P-34392
A low percentage may indicate a pump problem.
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
from the pump.
WARNING
W-2017-0286
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HYDRAULIC PUMP (CONT’D) Figure 20-60-4
Checking The Output Of The Steering Pump

Figure 20-60-3
1
P-26702
Connect the INLET hose from the tester to the OUTLET

P-43805
of the pump. Connect the OUTLET hose from the tester
to the filter which was disconnected from the hose
The tools listed will be needed to do the following [Figure 20-60-4].
procedure:
MEL10003 - Hydraulic Tester Start the engine and run at low idle RPM. Make sure the

tester is connected correctly. If no flow is indicated on the
MEL10006 - Hydraulic Test Kit tester, the hoses are connected wrong. With the hoses
NOTE: Make sure all the air is removed from the connected correctly, increase the engine speed to full
hydraulic system before beginning the test. RPM.
Air in the system can give an inaccurate test.
Warm the fluid to 140° F (60° C) by turning the restrictor
*Relief pressure must be per specification control on the tester to about 1000 PSI (6895 kPa). DO
before the test is done. NOT exceed system relief pressure. Open the restrictor
Lift and block the loader. (See Procedure on Page 10-10- control and record the free flow (GPM) at full RPM.
1.)
Turn the restrictor down to system operating pressure.
Raise the lift arms and install an approved lift arm support DO NOT EXCEED SYSTEM RELIEF PRESSURE. (2000
device. (See Installing The Lift Arm Support Device on PSI) The highest pressure flow must be at least 80% of
Page 10-20-1.) free flow.
Raise the operator cab. (See Raising The Operator Cab HIGH PRESSURE FLOW (GPM)
on Page 10-30-1.) %= X100
FREE FLOW (GPM)
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.)
A low percentage may indicate a pump problem.
Disconnect the OUTLET hose (Item 1) [Figure 20-60-3]
that comes from the pump to the filter.
WARNING
A300 Bobcat Loader

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HYDRAULIC PUMP (CONT’D) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-2.)
DANGER Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the right rear tire assembly [Figure 20-60-5].
Figure 20-60-6
2
P-90328
2
AVOID DEATH
1

D-1009-0409
P-26595A
Remove the two bolts (Item 1) [Figure 20-60-6] from the

WARNING wheel position sensor / steering cylinder cover.

Never work on a machine with the lift arms up unless from the access panel.
support device. Failure to use an approved lift arm Remove the wheel position sensor / steering cylinder
support device can allow the lift arms or attachment cover from the loader.
Figure 20-60-7
W-2059-0598
Figure 20-60-5
P-26596
Disconnect the wheel position sensor harness (Item 1)

P-26594 [Figure 20-60-7] from the loader harness.
Push the loader harness connector through the hole in
Raise the lift arms and install an approved lift arm support the access panel.
Page 10-20-1.) Remove the access panel from the loader.
A300 Bobcat Loader

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Figure 20-60-8
1
1
2
P-26733
Remove the hydraulic hose (Item 1) [Figure 20-60-10]

P-26734 from the return hose fitting, at the front side of the gear
pump.
Mark all the hydraulic hoses for proper installation. Remove the two return hoses (Item 2) [Figure 20-60-10]
from the gear pump.

Remove the two outlet hoses (Item 1) [Figure 20-60-8]
from the gear pump. Figure 20-60-11
Figure 20-60-9
P-43808
P-26640
Remove the pump mounting bolt (Item 1) [Figure 20-60-
11] from the engine mount casting.
Remove the two return hoses (Item 1) [Figure 20-60-9]
from the pump. Installation: Tighten the mounting bolts to 25 - 27 ft.-lb.
(34 - 37 N•m) torque.
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Figure 20-60-12
1
P-26648
Remove the pump-tail stock support bracket (Item 1)

P-43809 [Figure 20-60-14].
Remove the lower pump mount bolt (Item 1) [Figure 20-

60-12]. WARNING

Figure 20-60-13
explosion or fire.
1 W-2103-0508
Figure 20-60-15
P-26646
Remove the front pump mount bolt (Item 1) [Figure 20-

60-13].
1
P-26647
Remove the rear pump mount bolt (Item 1) [Figure 20-

60-15].
Remove the gear pump from the loader.
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HYDRAULIC PUMP (CONT’D)
10
9
8 4
6 7
5
4
1 2 3
13

15
7 4
5 13
2 3 4
11
12
1. Body
2. Seal
3. Seal
4. Seal
5. Wear Plate
6. Section
7. Wear Plate
8. Pin
9. Body
10. Bolt
11. Seal
12. Cover
13. Pin
14. Section
15. Shaft
TS-1022
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IMPORTANT 1
damage the system.
I-2003-0888
P-43020
Figure 20-60-16
Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-60-17] from the steering pump.
Figure 20-60-18
1
1

1
1
P-43019
1 2
Mark the pump sections for correct assembly [Figure 20-
60-16].
P-39139
Remove the eight pump housing bolts (Item 2) [Figure
20-60-16].
Remove the wear plate (Item 1) and the section seal
Installation: Tighten the eight bolts (Item 1) [Figure 20- (Item 2) [Figure 20-60-18].
60-16] to 45 - 50 ft.-lb. (60 - 67 N•m) torque.
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Disassembly And Assembly (Cont'd)
Figure 20-60-19
4
1
2
P-39142
1 NOTE: Inspect the steering pump center section (Item

P-39140 1) [Figure 20-60-21]. If excessive wear or
damage is visible, the pump must be
replaced.
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-60-19] and replace as needed. Figure 20-60-22

NOTE: Position the wear plate (Item 1) [Figure 20-60-
19] inlets and traps as shown with the bronze
side toward the gears.
NOTE: Inspect the pump end section (Item 3) and

1
bushings (Item 4) [Figure 20-60-19]. If
excessive wear or damage is visible, the
pump must be replaced.
Figure 20-60-20
P-43022
Remove the idler gear (Item 1) [Figure 20-60-22] from

the steering pump.
P-43021
Remove the steering pump center section (Item 1)

[Figure 20-60-20] from the auxiliary pump.
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Figure 20-60-23
P-39146
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-

P-39144 25]. If excessive wear or damage is visible, the
NOTE: Inspect the idler gear (Item 1) [Figure 20-60- Figure 20-60-26
23]. If excessive wear or damage is visible, the

Figure 20-60-24
3
1
1
2
P-43024
Remove the wear plate (Item 1) and section seal (Item 2)

P-43023 [Figure 20-60-26] from the front section of the steering
pump.
Remove the drive gear (Item 1) [Figure 20-60-24] from Remove the locating pins (Item 3) [Figure 20-60-26]
the steering pump. from the front section of the steering pump.
A300 Bobcat Loader

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Figure 20-60-27
P-39149
1
NOTE: Later serial number pumps have no oil drain

P-39148 galley [Figure 20-60-29].
Figure 20-60-30
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-60-27] and replace as needed.

NOTE: Position the wear plate (Item 1) [Figure 20-60-
27] inlets and traps as shown with the bronze
side toward the gears.
Figure 20-60-28
1
2
2
P-43026
1
Remove the Pre-load seal (Item 1) [Figure 20-60-30]
from the front section of the charge pump.
P-43025
Remove the load seal (Item 1) [Figure 20-60-28] from

the front section of the charge pump.
NOTE: Earlier serial number pumps have an oil drain

galley (Item 2) [Figure 20-60-28].
A300 Bobcat Loader

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Figure 20-60-31 1
2
1
2 P-43028
Remove the wear plate (Item 1) [Figure 20-60-33] &

P-39151 [Figure 20-60-34] and section seal (Item 2) [Figure 20-
60-33] & [Figure 20-60-34] from the pump section.
Inspect the load seal (Item 1) and the Pre-load seal (Item Figure 20-60-34
2) [Figure 20-60-31] and replace as needed.

Figure 20-60-32
3
1 1
2 P-43029
P-43027 NOTE: Position wear plate (Item 1) [Figure 20-60-34]

inlets and traps as shown with bronze side
toward gears.
Inspect the pump center section and bushings (Item 1)
[Figure 20-60-32]. If excessive wear or damage is NOTE: Inspect the pump center section (Item 3) and
visible, the pump must be replaced. bushings (Item 4) [Figure 20-60-34]. If
Remove the pump center section (Item 2) [Figure 20-60- pump must be replaced.
32].
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Figure 20-60-35 1
P-43032
Remove the idler gear (Item 1) [Figure 20-60-37] &

P-43030 [Figure 20-60-38].
Figure 20-60-38
Remove the pump section (Item 1) [Figure 20-60-35]
from the pump end section.

Figure 20-60-36
1
1
P-43033
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

P-43031 38]. If excessive wear or damage is visible, the
NOTE: Inspect the pump section (Item 1) [Figure 20-

60-36]. If excessive wear or damage is visible,
the pump must be replaced.
A300 Bobcat Loader

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Figure 20-60-39
P-43036
Remove the spline shaft (Item 1) [Figure 20-60-41] from

P-43034 the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-60-

Remove the drive gear (Item 1) [Figure 20-60-39] from 41]. If excessive wear or damage is visible, the
the pump end section. pump must be replaced.

Figure 20-60-40 Figure 20-60-42
1
1
P-43035 P-43037
NOTE: Inspect the drive gear (Item 1) [Figure 20-60- Remove the wear plate (Item 1) and section seal (Item 2)
40]. If excessive wear or damage is visible, the [Figure 20-60-42].
Remove the locating pins (Item 3) [Figure 20-60-42].
A300 Bobcat Loader

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Figure 20-60-43
1
2
P-43040
Remove the pre-load seal (Item 1) [Figure 20-60-45].

P-43038
Figure 20-60-46
Inspect the wear plate (Item 1) and the section seal (Item 1
2) [Figure 20-60-43].

NOTE: Position wear plate (Item 1) [Figure 20-60-43]
inlets and traps as shown with bronze side 2
toward gears.
Figure 20-60-44
P-43041
1
NOTE: Inspect the pump end section (Item 1) and
bushings (Item 2) [Figure 20-60-46]. If
P-43039
Remove the load seal (Item 1) [Figure 20-60-44].
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HYDRAULIC / HYDROSTATIC FILTER Raise the lift arms and install an approved lift arm support
Housing Removal And Installation Page 10-20-1.)

on Page 10-30-1.)
DANGER Disconnect the electrical connector (Item 1) [Figure 20-
70-1] from the filter sender.
Loosen the nut (Item 2) [Figure 20-70-1] and remove the

electrical wire from the filter block.
Figure 20-70-2
P-90328
AVOID DEATH
• Keep out of this area when lift arms are raised 1

D-1009-0409
P-34076
WARNING
Remove the hose clamp (Item 1) [Figure 20-70-2], and
Never work on a machine with the lift arms up unless remove the hydraulic hose from the filter housing.
support device. Failure to use an approved lift arm Figure 20-70-3
to fall and cause injury or death. 1
W-2059-0598
Figure 20-70-1
P-30988
Remove the four mounting bolts (Item 1) [Figure 20-70-

3].
P-30986
Installation: Tighten the mounting bolts to 25 ft.-lb. (34
N•m) torque.
A300 Bobcat Loader

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HYDRAULIC / HYDROSTATIC FILTER (CONT’D)
Housing Removal And Installation
Figure 20-70-4
P-30989
Install tool MEL1613 (Item 1) to the outside of the rubber

sleeve (Item 2) [Figure 20-70-4].

Slide the rubber sleeve toward the filter housing.
Remove the filter housing from the loader.
NOTE: When installing the filter housing, the filter

should make a clicking sound when pushed
together.
Mount Removal And Installation
Figure 20-70-5
N-19609
Remove the two filter bracket mount bolts (Item 1)

[Figure 20-70-5].
Remove the bracket from the loader.
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HYDRAULIC FLUID RESERVOIR Figure 20-80-1
Fluid Removal
DANGER
P-31286
P-90328
AVOID DEATH Remove the left side motor cover from the loader frame.
tubeline, hose, fitting, component or a part failure Pull the reservoir drain hose (Item 1) [Figure 20-80-1]
can cause lift arms to drop. out of the side of the loader frame.
unless supported by an approved lift arm Remove the hose end cap and drain fluid into a

container.
D-1009-0409
WARNING device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)
AVOID INJURY OR DEATH Raise the operator cab. (See Raising The Operator Cab
Always clean up spilled fuel or oil. Keep heat, flames, on Page 10-30-1.)
Failure to use care around combustibles can cause Drain the fluid from the reservoir.
explosion or fire.
W-2103-0508 Remove the control panel. (See Removal And Installation
on Page 50-100-1.)
Remove bucket position valve. (If so equipped.) (See

WARNING Removal And Installation on Page 20-90-2.))

W-2059-0598
A300 Bobcat Loader

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HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-4
Figure 20-80-2 1
2
P-34395
Disconnect the wiring harness connector (Item 1) [Figure

P-34063 20-80-4]

Remove the two mount bolts (Item 1) [Figure 20-80-2] from the reservoir. Cap the hose and plug the fitting on
from the bucket position valve mount plate. (If so the reservoir.

equipped.)
Figure 20-80-5
Remove the mount plate from the loader. (If so
equipped.)
Figure 20-80-3
1
1
1
P-34396
Remove the two mount bolts (Item 1) [Figure 20-80-5]

P-34064 from the steering valve / brake valve mount bracket.
Move the valve assembly to the side to allow clearance
for the reservoir removal.
Loosen the two hose clamps (Item 1) [Figure 20-80-3]
and remove the reservoir fill hose.
A300 Bobcat Loader

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Figure 20-80-6
1
1
P-34071
Remove the lift tubeline (Item 1) [Figure 20-80-8].

P-34069
Figure 20-80-9
At the left fender, remove the two mount bolts (Item 1)

[Figure 20-80-6] from the front reservoir mount bracket.

Remove the mount bracket from the loader.
Figure 20-80-7
1
1 P-34074
Remove the hose clamp (Item 1) [Figure 20-80-9] and

remove the inlet hose from the pump fitting.
NOTE: Removing the inlet hose from the pump

P-34070 allows the reservoir to be move forward so the
hose clamp and hose can be remove from the
bottom of the reservoir through the left side
Remove the two mount bolts (Item 1) [Figure 20-80-7] motor cover hole.
from the side panel.
Remove the side panel from the loader.
A300 Bobcat Loader

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Figure 20-80-10
2
1
1
N-19610

P-34073 on Page 10-30-1.)
Remove the two hose clamps (Item 1) and remove the

Slide the reservoir ahead. At the left motor access hole hydraulic fill hose (Item 2) [Figure 20-80-12] from the
remove the hose clamp and hose (Item 1) [Figure 20-80- hydraulic reservoir.

10] from the bottom of the reservoir.
Figure 20-80-13
Figure 20-80-11
N-17718A
P-34072
Remove the hydraulic fluid screen (Item 1) [Figure 20-

Remove the drain hose and fitting (Item 1) [Figure 20- 80-13] from the reservoir.
80-11] from the bottom of the reservoir
Wash the screen in clean solvent and air dry, before
Remove the hydraulic reservoir from the loader. replacing.
Hydraulic Fluid Screen
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BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation
2 1
Figure 20-90-1
P-26912
Inspect the solenoid stem and replace the O-rings (Item

P-34204 1) and the back-up washer (Item 2) [Figure 20-90-3].
Solenoid Testing
20-90-1] from the bucket position solenoid. Figure 20-90-4

Remove the solenoid nut (Item 2) [Figure 20-90-1].
Installation: Tighten the solenoid nut to 60 in.-lb. (6,78

N•m) torque.
Figure 20-90-2
1
2
P9175
Use a test meter to measure coil resistance [Figure 20-

90-4]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
P-34205
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Move the solenoid until it touches the tubeline (Item 1)
[Figure 20-90-2].
Remove the solenoid stem and solenoid (Item 2) [Figure

20-90-2] from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.
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BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly
Removal And Installation Figure 20-90-7
Figure 20-90-5
2
N-19069
P-34204
Disconnect the electrical harness (Item 1) [Figure 20-90- Installation: Tighten the nut to 60 in.-lb. (6,78 N•m)
5]. torque.

Disconnect the two tubelines (Item 2) [Figure 20-90-5]. Figure 20-90-8
Figure 20-90-6
1
1
1 N-19070
P-34206
Remove the solenoid (Item 1) and the solenoid stem
(Item 2) [Figure 20-90-8].
Disconnect the three tubelines (Item 1) [Figure 20-90-6].
Installation: Tighten the solenoid stem to 30 - 35 ft.-lb.
Remove the mounting bolts (Item 2) [Figure 20-90-6] (40,8 - 47,6 N•m) torque.
from the bucket position valve.
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BUCKET POSITION VALVE (CONT’D) Figure 20-90-11
Disassembly And Assembly (Cont’d)
Figure 20-90-9
N-18339
1
Remove the plug (Item 1), and flow control spool (Item 2)
N-19072 [Figure 20-90-11].
Check the flow control spool for wear, check the O-ring
Remove the flow adjustment valve and O-ring (Item 1) on the plug and replace as needed.
[Figure 20-90-9]

Figure 20-90-12
NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
for wear or damage and replace as needed.
Figure 20-90-10
3
N-19042
Remove the tilt cylinder check valve (Item 1) spring (Item

1 2) and plug (Item 3) [Figure 20-90-12]. Check for wear,
N-19041 check the O-ring and replace as needed.
Remove the plug (Item 1) [Figure 20-90-10].
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BUCKET POSITION VALVE (CONT’D)
Figure 20-90-13
N-19045
Remove the plug [Figure 20-90-13].

Figure 20-90-14
1
N-19046
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-90-14].
Check all parts and replace as needed. Install a new O-

ring on the plug before installing.
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REAR AUXILIARY DIVERTER VALVE (EARLY Figure 20-100-3
MODELS)
Removal and Installation
Figure 20-100-1 1
P-34744
1 Disconnect the pilot hose (Item 1) [Figure 20-100-3]

from the fitting on the diverter block.
P-34722
Figure 20-100-4
and remove the left side access panel.

Figure 20-100-2 1
1 P-34715
1
Disconnect the tubeline (Item 1) [Figure 20-100-4] from
the fitting on the “F2” port.
P-34751
Disconnect the two electrical connectors (Item 1) [Figure
20-100-2] from the diverter block.
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REAR AUXILIARY DIVERTER VALVE (EARLY
MODELS) (CONT’D)
Removal and Installation (Cont’d)
Figure 20-100-5
P-34739

A300 Bobcat Loader

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REAR AUXILIARY DIVERTER VALVE (EARLY Remove the pilot check valves from block ports PC1 and
MODELS) (CONT’D) PC2 (Item 1) [Figure 20-100-7].
Disassembly and Assembly Remove the shuttle check valve from block port SH1
(Item 2) [Figure 20-100-7].
Figure 20-100-8
IMPORTANT
4
parts clean. Always use caps and plugs on hoses, 2
3
damage the system. 5
I-2003-0888 2
2
Figure 20-100-6
3
2 1
N-0528

Remove the nuts (Item 1) [Figure 20-100-8], seal
washers (Item 2) [Figure 20-100-8], and solenoid valve
coils (Item 3) [Figure 20-100-8].
Remove the diverter control solenoid valve (Item 4)

[Figure 20-100-8] from port SV1. Remove the pressure
1 relieving solenoid valve (Item 5) [Figure 20-100-8] from
1 block port SV2.
N-0527
Inspection
Clean the diverter block to remove dirt before Inspect cartridges, check valves, solenoid valves and
disassembly. Block ports are labeled for correct sealing washers for contamination or damage. Wash all
assembly. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Remove the logic cartridge valves from block ports LC1
and LC2 (Item 1) [Figure 20-100-6]. Inspect diverter block cavities for contamination. Wash
block in clean solvent. Use air pressure to dry.
Figure 20-100-7
2
N-0529
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REAR AUXILIARY DIVERTER VALVE (EARLY
MODELS) (CONT’D)
Solenoid Testing
Figure 20-100-9
P9137


is 6-9 ohms.
Assembly
Put oil on O-rings and back-up washers.
Tighten the Logic cartridge valves (Item 1) [Figure 20-

100-6] to 65 ft.-lb. (88 N•m) torque.
Tighten the pilot check valves (Item 1) [Figure 20-100-7],

and shuttle check valve (Item 2) [Figure 20-100-7] to 35
ft.-lb. (47 N•m) torque.
Tighten the solenoid valves (Items 4 & 5) [Figure 20-

100-8] to 12 ft.-lb. (16,3 N•m) torque. Install the sealing
washers (Item 2) [Figure 20-100-8] and coils (Item 3)
[Figure 20-100-8]. Tighten the nuts (Item 1) [Figure 20-
100-8] to 10 in.-lb. (1,13 N•m) torque.
A300 Bobcat Loader

170 of 772
REAR AUXILIARY DIVERTER (LATER MODELS) Figure 20-101-3
Figure 20-101-1
2
1
1
P-43678
1
Disconnect the hose (Item 1) [Figure 20-101-3] from the

P-43683 base end fitting.

Remove the two access cover mount bolts (Item 1) rod end fitting.
[Figure 20-101-1] from the right side access cover.

Remove the access cover. Disconnect the hose (Item 3) [Figure 20-101-3] from the
pressure out port.
Mark all wires and hoses for proper installation.
Cap and plug all fittings and hoses.
Figure 20-101-2
Figure 20-101-4
1
P-43681
P-43711
Disconnect the four electrical connectors (Item 1) [Figure

20-101-2] from the diverter solenoids. Disconnect the hose (Item 1) [Figure 20-101-4] from the
pressure in fitting.
A300 Bobcat Loader

171 of 772
(CONT’D)
Removal and Installation (Cont’d)
Figure 20-101-5
P-43708
1

from the block.
P-43711
Remove the diverter valve from the loader.
pressure in fitting.

Figure 20-101-6
P-43693

fitting that goes to tank.
A300 Bobcat Loader

172 of 772
REAR AUXILIARY DIVERTER (LATER MODELS)
(CONT’D)
Disassembly And Assembly IMPORTANT

Figure 20-101-8 When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Figure 20-101-10
1
1 1
P-48751
Figure 20-101-9

P-48755
1
Figure 20-101-11
2 2 2
P-48752 1
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-101-8] & [Figure 20-

101-9] are located all over the diverter valve and can be P-48756
removed for cleanout purposes.

Remove the shuttle valve (Item 1) [Figure 20-101-10] &
Installation: Put oil on O-rings and back-up
[Figure 20-101-11] from diverter valve and inspect the
washers.Tighten to 10 ft.-lb. (13,6 N•m) torque.
O-rings and back-up washers (Item 2) [Figure 20-101-
11] for damage.
Installation: Put oil on the O-rings and back-up washers.

Tighten to 10 - 12 ft.-lb. (14 - 16 N•m) torque.
A300 Bobcat Loader

173 of 772
(CONT’D)
Figure 20-101-12
P-48753
1
Figure 20-101-15
P-48755
1
Figure 20-101-13

2
2
2
1
P-48754
Remove the relief valve (Item 1) [Figure 20-101-14] &

[Figure 20-101-15] from the diverter valve and inspect
P-48757 the O-rings and back-up washers (Item 2) [Figure 20-
101-15] for damage.
Remove the differential sensing valve (Item 1) [Figure Installation: Put oil on O-ring and back-up washers.
20-101-12] & [Figure 20-101-13] from diverter valve and Tighten to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
inspect the O-rings and back-up washers (Item 2)
[Figure 20-101-13] for damage.
Installation: Put oil on O-ring and back-up washers.

A300 Bobcat Loader

174 of 772
(CONT’D)
Figure 20-101-16 1
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
P-48759
Remove the nuts (Item 1) [Figure 20-101-18] from the
solenoid valve stems.
Figure 20-101-17

torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-101-16] & [Figure

20-101-17] from the solenoid valve stem.

torque.
Remove the spacer (Item 2) and solenoid valve coils

(Item 3) [Figure 20-101-17].
A300 Bobcat Loader

175 of 772
(CONT’D)

1
Figure 20-101-19
P-48763A
Figure 20-101-22
P-48762
Figure 20-101-20

1 2
2 2 P-48764
1 1
Remove the solenoid valve stem (Item 1) [Figure 20-

101-21] & [Figure 20-101-22] and inspect the O-rings
P-48763 and back-up washers (Item 2) [Figure 20-101-22] for
damage.
Remove the solenoid valve stem (Item 1) [Figure 20- Installation: Put oil on O-rings and back-up washers.
101-19] & [Figure 20-101-20] and inspect the O-rings Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
and back-up washers (Item 2) [Figure 20-101-20] for
damage.
Installation: Put oil on O-rings and back-up washers.

A300 Bobcat Loader

176 of 772
(CONT’D)
Figure 20-101-23
P-48765
P-48765 Installation: Tighten the plug to 10 ft.-lb. (13,6 N•m)

torque.
Remove the plug (Item 1) [Figure 20-101-23]. Figure 20-101-26

Installation: Tighten the plug to 38 ft.-lb. (51,5 N•m)
torque.
Figure 20-101-24
P-48786
Remove the orifice (Item 1) [Figure 20-101-26].

1
P-48766 Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-101-

24] for dirt and debris.
Installation: Tighten the orifice to 22 ft.-lb. (29,8 N•m)

torque.
A300 Bobcat Loader

177 of 772
REAR AUXILIARY DIVERTER (LATER MODELS) Solenoid Testing
(CONT’D)
Figure 20-101-28
Figure 20-101-27
P9137
P-48758 Use a test meter to measure coil resistance [Figure 20-

101-28]. Coil wires do not have polarity. Correct
resistance is 8.6 - 9.5 ohms @ 68° F.
Remove the plugs (Item 1) [Figure 20-101-27].

Installation: Tighten the plug to 14 ft.-lb. (19 N•m) and hear the spool shift.
torque.
Inspection
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.
A300 Bobcat Loader

178 of 772
POWER BOB-TACH BLOCK (EARLY MODELS) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
10-10-1.)
Figure 20-110-2
P-90328 2
2
AVOID DEATH

D-1009-0409 1
P-26595
Remove the two bolts (Item 1) [Figure 20-110-2] from

WARNING the wheel position sensor / steering cylinder cover.

Never work on a machine with the lift arms up unless from the access cover.
support device. Failure to use an approved lift arm Figure 20-110-3
W-2059-0598
Figure 20-110-1
P-26596

cover from the loader.

P-26594
[Figure 20-110-3] from the loader harness.
Raise the lift arms and install an approved lift arm support Push the loader harness connector through the hole in
device. (See Installing The Lift Arm Support Device on the access cover.
Page 10-20-1.) Remove the access cover from the loader.
A300 Bobcat Loader
179 of 772
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-110-6
(CONT’D)
Figure 20-110-4
P-26600
1
that goes from the gear pump to the steering block. Cap
P-26598 and plug the hose.
Figure 20-110-7
that goes from the gear pump to the select valve.

Plug and cap the hose and fitting. 1
Figure 20-110-5
1
P-26601
Remove the hydraulic hose that goes from the top of the
Power Bob-Tach Block to the control valve (Item 1)
[Figure 20-110-7].
P-26599
Remove the A/C compressor (If so equipped).
Remove the hydraulic fitting (Item 1) [Figure 20-110-5] Remove the alternator. (See Contents Page 60-01.)
from the gear pump. Plug the hole.
A300 Bobcat Loader

180 of 772
(CONT’D)
Figure 20-110-8 1
P-26607
Remove the four Power Bob-Tach Block mount bolts

1 1 (Item 1) [Figure 20-110-10].
P-26605
Installation: Tighten the mount bolts to 25 - 28 ft.-lb. (34
- 38 N•m) torque.

Remove the Power Bob-Tach Block from the loader.
Remove the three hydraulic hoses (Item 1) [Figure 20-
110-8] from the back of the Power Bob-Tach block.
Cap and plug the hoses and the fittings.
Figure 20-110-9
P-26606
Mark the two electrical connectors (Item 1) [Figure 20-

110-9] for proper installation.
Disconnect the two solenoid connectors, from the loader

harness.
A300 Bobcat Loader

181 of 772
(CONT’D)
Figure 20-110-11
2
1
3
P-26103
2
Remove the spring (Item 1) and compensator (Item 2)

[Figure 20-110-12].
P-26100
Check the O-ring (Item 3) [Figure 20-110-12] on the plug
and replace as needed.
Clean the diverter block (Item 1) [Figure 20-110-11] to
remove dirt before disassembly. Block ports are labeled

Figure 20-110-13
for correct assembly.

torque.
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
P-26105
damage the system.
I-2003-0888

torque.
A300 Bobcat Loader

182 of 772
(CONT’D)
6
Figure 20-110-14
P-26208
3
2
1
4
5 P-26112
2
1 3 Remove the pressure reducing valve plug (Item 1)
[Figure 20-110-15] &[Figure 20-110-16].
P-26107
Installation: Tighten the pressure reducing valve plug to
to 46 ft.-lb. (62,4 N•m) torque.
Remove the spring (Item 1) and check ball (Item 2)
[Figure 20-110-14].

Remove the relief piston (Item 2), spring (Item 3), ball
seat spring guide (Item 4) [Figure 20-110-16].
and replace as needed. Check the O-ring (Item 5) [Figure 20-110-16] on the
pressure reducing valve plug and replace as needed.
Figure 20-110-15
NOTE: The relief valve seat (Item 6) [Figure 20-110-
16] is a non-serviceable part. If seat is
damaged, order a new power Bob-Tach block
from Bobcat parts.
1
P-26109
A300 Bobcat Loader

183 of 772
(CONT’D)
Figure 20-110-17
P-26116
1 Remove the first solenoid coil (Item 2), spacer (Item 3)

and the second solenoid coil (Item 4) [Figure 20-110-20].
P-26113
NOTE: Remember the solenoid coil orientation for
ease of installation.
Remove the plug (Item 1) [Figure 20-110-17] & [Figure
20-110-18].

Figure 20-110-20
Installation: Tighten the plug to 32 in.-lb. (3,6 N•m)
torque.
Figure 20-110-18
4
3
2
P-26117
3
Remove the nut (Item 1) [Figure 20-110-19] & [Figure

2 1 20-110-20].
P-26114
Installation: Tighten the nut to 5 ft.-lb. (6,8 N•m) torque.

Check the O-ring (Item 3) [Figure 20-110-18] and

replace as needed.
A300 Bobcat Loader

184 of 772
(CONT’D)
Figure 20-110-21
1
P-26123
1

20-110-24].
P-26120
torque.
Remove the solenoid valve stem (Item 1) [Figure 20-
110-21].

Figure 20-110-24
Installation: Tighten the solenoid valve stem to 20 ft.-lb.
(27,1 N•m) torque.
Figure 20-110-22
2
1
3 P-26309
2
Remove the dowel pin shuttle (Item 2) [Figure 20-110-

24].
P-26122
replace as needed.
Check the O-rings and back-up washers (Item 1) [Figure
20-110-22] and replace as needed.
Installation: Put oil on O-rings and back-up washers.

replace as needed.
A300 Bobcat Loader

185 of 772
(CONT’D)
Figure 20-110-25
P-26128

1 20-110-28].
P-26125
torque.
20-110-26].

Figure 20-110-28
torque.
Figure 20-110-26
2
P-26129
2
1
replace as needed.
3 P-26127
Remove the pilot piston (Item 2) [Figure 20-110-26].

replace as needed.
A300 Bobcat Loader

186 of 772
(CONT’D)
Figure 20-110-29
P-26133
Make sure orifice is clean and not plugged [Figure 20-

110-31].
P-26130
Figure 20-110-32
20-110-30].

torque.
Figure 20-110-30
1
P-26134

20-110-33].
2
1 Installation: Tighten the plug to 198 in.-lb. (22,4 N•m)
torque.
3 P-26132
Remove the orifice (Item 2) [Figure 20-110-30] with a 5/

32 in. allen wrench.
Installation: Hand tighten until snug.
A300 Bobcat Loader

187 of 772
(CONT’D)
Figure 20-110-33
2
3 P-26139
2
1 Remove the dowel pin orifice (Item 1) [Figure 20-110-
35].
4 P-26136
replace as needed.
Remove the relief spring (Item 2) [Figure 20-110-33].

Figure 20-110-36
Remove the ball seat spring guide (Item 3) [Figure 20-
110-33].

replace as needed.
Figure 20-110-34
P-26140

1 20-110-37].

P-26137 torque.
Remove the plug (Item 1) [Figure 20-110-34]

torque.
A300 Bobcat Loader

188 of 772
(CONT’D)
Figure 20-110-37
2
1
3
P-26143
2
1 Remove the flow control spring (Item 1) [Figure 20-110-
39].
P-26141
Remove the flow control (Item 2) [Figure 20-110-39].
Check the O-ring (Item 2) [Figure 20-110-37] and Check the O-ring (Item 3) [Figure 20-110-39] and
replace as needed.

replace as needed.
Figure 20-110-38
P-26141

torque.
A300 Bobcat Loader

189 of 772
A300 Bobcat Loader

190 of 772
POWER BOB-TACH BLOCK (LATER MODELS) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
10-10-1.)
Figure 20-111-2
P-90328 2
2
AVOID DEATH

D-1009-0409 1
P-26595
WARNING wheel position sensor / steering cylinder cover.

from the access cover.
the lift arms are secured by an approved lift arm Figure 20-111-3
W-2059-0598
Figure 20-111-1
P-26596


P-26594 [Figure 20-111-3] from the loader harness.
Push the loader harness connector through the hole in

Raise the lift arms and install an approved lift arm support the access cover.
Page 10-20-1.) Remove the access cover from the loader.
A300 Bobcat Loader

191 of 772
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-111-6
(CONT’D)
Figure 20-111-4
P-26600
1
that goes from the gear pump to the steering block. Cap
P-26598 and plug the hose.
Remove the A/C compressor (If so equipped). (See

Disconnect the hydraulic hose (Item 1) [Figure 20-111-4] Contents Page 80-01.)
that goes from the gear pump to the select valve.

Remove the alternator. (See Removal And Installation on
Plug and cap the hose and fitting. Page 60-30-4.)
Figure 20-111-5
P-26599
Remove the hydraulic fitting (Item 1) [Figure 20-111-5]

from the gear pump. Plug the hole.
A300 Bobcat Loader

192 of 772
(CONT’D)
Removal And Installation (Cont'd) 1

1
Figure 20-111-7
P-48591
1
9].
P-26606
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb.
(34 - 38 N•m) torque.
Disconnect and cap the two electrical solenoid
connectors (Item 1) [Figure 20-111-7] from the loader Remove the power Bob-Tach block.

electrical harness.
Figure 20-111-8
2
2
P-48590
Disconnect and cap the outlet hose (Item 1) [Figure 20-

111-8] from block.

Disconnect and cap the hose (Item 2) [Figure 20-111-8]
from block.
A300 Bobcat Loader

193 of 772
(CONT’D)
Figure 20-111-10
3
1
4
2 1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
spool (Item 3) [Figure 20-111-11].
P-48115
Clean the block (Item 1) [Figure 20-111-10] to remove
dirt before disassembly. Block ports are labeled for

Figure 20-111-12
correct assembly.
Installation: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6

N•m) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-111-12].
Installation: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.
A300 Bobcat Loader

194 of 772
(CONT’D)
Figure 20-111-13
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-111-15].
P-48382 NOTE: Do not remove plugs. If the plugs are removed

the internal pressure relieving spring setting
will be altered.
Remove the check valve (Item 1) [Figure 20-111-13].

Figure 20-111-16
Installation: Oil the check valve and O-rings and tighten
the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Figure 20-111-14
2
1
P-48384
3
Remove the plug (Item 1) [Figure 20-111-16], inspect the
P-48119 O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-111-

Inspect the check valve (Item 1) and piston assembly 16] to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
(Item 2) [Figure 20-111-14].
Check the O-rings and back up washers (Item 3) [Figure

20-111-14] on the check valve and piston assembly and
replace as needed.
A300 Bobcat Loader

195 of 772
(CONT’D)

3
Figure 20-111-17
2
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)

and the second solenoid coil (Item 3) [Figure 20-111-19].
P-48664
NOTE: Remember the solenoid coil orientation for
ease of installation.
Remove the orifice screw (Item 2) located behind the
plug (Item 1) [Figure 20-111-17].

Figure 20-111-20
Installation: Tighten the orifice screw (Item 2) [Figure
20-111-17] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Figure 20-111-18
1
2 P-48386
P-48127 Installation: Tighten the solenoid stem to 20 - 25 ft.-lb.

(27,1 - 34 N•m) torque.
NOTE: This plug is a zero leak plug and should not be

removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-111-18].
Installation: Tighten the solenoid valve stem nut to 15 -

45 in.-lb. (1,7 - 5,1 N•m) torque.
A300 Bobcat Loader

196 of 772
(CONT’D)
Figure 20-111-21 1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-
111-23].
P-48175
Installation: Tighten the screened orifice plug to 11 - 12
ft.-lb. (14,9 - 16,3 N•m) torque.
Remove the armature rod assembly (Item 1) [Figure 20-
111-21].

Figure 20-111-24
Figure 20-111-22
2
2
1
1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-111-
24] for damage replace as needed. If the screened orifice
Inspect the solenoid stem (Item 1), armature assembly plug is blocked replace with a new plug.
(Item 2) and the spool (Item 3) for damage [Figure 20-
111-22]. Check the O-ring (Item 2) [Figure 20-111-24] and
replace as needed.
NOTE: If the solenoid stem is damaged (Item 1) check
the armature assembly (Item 2) for damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-111-
22].
A300 Bobcat Loader

197 of 772
A300 Bobcat Loader

198 of 772
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Removal and Installation Figure 20-120-2
IMPORTANT 1

clean the work area before disassembly and keep all 2
tubelines and ports to keep dirt out. Dirt can quickly 4
damage the system.
I-2003-0888
3
Figure 20-120-1
P-34661
2 Figure 20-120-3

3
6 2
4
5 3
P-31242
Disconnect the auxiliary hoses (Item 1) and drain hose

(Item 2) [Figure 20-120-1] from the coupler block. P-34760
Remove the two mounting bolts (Item 3) [Figure 20-120-

1]. Remove the male coupler (Item 1) [Figure 20-120-2] &
[Figure 20-120-3].
Installation: Tighten the male coupler (Item 1) [Figure

20-120-2] & [Figure 20-120-3] to 59 ft.-lb. (80 N•m)
Remove the drain coupler (Item 2) [Figure 20-120-2] &

[Figure 20-120-3].
Installation: Tighten the drain coupler (Item 2) [Figure

20-120-2] & [Figure 20-120-3] to 37 ft.-lb. (50 N•m)
Remove the female coupler (Item 3) [Figure 20-120-2] &

[Figure 20-120-3].
Installation: Tighten the female coupler (Item 3) [Figure

20-120-2] & [Figure 20-120-3] to 59 ft.-lb. (80 N•m)
Remove the fittings (Item 4) [Figure 20-120-2] & [Figure

20-120-3] check the O-rings (Item 5) [Figure 20-120-3]
Remove the springs (Item 6) [Figure 20-120-3].
A300 Bobcat Loader

199 of 772
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-120-6
(CONT’D)

1
Figure 20-120-4
1
2
P-34665
Check the O-rings (Item 1) back-up O-rings (Item 2)

[Figure 20-120-6] for damage and replace as needed.
P-34663
Figure 20-120-7
Check the O-ring (Item 1) [Figure 20-120-4] for damage

1
Figure 20-120-5
P-34664
Check the O-rings (Item 1) back-up O-rings (Item 2)

[Figure 20-120-7] for damage and replace as needed.
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-120-5] for damage and replace as
needed.
A300 Bobcat Loader

200 of 772
HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Hydrostatic Charge Pressure Sender . . . . . . . . . . . . . . . . 30-30-1
SAFETY &
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAINTENANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1 HYDROSTATIC
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-2 SYSTEM
Tensioner Pulley Tension Spring . . . . . . . . . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 DRIVE

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-13 YSTEM
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . 30-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5

ELECTRICAL
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2 SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1 ANALYSIS
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-39 ENGINE
Charge Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-25 SERVICE
Charge Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . 30-40-26
Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-23
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-28 SPECIFICATIONS
Hydrostatic Pump Calibration . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-35
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . 30-40-13
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . 30-40-11
Pump Controller Neutral Adjustment . . . . . . . . . . . . . . . . 30-40-51
Pump Controller Removal And Installation . . . . . . . . . . . . 30-40-1
Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-40-48
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-18
Shaft Seal And Shaft Installation . . . . . . . . . . . . . . . . . . . 30-40-21
Shaft Seal And Shaft Replacement . . . . . . . . . . . . . . . . . 30-40-19
System Check Relief Valves (High Pressure Relief, Charge Check
& By-Pass Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
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HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER (SEAL TO CONNECT) (STC). . . . . . . . . . . . . . 30-60-1

Hydraulic Oil Cooler Removal And Installation . . . . . . . . . 30-60-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE
SPECIFICATIONS FOR BOLTS on Page SPEC-40-1.) UNLESS OTHERWISE
SPECIFIED
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HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart WARNING

The following trouble shooting 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
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
The hydraulic system is overheating 8,9,10,11
Service3 code HP2 appears (Warning, low charge pressure) or the warning light comes ON. 8,11,12,13,14,

1. The hydrostatic pump replenishing valves are not seating.
2. The steering linkage needs adjustment.

3. The hydraulic pump has damage.
4. The final drive chains are broken.
5. The hydraulic motor has damage
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydraulic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12.The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged
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HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replenishing Valve Function
The functions of the replenishing valves are: CHARGE OIL
• To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling: Function 1
• To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry: Function 2
IMPORTANT
Valve Moves for Charge
When repairing hydrostatic and hydraulic systems, Oil Replacment
FUNCTION 1
damage the system.

I-2003-0888
VALVE Stays on Seat to

Hold High Pressure for Drive
FUNCTION 2 B-2804
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HYDROSTATIC MOTOR Raise the lift arms and install an approved lift arm support
Removal And Installation Page 10-20-1.)
DANGER on Page 10-30-1.)

Remove the motor cover mount bolts (Item 1) [Figure
30-20-1].
Remove the motor cover from the loader.
Figure 30-20-2
P-90328
AVOID DEATH 3
• Keep out of this area when lift arms are raised 2
1

D-1009-0409
WARNING N-22484
Mark the hoses for correct installation.

Never work on a machine with the lift arms up unless Disconnect the hydraulic hose (Item 1) [Figure 30-20-2]
the lift arms are secured by an approved lift arm that goes to the two-speed port on the two-speed / brake
support device. Failure to use an approved lift arm block.
support device can allow the lift arms or attachment Disconnect the hydraulic hose (Item 2) [Figure 30-20-2]
to fall and cause injury or death. that goes to the brake port on the two-speed / brake
W-2059-0598 block.
Figure 30-20-1 that goes to the make-up port on the two-speed / brake
block.
Figure 30-20-3
1
1 1
N-22483
Lift and block the loader. (See Procedure on Page 10-10- N-22485
1.)
that goes to the case drain filter.
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HYDROSTATIC MOTOR (CONT’D Figure 30-20-6
Figure 30-20-4
N-22487
2
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

N-22486 20-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold

Remove the hydraulic fitting (Item 1) [Figure 30-20-4] the cam ring to the motor and do not have to
from the motor. be remove for motor removal. Remove the

motor from the loader.
Remove the eight flange bolts (Item 2) [Figure 30-20-4]
from the high pressure hoses on the motor. Figure 30-20-7
Installation: Install the lower collar to the motor and

connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 25 ft.-lb.
(34 N•m) torque.
Figure 30-20-5
1
N-22535
1
Installation: Replace the O-ring (Item 1) [Figure 30-20-

7] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lb. (149
N•m) torque.
N-22488
Remove the hydraulic fitting (Item 1) [Figure 30-20-5]

from the motor.
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HYDROSTATIC MOTOR (CONT’D
8
7
6
5
4
3
2
29
28
26 27
9 25
17
25
16 31

15
39
10 34
33
11 37 38
36
18 21 35
19 24
22
14 20
23 48
12 13 47
46 49
45
44
43
32
42
41
40
B-16657
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HYDROSTATIC MOTOR (CONT’D)
Parts Identification (Cont'd)
Ref. Description Ref. Description
1. Motor 26. Spool

2. Distributor 27. Washer
3. Spring 28. O-ring
4. Seal / O-ring 29. Plug
5. Seal / O-ring 30. Housing
6. Seal / O-ring 31. Quad Ring
7. Seal / O-ring 32. Bushing
8. Seal / O-ring 33. Snap Ring
9. Bushing 34. Snap Ring
10. Roller 35. Spool
11. Piston 36. Spring
12. Block 37. Washer
13. Cam 38. Quad Ring
14. Quad Ring 39. Bolt
15. Plug 40. Shaft
16. O-ring 41. Brake Disc-Outer
17. Locating Pin 42. Brake Disc-Inner
18. Housing 43. Piston
19. Shim 44. O-ring
20. O-ring 45. Washer
21. Poppet 46. Washer

22. Spring 47. Gasket
23. Plug 48 Cover
24. Bolt 49. Bolt
25. Spring
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Disassembly
Figure 30-20-8
1
3
N-22491
Remove the cover plate gasket (Item 1) [Figure 30-20-

N-22489 10].
Remove the disk spring washer (Item 2) and the disk

NOTE: Mark the motor, brake and motor carrier spring (Item 3) [Figure 30-20-10] from the brake
housings for proper alignment for ease of housing.

assembly [Figure 30-20-8].
NOTE: Mark the top side of the disk spring for proper
Drain the oil from the motor casing. installation.
1
2
N-22490 N-22493
Remove the twelve mounting bolts (Item 1) [Figure 30- Remove the piston (Item 1) [Figure 30-20-11] from the
20-9] from the brake cover plate. brake housing.
NOTE: Unscrew the bolts alternately, one turn at a NOTE: The use of air pressure through the brake line
time to release the preload on the end cap. connection (Item 2) [Figure 30-20-11] will aid
in piston removal.
Remove the cover plate from the brake housing.
HYDROSTATIC MOTOR (CONT’D
Disassembly (Cont'd)
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Figure 30-20-12 Figure 30-20-14
1
1
2
N-22494 N-22496
Remove the eight mounting bolts (Item 1) [Figure 30-20- Remove the O-ring (Item 1) [Figure 30-20-14] from the
12] from the brake housing. brake housing.
Remove the brake housing (Item 2) [Figure 30-20-12] Figure 30-20-15

from the rear housing.

Figure 30-20-13
1
N-22497
N-22495
Remove the seal (Item 1) [Figure 30-20-15] from the
brake housing.
Remove the brake disks (Item 1) [Figure 30-20-13] from

the brake shaft.
Remove the O-ring (Item 2) [Figure 30-20-13] from the

housing.
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Figure 30-20-16
1
1
2
N-22502

N-22499 housing.
Installation: Tighten the plug to 18 - 22 ft.-lb. (25 - 30

Remove the two-speed spool (Item 1) [Figure 30-20-16] N•m) torque.
from the housing assembly.

Remove the plugs (Item 2) [Figure 30-20-18] from the
Figure 30-20-17 housing.
Installation: Tighten the plugs to 9 - 11 ft.-lb. (12 - 15

1 N•m) torque.
Figure 30-20-19
4 1
3
2
N-22501
Inspect the spool (Item 1), the spring (Item 2) washer

(Item 3) and the snap ring (Item 4) [Figure 30-20-17],
N-22503
NOTE: The spool (Item 1) [Figure 30-20-17] is marked

with either an A or B. The spool must be Remove the flushing spool assembly (Item 1) [Figure 30-
replaced with a spool with the same mark. 20-19] from the housing.
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Figure 30-20-20
4
1 1
2 3
N-22506
Remove the poppet assembly (Item 1) [Figure 30-20-22]

N-22504 from the housing.
Figure 30-20-23
Remove the spring (Item 1), washer (Item 2), and rear
spring (Item 3) from the spool (Item 4) [Figure 30-20-20].

Inspect all parts and replace as needed.
Figure 30-20-21
1 2
3
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring

(Item 3) [Figure 30-20-23] for wear and replace as
needed.
N-22505

housing.
Installation: Tighten the plug to 9 - 11 ft.-lb. (12 - 15

N•m) torque.
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Figure 30-20-24
1 1
N-22511
Remove the roller / piston assembly (Item 1) [Figure 30-

N-22508 20-26] from the cylinder block.
NOTE: Put all roller / piston assembles back in the

Loosen the two (8 mm) cam ring mount bolts (Item 1) original bore.
[Figure 30-20-24].

Figure 30-20-27
Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Remove the cam ring mount bolts, and remove the cam
ring from the housing.
Figure 30-20-25 1
N-22512
2
Remove the brake shaft (Item 1) [Figure 30-20-27] from
the housing.
N-22509
Remove the cylinder block (Item 1) [Figure 30-20-25]

from the housing.

housing.
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Figure 30-20-28 1
N-22516
NOTE: The distributor removal, is best accomplished

N-22513 by lifting the housing (Item 1) 2-3 in. above a
wooden surface, and dropping the housing
[Figure 30-20-30].
NOTE: The snap ring end of the shaft (Item 1) [Figure
30-20-28] goes up toward the cam ring end of Figure 30-20-31

the motor.
Figure 30-20-29
N-22521
N-22515 Remove the locating pin (Item 1) [Figure 30-20-31] from

the distributor.
Remove the distributor (Item 1) [Figure 30-20-29] from

the housing.
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Figure 30-20-32
2 1
N-22519
Remove the six seals (Item 1), and six back-up O-rings
N-22522 (Item 2) [Figure 30-20-34] from the distributor.
Inspection
Remove the twelve springs (Item 1) [Figure 30-20-32]
from the distributor. Figure 30-20-35

Figure 30-20-33
N-22498
N-22523
Clean all parts in clean solvent and use air pressure to
dry them. Do Not use cloth or paper because small
Remove the bushing (Item 1) [Figure 30-20-33] from the pieces of material can get into the system and cause
distributor, if worn or scratched. damage.
Before the motor is assembled, check the following

items:
Check the brake piston (Item 1) and seal (Item 2) [Figure

30-20-35] and replace as needed.
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Inspection (Cont’d)
Figure 30-20-36
3
1
N-22526
Check all rollers (Item 1), pistons (Item 2) and piston

N-22520 rings (Item 3) [Figure 30-20-38] for wear and replace as
needed.
Check the surfaces of the distributor for wear and NOTE: Put all roller / piston assembly back in their
scratches [Figure 30-20-36]. original position.

Figure 30-20-37 Figure 30-20-39
N-22510 N-22514
Check the cam ring inside surface for wear and scratches Check the brake shaft (Item 1) [Figure 30-20-39] for
[Figure 30-20-37]. wear and replace as needed.
Check the brake shaft snap ring (Item 2) [Figure 30-20-

39] and replace as needed.
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Assembly
Figure 30-20-40 1
N-22525
1
Install a new bushing (Item 1) [Figure 30-20-42] in the

N-22511 distributor if the old bushing was removed.
Figure 30-20-43
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.

Dip the roller / piston assembly (Item 1) [Figure 30-20-
1
40] in oil and replace back its original bore.
Repeat procedure for each roller / piston assembly.
Figure 30-20-41
N-22522
Install new O-rings and seals on the distributor [Figure

30-20-43]
NOTE: When installing seals, apply a light coating of

oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
N-22518 30 minutes for the seals to set on the
distributor before installing the distributor in
the housing.
Apply a small amount of grease to the locating pin (Item
1) [Figure 30-20-41] and install the locating pin in the Using a small amount of grease, install the twelve springs
housing into the distributor valve (Item1) [Figure 30-20-43].
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Assembly (Cont'd)
1
Figure 30-20-44
N-22513
Install the brake shaft (Item 1) [Figure 30-20-46] in the

N-22515 housing.
Figure 30-20-47
Install the distributor (Item 1) [Figure 30-20-44] in the
housing.

1
Figure 30-20-45
1
N-22512
Apply a light coating of grease, and install the O-ring

N-22516 (Item 1) [Figure 30-20-47] to the housing.
Align the locating pin (Item 1) [Figure 30-20-45] in the

housing with the alignment hole in the distributor, an tap
the distributor in place with a rubber mallet.
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Assembly (Cont'd)
Figure 30-20-48
2
1
1
N-22499
Install a new O-ring on the housing assembly (Item 1)

N-22509 [Figure 30-20-50] and lightly smear with grease.
Install the two speed spool (Item 2) [Figure 30-20-50].

Install the cylinder block assembly (Item 1) [Figure 30-
20-48] to the brake shaft. Figure 30-20-51

Install the cam ring to the rear housing and start the
mount bolts and finger tighten.
Figure 30-20-49
1
N-22496
1 1 Install a new O-ring on the housing assembly (Item 1)

[Figure 30-20-51] and lightly smear with grease.
N-22508
Turn the motor so that it sets on the cam ring, and

cylinder block [Figure 30-20-49].
NOTE: Be careful when turning or moving the motor

so the cylinder block stays in the motor
housing.
Tighten the two cam ring mounting bolts to 26 - 29 ft.-lb.

(35 - 39 N•m) torque.
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Assembly (Cont'd)
Figure 30-20-52
N-22530
Install the brake disc pack starting with an outer disc

N-18348 (Item 1) [Figure 30-20-54] and alternating with an inner
disc, throughout the pack.
Measure the thickness of the individual brake disc's Figure 30-20-55

[Figure 30-20-52] to determine the amount of wear on

each disc.
The normal thickness of the individual brake disc is 0.039

in. (1 mm). 1
If the individual disc's thickness is 0.037 in. (0,95 mm) or

less, replace the complete disc pack.
Figure 30-20-53
1
2 N-22532
End the disc pack with an outer disc (Item 1) [Figure 30-
20-55].
N-22529
Install the brake housing (Item 1) [Figure 30-20-53] on

the motor housing and align the marks.
Install the eight mounting bolts (Item 2) [Figure 30-20-

53] and tighten evenly to 52 - 57 ft.-lb. (70 - 77 N•m)
torque.
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Assembly (Cont'd)
Figure 30-20-56
N-22493
Install the piston (Item 1) [Figure 30-20-58] in the brake

N-22533 housing.
NOTE: If the brake pack was not replaced, the

Install the brake seal (Item 1) [Figure 30-20-56]. procedure described below for determining
brake washer thickness, need not be

Figure 30-20-57 preformed.
Install the motor assembly in a hydraulic press. Apply a

downward force of 4500 lb. (20 Kn), on the brake piston
[Figure 30-20-58].
NOTE: The 4500 lb. of force, is NOT the amount of

pressure required by the press. It is the
amount of downward force applied by the
1 press.
The amount of force applied to the brake piston, by the

press, is determined by the diameter of the piston on the
press cylinder and the PSI applied to the press piston.
N-22498 Determine the diameter of the piston on the press

cylinder d and use the following formula to determine the
PSI of pressure to apply to the press cylinder piston.
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-20-57].
1432
( d=6 in.
2 ) 3²=9 1432
9
=159 PSI
Example: d = 6 in. (152 mm) piston diameter of the

press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.
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Assembly (Cont'd)
Figure 30-20-59
1
1
2
N-22491
The correct washer thickness must be determined before

N-22534
the washer (Item 1) [Figure 30-20-61] can be installed.
With the motor in a hydraulic press and the Use the recorded measurement obtained in [Figure 30-
predetermined amount of pressure applied on the 20-59]. Plus the thickness of the gasket (Item 2) [Figure

piston, use a straight edge, and measure the distance 30-20-60], which is 0.012 in. (0,3 mm). Minus the
from the top of the brake housing (Item 1) to the top of thickness of the brake plate (Item 1) [Figure 30-20-60],
the piston (Item 2) [Figure 30-20-59]. which is 0.281 in. (7,15 mm).
Record the measurement to three decimal places. Select a washer, or combination of washers to suit the
calculated thickness within + 0.006 in. (0,15 mm).
Remove the motor from the hydraulic press.
Install the proper brake washer or washers.
Figure 30-20-60
Figure 30-20-62
N-22492
N-22490
Install the brake plate (Item 1) [Figure 30-20-60].

Install the brake end cover (Item 1) [Figure 30-20-62].
Install the end plate gasket (Item 2) [Figure 30-20-60].
Install the twelve end cover mount bolts and tighten
evenly to 10 - 12 ft.-lb. (14 - 16 N•m) torque.
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HYDROSTATIC MOTOR CARRIER Figure 30-21-2
Figure 30-21-1
1
1
P5467

1.)

Raise the lift arm and install an approved lift arm support
Page 10-20-1.)

on Page 10-30-1.)
Remove the fluid from the chaincase. (See Replacing P5489

The Oil on Page 10-130-1.)
Remove the front axle. (See Axle, Sprocket And Bearings Slide the motor carrier toward the rear and remove the
Removal And Installation on Page 40-30-2.) rear drive chain.
If the motor carrier is removed from the right side, NOTE: For easier access for the motor carrier
remove the lift arm bypass control valve. (See Removal coming out and going into the chaincase, tie
And Installation on Page 20-50-1.) and remove the the front drive chain to the chaincase with a
hydraulic control valve. (See Removal And Installation on wire [Figure 30-21-2].
Page 20-40-3.)
Slide the motor carrier out of the chaincase far enough to
Remove the six mounting bolts (Item 1) [Figure 30-21-1] install a chain and chain hoist to the carrier [Figure 30-
from the carrier. 21-2].
Installation: Tighten the mounting bolts to 330 ft.-lb. NOTE: When installing the motor carrier into the
(447 N•m) torque. loader, use caution to protect the wheel speed
washer from damage.
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HYDROSTATIC MOTOR CARRIER (CONT’D)
1 2 3 4 6
5
4
3 7

PE-1395A
Ref. Description
1. Snap Ring
2. Spacer
3. Bearing
4. Race
5. Seal
6. Housing
7. Speed Washer
8. Shaft
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HYDROSTATIC MOTOR CARRIER (CONT’D) Put the motor carrier in a hydraulic press [Figure 30-21-
4].
Disassembly
Put a small amount of pressure on the shaft to release
Figure 30-21-3 the pre-load on the snap ring.
Figure 30-21-5
P5760 1
P-28155
Remove the large O-ring from the groove (Item 1)
[Figure 30-21-3] in the housing.

Remove the snap ring (Item 1) [Figure 30-21-5] and
Figure 30-21-4 washer from the shaft.
Figure 30-21-6
P5766
P-28154 Use a hydraulic press, remove the shaft from the housing
[Figure 30-21-6].
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HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-21-9
Disassembly (Cont’d)
Figure 30-21-7
P-28158
Use the hydraulic press to remove the bearing from the

P-28156 shaft [Figure 30-21-9].
Figure 30-21-10
NOTE: The bearing (Item 1) and the wheel speed
washer (Item 2) [Figure 30-21-7], must both be

replaced, due to damage to the wheel speed
washer from removing the bearing.
Figure 30-21-8
1
P-28162
Remove the wheel speed washer (Item 1) [Figure 30-21-

10] from the shaft.
P-28157
Install the bearing puller tool (Item 1) [Figure 30-21-8]

under the bearing flange, between the bearing and the
speed washer.
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HYDROSTATIC MOTOR CARRIER (CONT’D) Assembly
Disassembly (Cont'd) Figure 30-21-12
Figure 30-21-11
2
1
P5764
P-28164
The tool listed will be needed to the following procedure:
Remove the two seals (Item 1) [Figure 30-21-11] from MEL1431 - Seal Driver Tool
the housing.

Install the first seal (Item 1) [Figure 30-21-12] into the
Check the bearing cup (Item 2) [Figure 30-21-11] (both housing with the seal lip facing away from you.
sides) and replace as needed.
Use the tool (Item 2) [Figure 30-21-12] as shown in the
figure.
Figure 30-21-13
P5762
Install the second seal (Item 1) [Figure 30-21-13] into the

housing with the seal lip facing toward you.
Use the tool (Item 2) [Figure 30-21-13] as shown in the

figure.
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Assembly (Cont'd)
Figure 30-21-14
P-28160
The wheel speed washer, has three alignment pins (Item

P-28159 1) [Figure 30-21-16].
Figure 30-21-17
Check the new wheel speed washer with a straight edge,
to be sure it is square [Figure 30-21-14].

If the washer is more than 0.080 (2,03 mm) out of square,
it must be replaced.
Figure 30-21-15
1
P-28162
Install the wheel speed washer on the shaft [Figure 30-

21-17].
P-28162
Inspect the wheel speed washer for damage to the

magnetic surface (Item 1) [Figure 30-21-15].
NOTE: Do not contact the magnetic surface of the

wheel speed washer (Item 1) [Figure 30-21-
15], with a magnet. This may cause damage to
the magnetic surface.
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Assembly (Cont'd)
Figure 30-21-18
1
1
P-28161
Align the three pins (Item 1) [Figure 30-21-18] in the

sprocket.

Figure 30-21-19
P-5769
1
Install the shaft / bearing assembly into the housing.
Install the bearing (Item 1) using the tool (Item 2) [Figure

30-21-20] (MEL1431).
After the bearing is seated. Install the washer and snap

ring on the shaft.
P-28163
It may be necessary to use the tool to push the washer
and snap ring down into position because of the pre-load
Install the bearing on the shaft [Figure 30-21-19]. on the bearings.
Use a pipe (Item 1) [Figure 30-21-19] with O.D. that

seats on the I.D. of the bearing.
Seat the bearing on the shaft, down against the wheel

speed washer.
NOTE: The wheel speed washer should be tight on

the shaft.
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CHARGE PRESSURE
Hydrostatic Charge Pressure Sender
Figure 30-30-1
2
N-19742A
To remove and install the charge pressure sender, use

the following procedure.

Disconnect the wire (Item 1) [Figure 30-30-1] from the
sender.

from the charge pressure sender.
Remove the charge pressure sender from the control

valve at the connector (Item 3) [Figure 30-30-1].
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HYDROSTATIC PUMP Figure 30-40-3
Pump Controller Removal And Installation
Figure 30-40-1
P-26465
Remove the control spool plug (Item 1) [Figure 30-40-3]

P-26463 at the front side of the pump.
Figure 30-40-4
Raise the lift arms and install and approved lift arm
support device. (See Installing The Lift Arm Support

Device on Page 10-20-1.)
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
Raise the operator cab. (See Raising The Operator Cab 1

on Page 10-30-1.)
Locate the two pump controllers (Item 1) [Figure 30-40-

1] on the hydrostatic pumps.
Figure 30-40-2
P-26469
Do Not remove the spring (Item 1) [Figure 30-40-4],as it

is attached to the control spool.
P-26464
Disconnect the electrical connectors (Item 1) [Figure 30-

40-2] from the loader harness.
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HYDROSTATIC PUMP (CONT'D) Figure 30-40-7
Pump Controller Removal And Installation (Cont'd)
Figure 30-40-5
1 2
1
P-26472
Use a small amount of grease on a new gasket and

P-26465 install the gasket on the pump controller (Item 1) [Figure
30-40-7].
Remove the seven mount bolts (Item 1) [Figure 30-40-5] Be sure the pump surface is clean.
from the pump controller.

Figure 30-40-8
Remove the controller from the pump.
Remove the controller gasket from the pump.

2 1
Figure 30-40-6
P-26473
Align the summing link pin (Item 1) on the pump with the
bore (Item 2) [Figure 30-40-8] in the pump controller
P-26471 module.
Installation:
Be sure the summing link pin (Item 1) [Figure 30-40-6] is

in the center.
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Pump Controller Removal And Installation (Cont'd)
Figure 30-40-9
2
1
1 2
P-26469
Be sure the spring (Item 1) [Figure 30-40-11] is properly

P-26465 attached to the control spool.
Figure 30-40-12
Install the pump controller on the hydrostatic pump.

Align the bolt holes.
Install the seven mount bolts. 2
Figure 30-40-10 1
7 4
3
1 (8)
P-26465
2
Install the control spool bore plug (Item 1) [Figure 30-40-

12] in the pump and tighten to 30 - 70 ft.-lb. (41 - 94 N•m)
5 torque.
6
P-30692 Connect the electrical connectors (Item 1) [Figure 30-40-
12] to the loader harness.
Tighten the controller mounting bolts to 11 - 13 ft.-lb. (15 - NOTE: When a pump controller is replaced the
17,5 N•m) torque using the tightening pattern [Figure 30- hydrostatic pumps must be calibrated. (See
40-10] Hydrostatic Pump Calibration on Page 30-40-
4.) for the proper procedure.)
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HYDROSTATIC PUMP (CONT'D) Turn the key (Item 1) [Figure 30-40-13] to the RUN
position or press the RUN/ENTER button (Item 1)
Hydrostatic Pump Calibration [Figure 30-40-14] for power, without starting the loader.
Figure 30-40-15
WARNING
fall or move and cause injury or death. 1
W-2017-0286
Figure 30-40-13
P-24800
Verify the parking brake (Item 1) [Figure 30-40-15] is

OFF.

Figure 30-40-16
P-26475
Figure 30-40-14
P-26476
Move the left joystick to the forward position and toward

the side screen [Figure 30-40-16] and hold in position.
1
P-26480

10-10-1.)
Operator must be in the seat and the seat bar down.
Verify that the wheels are straight.
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Hydrostatic Pump Calibration (Cont'd)
Figure 30-40-17
2 38-05
3
P-26476
1
Move the left joystick to the reverse position and toward
P-26477A the operator [Figure 30-40-19] and hold in position.
Figure 30-40-20
Press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 30-40-17].

Three audible beeps will sound and an error code (Item
2) (38-05 & 38-07) will be displayed if the operator 38-05
presses the PRESS FOR CODES, (LIGHTS) switch
(Item 3) [Figure 30-40-17].
Figure 30-40-18
1
1
P-26477A

1) [Figure 30-40-20].
P-26479
The warning light (Item 1) [Figure 30-40-18] on the right

console will be ON.
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Figure 30-40-21
2 38-98
1 3
P-26477A

P-26479 1) [Figure 30-40-23].
Three audible beeps will sound and the error code (Item
The warning light (Item 1) [Figure 30-40-21] on the right 2) (38-98) will be displayed if the operator presses the
console will continue to be ON. PRESS FOR CODES (LIGHTS) switch (Item 3) [Figure

30-40-23].
Figure 30-40-22
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
P-26474
Allow the left joystick to go to the neutral position [Figure

30-40-22].
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Figure 30-40-24
P-26482
Move and hold the left joystick to the forward position

P-26481 [Figure 30-40-25] until the forward calibration is
completed.
Move the throttle (Item 1) [Figure 30-40-24] to high idle. The pump controller will start increasing the electrical
current to the hydrostatic pumps until it sees a pulse from

NOTE: If at any time, during calibration, the operator the wheel sensors.
needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the The loader wheels will rotate a short distance forward
neutral position. each time it sees a pulse.
The calibration procedure will stop. The four wheels will then go to Full Speed Forward.
Continue holding the joystick in the forward position until
To return to calibration mode the operator must the wheels stop and there is an audible beep. Forward
start the complete procedure from the calibration is complete.
beginning.
NOTE: If the wheels do not stop going in Full Speed
Forward in 2 minutes or less, there was an
error in the calibration procedure. The
WARNING operator must shut the loader OFF, and start
the calibration procedure from the beginning.
W-2017-0286
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HYDROSTATIC PUMP (CONT'D) Stop the engine, and remove the loader from jackstands.
Hydrostatic Pump Calibration (Cont'd) Start the loader, press the PRESS TO OPERATE
LOADER button and return to normal loader operation.
Figure 30-40-26
Figure 30-40-27
P-26483
1
Move and hold the left joystick to the reverse position
P5552
[Figure 30-40-26] until the reverse calibration is

completed.
Remove the hydrostatic pump / engine assembly from
The pump controller will start increasing the electrical the loader. (See Removal And Installation on Page 70-
current to the hydrostatic pumps until it sees a pulse from 80-1.)
the wheel speed sensors.
Remove the belt shield clips (Item 1) and belt shield (Item
The loader wheels will rotate a short distance in reverse 2) [Figure 30-40-27].
each time it sees a pulse.
Figure 30-40-28
The four wheels will then go to Full Speed Reverse.
Continue holding the joystick in the reverse position until
the wheels stop and there is an audible beep. Reverse
calibration is complete.
NOTE: If the wheels do not stop going in Full Speed 2

Reverse in 2 minutes or less, there was an 1
error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
3
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 38-98 error code will clear. P5554
Allow the joystick to go to the neutral position.

Loosen the stop mounting bolts (Item 1) [Figure 30-40-
The calibration procedure is completed. 28].
Press the PRESS TO OPERATE LOADER button. Move Loosen the spring tension bolt (Item 2) [Figure 30-40-
the joystick to forward position [Figure 30-40-25] and 28].
check for normal forward wheel rotation.
Remove the drive belt (Item 3) [Figure 30-40-28].
Move the joystick to the reverse position [Figure 30-40-
26] and check for normal reverse wheel rotation.
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HYDROSTATIC PUMP (CONT’D) Figure 30-40-31
Figure 30-40-29 2
1
1
P5658
Figure 30-40-32
P5557
Remove the washer and nut (Item 1) [Figure 30-40-29]

from the hydrostatic pump drive shaft.

Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271
N•m) torque 1
Figure 30-40-30
P-28072

31] and nuts (Item 1) [Figure 30-40-32].
Installation: Tighten the mounting bolts and nuts to 65 -

70 ft.-lb. (88 - 95 N•m) torque. Make sure the key (Item 2)
[Figure 30-40-31] is installed.
1
P5657
Install the nut on the end of the pump drive shaft (without
washer).
Use a puller (Item 1) [Figure 30-40-30] to remove the

pulley from the pump drive shaft.
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HYDROSTATIC PUMP (CONT'D)
Figure 30-40-33
P-28073
Remove the mounting bolt (Item 1) [Figure 30-40-33] at

the hydraulic pump end of the pump.

Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
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HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
2 5 1
23
24 25
26
20 21 27
19 28 21
22 29 20
18
17 19
14 30 18 17
13 16 33
4 23 16 33
6 15 31 34

7 29 34
8 32
35 36
9
3
39
37
10
11 38
66 42 43 41 40
68 46
70 65 44 45 48
67 47 49
52
69 51
64 63 64
5
43 63 50 55
15
14 53
72 54
71 73 56
32
75 74
76 31
28
73 27
77 57
26
25 78
23 25 58
60 61 34
24
62 33
59
60
B-16054A
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Parts Identification (Right Half) (Cont'd)
1. Pump 40. Link

2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Gerotor
9. Snap Ring 48 Bearing
10. Bearing 49. Cover
11. Shaft 50. O-ring
13. Bearing 52. Gasket
14. Plug 53. Cover
15. O-ring 54. Screw
17. Valve 56. Gear Pump
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw

22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swash plate
38. Gasket 77. Gasket
39. Screw 78. Cover
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Parts Identification (Left Half)
5
2
1
23
22
25
26
23 27
19
28
18 20 21
29
22
17 19
16 18
14 30 17
13 23 33
16
4
29 34 33
6 15 31 34

7 32
8
56 35 36
9
3
39 38
10
11
38
12 66 41 40
42 43 46
68
70 44 45 48
65 47
49
67
69 51 52
63 64
64
43 63 50
55
15
14
72 53
54
71
73
75 74 32
31
76 28
73 27
57
25 26
77
78 23 25 58
60
61 34
24
62 59
33
60
B-16055A
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Parts Identification (Left Half) (Cont’d)
1. Pump 40. Link

2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Gerotor
9. Snap Ring 48 Bearing
10. Bearing 49. Cover
13. Bearing 52. Gasket
14. Plug 53. Cover
15. O-ring 54. Screw
17. Valve 56. Key
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw

22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swash Plate
38. Gasket 77. Gasket
39. Screw 78. Cover
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System Check Relief Valves (High Pressure Relief,

3
Charge Check & Bypass Valve)
Figure 30-40-34
2
1
1 1
1
P-28615
Check the valve seat plug O-rings (Item 1) and back-up

ring (Item 2) [Figure 30-40-36], and replace as needed.
P-28613
Check the valve seat surface (Item 3) [Figure 30-40-36]
for scratches and replace as needed.
There are four system check relief valves (Item 1)

[Figure 30-40-34] in the hydrostatic pump. Two are Figure 30-40-37
located on the back side of each pump half.
Figure 30-40-35
1 1
P-28616
P-28614 Remove relief valve assembly (Item 1) [Figure 30-40-37]

from the pump housing.
Remove the valve seat plug (Item 1) [Figure 30-40-35] Check the conical spring (Item 2) [Figure 30-40-36] to be
from the pump. sure it is retained on the relief valve. DO NOT REMOVE.
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HYDROSTATIC PUMP (CONT’D) Charge Relief Valve
System Check Relief Valves (High Pressure Relief, Figure 30-40-40

Charge Check & Bypass Valve) (Cont'd)
Figure 30-40-38
1 1
P-28613
P-28617 There are two charge pressure relief valves (Item 1)

[Figure 30-40-40].
Install relief valve into the pump housing spring first The charge pressure relief valves are located on the

[Figure 30-40-38]. bottom side of the pumps, with one valve on each pump
section [Figure 30-40-40].
Figure 30-40-39
Figure 30-40-41
P-28614
P-28625
Install the valve seat plug (Item 1) [Figure 30-40-39] in

the pump, and tighten to 30 - 70 ft.-lb. (40 - 95 N•m) Mark the plug (Item 1) the lock nut (Item 2) and the
torque. housing (Item 3) [Figure 30-40-41] for ease of assembly.
Loosen the lock nut.
Loosen the charge pressure plug, and remove the

complete assembly from the pump housing.
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Charge Relief Valve (Cont'd)
Figure 30-40-42
1
2
P-28627
Install the poppet (Item 1) and spring (Item 2) [Figure 30-

P-28626 40-44] into the pump housing.
Figure 30-40-45
Check and replace the O-ring (Item 1) [Figure 30-40-42].

Figure 30-40-43
1 2
2
3
1
P-28625
P-28627 Install the plug (Item 1) and its lock nut (Item 2) [Figure
30-40-45], align the marks made during disassembly.
Inspect the poppet (Item 1) [Figure 30-40-43] and the
mating seat in the pump housing for damage or foreign
material.
Inspect the spring (Item 2) and the adjustable charge

relief valve (Item 3) [Figure 30-40-43].
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Pump Separation
1
Figure 30-40-46
1 P-28640
2
Replace the O-ring (Item 1) [Figure 30-40-48].

P-28638
Remove the two mount bolts (Item 1) [Figure 30-40-46].

(Front and Rear.)

Remove the lifting bracket (Item 2) [Figure 30-40-46]
from the pump.
Figure 30-40-47
P-28639
Separate the two hydrostatic pumps [Figure 30-40-47].
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Shaft Seal And Shaft Replacement

1
Figure 30-40-49
P-28643

P-28641 top of the bearing.
Figure 30-40-52
Remove the snap ring (Item 1) [Figure 30-40-49].

Figure 30-40-50
1
P-28648
P-28642 Using a press, remove the old seal (Item 1) [Figure 30-
40-52] from the seal carrier.
With the pump shaft up, remove the seal carrier

assembly (Item 1) [Figure 30-40-50] using a screwdriver.
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Shaft Seal And Shaft Replacement (Cont'd)
Figure 30-40-53
P-28646
Remove the snap ring (Item 1) [Figure 30-40-55] from

P-28644 the shaft.
Figure 30-40-56
Press a new seal into the shaft bearing side of the seal
carrier (Item 1) [Figure 30-40-53].

Figure 30-40-54
P-28753
Remove the roller bearing [Figure 30-40-56] from the

P-28645 shaft.
Inspect the bearing for wear and replace as needed.

Grip the splines or threads of the input shaft and remove
the pump shaft and roller bearing assembly (Item 1)
[Figure 30-40-54].
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Shaft Seal And Shaft Installation
Figure 30-40-57
P-28646
Install the bearing and snap ring on the shaft [Figure 30-
P-28752 40-59].
Figure 30-40-60
Inspect the shaft [Figure 30-40-57] for wear and replace
as needed.

Figure 30-40-58
P-28645
Install the shaft and roller bearing in the pump housing

P-28754 [Figure 30-40-60].
Inspect the snap ring [Figure 30-40-58] and replace as

needed.
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Shaft Seal And Shaft Installation (Cont'd)
Figure 30-40-61
P-28648
Lubricate the seal (Item 1) [Figure 30-40-63] with

P-28643 petroleum jelly.
Figure 30-40-64
Install the O-ring (Item 1) [Figure 30-40-61] on top of the
shaft bearing.

Figure 30-40-62 2
1
P-28641
Slide the seal carrier (Item 1) [Figure 30-40-64]

P-28647 assembly over the shaft and into the housing bore. Press
against the O-ring. Hold downward pressure against the
shaft to compress the cylinder block spring while
Wrap the spline and key way with a thin layer of plastic to pressing the seal carrier into place.
prevent damage to the seal lip during installation [Figure
30-40-62]. Install the retaining ring (Item 2) [Figure 30-40-64].
Lubricate the O-ring with petroleum jelly [Figure 30-40-

62].
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Charge Pump Removal
Figure 30-40-65
P-28669
Remove the old charge pump cover gasket (Item 1)

P-28668 [Figure 30-40-67].
Figure 30-40-68
Position the pump so the auxiliary mounting pad is facing
up. 1

Mark pump housing for proper installation [Figure 30-40-
65].
Figure 30-40-66
1
1 P-28670
1 Remove the alignment pins (Item 1) [Figure 30-40-68].
Remove the gerotor cover (Item 2) [Figure 30-40-68].
P-28667
Remove the six auxiliary mount pad mount bolts (Item 1)

[Figure 30-40-66].
Remove the charge pump cover.
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Charge Pump Removal (Cont'd)
Figure 30-40-69
P-28673
Remove the inner gerotor and drive coupler (Item 1)

P-28671 [Figure 30-40-71].
Figure 30-40-72
Remove the old gerotor cover O-rings (Item 1) [Figure
30-40-69].

Figure 30-40-70 1
1 P-28674
Remove the retainer ring from the drive coupler (Item 1)

P-28672 [Figure 30-40-72].
Remove the outer gerotor assembly from the pump

housing (Item 1) [Figure 30-40-70].
Remove the gerotor cover alignment pin from the

housing.
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Charge Pump Removal (Cont'd)

2
Figure 30-40-73
P-28675
1
2 Inspect the inner gerotor assembly (Item 1) [Figure 30-
P-28675 40-75] for scratches and wear, if it must be replaced,
replace both the outer and inner gerotors as a set.
Remove the inner gerotor (Item 1) and key (Item 2) Inspect the drive coupler (Item 2) [Figure 30-40-75] for
[Figure 30-40-73] from the drive couple. wear, and replace as needed.

Charge Pump Inspection Figure 30-40-76
Figure 30-40-74 2
1
P-28675A
P-28757
Inspect the gerotor drive key (Item 1) and retainer ring
(Item 2) [Figure 30-40-76], and replace as needed.
Inspect the outer gerotor assembly [Figure 30-40-74] for
scratches and wear, if it must be replaced, replace both
the outer and inner gerotors as a set.
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Charge Pump Inspection (Cont’d)

2
Figure 30-40-77
P-28673
Be sure the pump surface (Item 1) [Figure 30-40-79] is

P-28758 clean and free of gasket material.
Install the drive coupler / inner gerotor in the pump

Inspect the inside of the gerotor cover (Item 1) [Figure housing (Item 2)] [Figure 30-40-79].
30-40-77] for scratches and foreign material, replace as

needed. Figure 30-40-80
Charge Pump Installation
Figure 30-40-78
2
1
4
2
P-28672
3
1 Install the outer gerotor (Item 1) and gerotor cover
P-28675 alignment pin (Item 2) [Figure 30-40-80].
Install the key (Item 1) in the drive coupler (Item 2)

[Figure 30-40-78].
Install the inner gerotor (Item 3) and the retaining ring

(Item 4) [Figure 30-40-78] on the drive coupler.
Lubricate the gerotor assembly with clean oil.
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Charge Pump Installation (Cont'd) 1
Figure 30-40-81
1
1
P-28670
Install the charge pump cover locating pins (Item 1)

P-28671 [Figure 30-40-83].
Figure 30-40-84
Install the new O-rings (Item 1) [Figure 30-40-81] on the
gerotor cover.

Figure 30-40-82
1
2
P-28669
Install a new charge pump cover gasket (Item 1) [Figure

P-28676 30-40-84]
.
Install the gerotor cover over the gerotor assembly (Item
1) and align the pin in the cover (Item 2) [Figure 30-40-
82].
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Charge Pump Installation (Cont'd)
Figure 30-40-85
1
1
1 P-28678
Press down on the swash plate with the handle of a clean

P-28667 rubber mallet (Item 1) [Figure 30-40-87] and remove the
side cover.
Align the charge pump cover on the alignment pins. Figure 30-40-88
Install the six cover bolts (Item 1) [Figure 30-40-85] and

tighten to 26 - 32 ft.-lb. (36 - 43 N•m) torque.
1
Disassembly
Figure 30-40-86
P-28679
1
Remove the gasket (Item 1) [Figure 30-40-88] from side

cover.
P-28677
Separate the two hydrostatic pumps. (See Pump

Separation on Page 30-40-18.)
Remove the charge pump. (See Charge Pump Removal

on Page 30-40-23.)
Remove the shaft and shaft seal. (See Shaft Seal And
Shaft Replacement on Page 30-40-19.)
Remove the six side cover bolts (Item 1) [Figure 30-40-

86].
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Figure 30-40-89
1
2 P-28683
Remove the swash plate needle bearing assembly (Item

P-28680 1) [Figure 30-40-91]. It may be necessary to rotate the
servo piston, so the bearing can be removed.
Lift the swash plate (Item 1) and remove cylinder block Figure 30-40-92
(Item 2) [Figure 30-40-89].

Figure 30-40-90
1
1
P-28684
P-28682 Remove the valve plate timing pin (Item 1) [Figure 30-
40-92].
Remove the swash plate (Item 1) [Figure 30-40-90].
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Figure 30-40-93
P-28687
Remove the control spool plug (Item 1) [Figure 30-40-

P-28685 95].
Figure 30-40-96
Remove the valve plate (Item 1) [Figure 30-40-93].

Figure 30-40-94
1 1
P-26469
P-28686 Do Not remove the spring (Item 1) [Figure 30-40-96], as

it is attached to the control spool.
Remove the seven mounting bolts from the electrical Remove the electrical displacement control from the
displacement control (Item 1) [Figure 30-40-94]. pump.
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Figure 30-40-97
P-28698
Remove control spool and spring (Item 1) [Figure 30-40-

P-28688 99].
Figure 30-40-100
Move the control spool and summing link (Item 1)
[Figure 30-40-97] until the summing link disconnects

from the control spool.
Figure 30-40-98
P-28691
1
Remove the linkage pivot bolt (Item 1) [Figure 30-40-
100].
P-28689
Remove the summing link (Item 1) [Figure 30-40-98].
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Figure 30-40-101 1
1 2
2
1
P-28700
Remove the five servo cover mount bolts (Item 1)

P-28692 [Figure 30-40-103] from the servo cover that does NOT
have the servo piston neutral adjustment tie bolt.
Slide the control feedback link (Item 1) toward the servo Remove the cover (Item 2) [Figure 30-40-103] and
piston and disengage it from the neutral adjustment link gasket.

(Item 2) [Figure 30-40-101].
Figure 30-40-104
Remove the control feedback link.
Figure 30-40-102
1
1
P-28701
P-28694 Remove the servo piston adjustment seal nut (Item 1)

[Figure 30-40-104] and discard.
Remove the neutral adjustment link (Item 1) [Figure 30- NOTE: Once a servo adjustment seal nut has been
40-102] from the pump housing. removed, it should be discarded and replaced
with new, to insure a proper seal.
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1
Figure 30-40-105
1
1
P-28705
Remove the servo cover (Item 1) [Figure 30-40-107]

P-28703 from the servo piston.
Figure 30-40-108
Remove the five servo piston cover mount bolts (Item 1)
[Figure 30-40-105].
1

Figure 30-40-106
P-28706
Remove the piston seals (Item 1) [Figure 30-40-108]

P-28704 and O-rings located under the seals, from the servo
piston.
Remove the servo cover and servo piston (Item 1)

[Figure 30-40-106] from the pump.
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Figure 30-40-109
1
1
1
P-28744
Remove the three holddown pins (Item 1) and retainer

P-28681 ring (Item 2) [Figure 30-40-111].
Inspection: Rotating Group

Remove the piston assemblies and slipper retainer (Item
1) [Figure 30-40-109] from the cylinder block.
Figure 30-40-110
P-28743
Remove the ball guide (Item 1) [Figure 30-40-110].
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Inspection
2
Figure 30-40-112
P-28747
Check the piston slippers (Item 1) [Figure 30-40-114] for

P-28745 any excess wear or damage.
Check the pistons (Item 2) [Figure 30-40-114] for any

Inspect the cylinder block surface, that runs against the discoloration, due to excessive heat.
valve plate (Item 1) [Figure 30-40-112] for nicks or burrs.

Figure 30-40-115
Figure 30-40-113
1
1
1
P-28750
P-28746
Check the pump housing and housing piston bore (Item

Check the cylinder bores (Item 1) [Figure 30-40-113] for 1) [Figure 30-40-115] for piston seal fragments,
grooves or scratches. scratches or damage.
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Inspection (Cont'd)
Figure 30-40-116
P-28755
Check the swash plate surface (Item 1) [Figure 30-40-

P-28706 118] for scratches or damage.
Check the swash plate bearing surface (Item 2) [Figure

Check the surface of the servo piston (Item 1) [Figure 30-40-118] for wear.
30-40-116] for scratches or damage.

Figure 30-40-119
Figure 30-40-117
P-28756
P-28751
Check the swash plate needle bearing (Item 1) [Figure

Check the valve plate for wear. Run a finger nail over the 30-40-119] and replace as needed, as this bearing is a
diameter of the sealing land surface (Item 1) [Figure 30- serviceable part.
40-117]. It should be free of deep groves.
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Inspection (Cont'd)
Figure 30-40-120 1
P-28699
Check the control spool and spring (Item 1) [Figure 30-

P-28767 40-122] for wear and replace as needed.
Figure 30-40-123
Check the pump housing swash plate needle bearing
(Item 1) [Figure 30-40-120] for wear. If this bearing

needs to be changed, the complete pump housing must
be replaced, as the bearing is a non-serviceable part. 1
Figure 30-40-121
P-28690
Check the summing link (Item 1) [Figure 30-40-123] for

wear and replace as needed.
P-28679
Check the pump side cover swash plate needle bearing

(Item 1) [Figure 30-40-121] for wear. If this bearing
needs to be changed, the complete pump side cover
must be replaced, as the bearing is a non-serviceable
part.
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Inspection (Cont'd)
Figure 30-40-124
1
1
P-28695
Check the neutral adjustment link (Item 1) [Figure 30-40-

126] for wear and replace as needed.
Figure 30-40-127
Check the linkage pivot bolt (Item 1) [Figure 30-40-124]
for wear and replace as needed.

Figure 30-40-125
P-28697
1
Check the complete linkage assembly for wear [Figure

30-40-127].
P-28693
Check the control feedback link (Item 1) [Figure 30-40-

125] for wear and replace as needed.
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Assembly
Figure 30-40-128
P-28787
Install a new O-ring (Item 1) [Figure 30-40-129] and new

P-28789 piston ring (Item 2) [Figure 30-40-129] on the tie bolt end
of the servo piston (Item 1) [Figure 30-40-130].
Position the pump housing so the charge pump face is Lubricate the piston ring with a liberal amount of
pointing downward [Figure 30-40-128]. hydraulic oil.

Figure 30-40-129 Figure 30-40-131
2
1
P-28788 P-28786
Install the servo piston in the corresponding housing bore

in the pump housing [Figure 30-40-131].
Install the non-tie bolt end of the servo piston into the
housing first [Figure 30-40-131].
Be sure the cavity for the servo piston / swash plate

needle bearing (Item 1) [Figure 30-40-131] faces the
center of the housing.
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HYDROSTATIC PUMP (CONT’D) Install a new servo cover gasket (Item 1) [Figure 30-40-
133].
Assembly (Cont'd)
Figure 30-40-134
Figure 30-40-132
P-28783
P-28785
Spin the servo cover down as far as possible and slide

Push the servo piston through the housing far enough the piston back in the housing so the servo cover is
that the other O-ring and piston seal may be installed holding the gasket against the housing [Figure 30-40-

(Item 1) [Figure 30-40-132]. 134].
NOTE: Do not let the tie bolt end of the piston ring Install the five servo cover mount bolts and finger tighten.
pass completely through its bore. This will
cause damage to the new piston rings earlier Figure 30-40-135
installed.
Install the new O-ring and piston ring. 1 1

Lubricate the piston ring with a liberal amount of
hydraulic oil.
Figure 30-40-133 1
1
1 1
P-28782
Install the second servo cover gasket and cover. Install

the five mount bolts (Item 1) [Figure 30-40-135] and
tighten to 11 - 13 ft.-lb. 15 - 17,5 N•m) torque.
P-28784
Push the servo piston back through the bore so the tie
bolt sticks back out of the housing and the piston is
almost flush with the housing [Figure 30-40-133].
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Assembly (Cont'd)
Figure 30-40-136
1 1
1 1 P-28780
Install the control spool and spring (Item 1) [Figure 30-

P-28701 40-138] into the pump housing.
Figure 30-40-139
Tighten the tie bolt end, mount bolts (Item 1) [Figure 30-
40-136] to 11 - 13 ft.-lb. 15 - 17,5 N•m) torque.

Install a new adjustment seal nut (Item 2) [Figure 30-40-
136] and tighten until the sealing face touches the servo
cover.
1
NOTE: The pump neutral adjustment must be made
to the pump after it is installed in the loader.
(See Pump Neutral Adjustment on Page 30-40-
48.)
2
Figure 30-40-137
P-28763
Install the center pin on the control feedback link (Item 1)

into the bore in the neutral adjustment link (Item 2)
[Figure 30-40-139].
P-28781
Rotate the pump housing so that the control face is

accessible [Figure 30-40-137].
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Assembly (Cont'd)
Figure 30-40-140
1
2
1
3
P-28776
The neutral adjustment link (Item 1) should mate and

P-28778 engage the neutral adjustment screw (Item 2), and both
links should align with the pivot screw hole (Item 3)
[Figure 30-40-142].
Figure 30-40-141
Figure 30-40-143

1
2
P-28777
P-28775
Install the end of the feedback link containing the hole

(Item 1) [Figure 30-40-140] into the servo piston slot Install the linkage pivot screw (Item 1) [Figure 30-40-
(Item 2) [Figure 30-40-141]. 143] and tighten to 6 - 11 ft.-lb. (8 - 15 N•m) torque.
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Assembly (Cont'd)
Figure 30-40-144
P-28772
Shift the control spool to the center of the housing until

P-28774 the summing link pin (Item 1) [Figure 30-40-146] is
located in the center.
Install the summing link (Item 1) [Figure 30-40-144] on to Figure 30-40-147

the feedback link pin.

Figure 30-40-145
P-28771
P-28773 Install a new gasket (Item 1) [Figure 30-40-147] on the

pump housing controller face.
Move the control spool (Item 1) until the summing link

(Item 2) [Figure 30-40-145] lines up with the flat spot on
the control spool.
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Assembly (Cont'd)
Figure 30-40-148 1
P-28687
Install the control spool bore plug (Item 1) [Figure 30-40-

P-28769 150] and tighten to 30 - 70 ft.-lb. (41 - 94 N•m) torque.
Figure 30-40-151
Install the control module on the pump housing.

NOTE: The pin on the summing link (Item 1) must
engage the bore (Item 2) [Figure 30-40-148] on
the control module for proper control
operation.
Figure 30-40-149
P-28768
1
Install the valve plate timing pin (Item 1) [Figure 30-40-
151] and allow it to stick out roughly 1/16 in., (1,588 mm)
beyond the interface of the pump housing side cover.
P-28770
Install the seven controller mount bolts (Item 1) [Figure

30-40-149] and tighten to 11 - 13 ft.-lb. (15 - 17,5 N•m)
torque.
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Assembly (Cont'd)
Figure 30-40-152
2 P-28766
Install the swash plate needle bearing (Item 1) [Figure

P-28684 30-40-154] on the swash plate, so the letters on the
bearing face the swash plate.
Install the pump valve plate (Item 1) and engage the Figure 30-40-155
valve plate timing pin (Item 2) [Figure 30-40-152].

Lubricate the top surface of the valve plate with a coating
of hydraulic fluid.
1
Figure 30-40-153
P-28765
Install the swash plate and needle bearing into the servo
piston cavity (Item 1) [Figure 30-40-155].
P-28767
Be sure the servo piston cavity (Item 1) [Figure 30-40-

153] is facing the center of the pump.
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Assembly (Cont'd)
Figure 30-40-156
P-28743
Install the ball guide (Item 1) [Figure 30-40-158] on the

P-28748 hold down pins.
Figure 30-40-159
Lightly coat all parts with hydraulic oil, before installing
the cylinder block.

Place the retainer ring (Item 1) [Figure 30-40-156] in the
cylinder block, so that it sits approximately 1/8 in. (3,175
mm) below the surface.
Figure 30-40-157
P-28681
1 Install the slipper retainer, containing the slippers and

pistons [Figure 30-40-159].
Apply a liberal amount of hydraulic oil to the top and

bottom of the slippers and cylinder block.
P-28749
Install the three hold down pins (Item 1) [Figure 30-40-

157], making sure they are setting squarely in the
grooves.
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Assembly (Cont'd)
Figure 30-40-160
P-28764
Install a new gasket (Item 1) [Figure 30-40-162] on the

P-28682 side cover.
Figure 30-40-163
Figure 30-40-161

1
1
P-28779
P-28680
Press down on the swash plate, with a clean rubber

Lift the end of the swash plate (Item 1) [Figure 30-40- mallet.
160] and insert the cylinder block assembly (Item 1)
[Figure 30-40-161]. Install the side cover / swash plate bearing assembly
(Item 1) [Figure 30-40-163] into the pump housing.
Visually center the cylinder block assembly over the
valve plate [Figure 30-40-161].
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Assembly (Cont'd)
Figure 30-40-164
1
P-28791
The pump neutral adjustment sets the position of the

P-28677 servo piston and pump swash plate relative to the
controlling mechanism.
Align the holes and the gasket, and install the six Place the loader on jackstands. (See Procedure on Page
mounting bolts (Item 1) [Figure 30-40-164] and tighten to 10-10-1.)

11 - 13 ft.-lb. (15 - 17,5 N•m) torque.
Raise the lift arms, and install an approved lift arm
Install the shaft assembly into the pump housing. (See support device. (See Installing The Lift Arm Support
Shaft Seal And Shaft Installation on Page 30-40-21.) Device on Page 10-20-1.)
Install the charge pump. (See Charge Pump Removal on Raise the operator cab. (See Raising The Operator Cab
Page 30-40-23.) on Page 10-30-1.)
Pump Neutral Adjustment Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
Figure 30-40-165
Connect a hydraulic hose between port M4 (Item 1)
[Figure 30-40-165] on the back side of the hydrostatic
pump, and port M5 (Item 1) [Figure 30-40-166] on the
front side of the hydrostatic pump, to equalize the
1
pressures on both ends of the servo piston.
P-28790
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Pump Neutral Adjustment (Cont’d)
Figure 30-40-167
P-28790
1
Loosen the pump neutral adjustment lock nut (Item 1)
P-28791 [Figure 30-40-169].
Start the loader using the remote start tool and run at an
Remove the plug (Item 1) [Figure 30-40-167] from the idle.
M1 port on the front side of the pump, and install a 7500

PSI pressure gauge. Figure 30-40-170
Figure 30-40-168
P-28790
1
P-28791
Turn the adjustment screw (Item 1) [Figure 30-40-170]
clockwise, until one of the gauges registers an increase
Remove the plug (Item 1) [Figure 30-40-168] from the in system pressure. Mark the position of the adjustment
M2 port on the front side of the pump, and install a 7500 screw.
PSI pressure gauge.
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Pump Neutral Adjustment (Cont’d)
Figure 30-40-171
P-28790
1
While holding the adjustment screw (Item 1) in position,
P-28790 tighten the seal lock nut (Item 2) [Figure 30-40-173] to
21 - 37 ft.-lb. (28 - 51 N•m) torque.
Turn the adjustment screw (Item 1) [Figure 30-40-171] Shut loader OFF.
counterclockwise, until the other gauge registers an

increase in system pressure. Mark the position of the Remove the hydraulic hose from the M4 and M5 ports on
adjustment screw. the pump. Install the plugs and tighten.
Figure 30-40-172 Remove the pressure gauges from the M1 and M2 ports
on the pump. Install the plugs and tighten.
NOTE: This pump is equipped with an EDC

Controller. The Controller Neutral Adjustment
procedure must be performed, before running
the loader. (See Pump Controller Neutral
Adjustment on Page 30-40-51.)
P-28790

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
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Pump Controller Neutral Adjustment
Figure 30-40-174
P-28790
Remove the M4 plug (Item 1) [Figure 30-40-175] and

P-26464 install a 500 PSI pressure gauge.
Figure 30-40-176
The pump controller neutral adjustment, aligns the pump
swash plate and the control spool so that a zero angle

control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump neutral setting is
adjusted.

10-10-1.) 1
Raise the lift arms, and install an approved lift arm

P-28791
on Page 10-30-1.)
Remove the M5 plug (Item 1) [Figure 30-40-176] and
Connect the remote start tool. (See REMOTE START on install a 500 PSI pressure gauge.
Page 10-60-1.)
Disconnect the pump controllers (Item 1) [Figure 30-40-
174] from the loader wiring harness.
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Pump Controller Neutral Adjustment (Cont’d)
Figure 30-40-177
P-28791

P-28791 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the control spool neutral adjustment seal lock nut
(Item 1) [Figure 30-40-177]. Figure 30-40-180

Start the loader using the remote start tool and run at an
idle.
Figure 30-40-178
P-28791

clockwise, to a position halfway between the recorded
P-28791 positions. The pressure gauges should read equal
pressures.

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
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Pump Controller Neutral Adjustment (Cont'd)
Figure 30-40-181
P-28791
While holding the adjustment screw (Item 1) in position,

tighten the seal lock nut (Item 2) [Figure 30-40-181] to

10 - 18 ft.-lb. (14 - 24 N•m) torque.
Shut loader OFF.
Remove the pressure gauges from the M4 and M5 ports

on the pump. Install the plugs and tighten.
Connect the pump controller wire connector to the loader

wiring harness.
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DRIVE BELT Adjustment
Shield Removal And Installation Figure 30-50-3
Figure 30-50-1
2
1 P-05554
P-26581
1
2
Stop the engine.

Open the rear door.
Remove the three belt shield holddown clips (Item 1)

[Figure 30-50-1].
Figure 30-50-2
P- 4681
The drive belt idler arm stop is located on the left side of
the engine below the air cleaner [Figure 30-50-3].
Loosen the two bolts (Item 1) [Figure 30-50-3] and slide

the stop against the idler arm. Tighten the bolts.
There is no adjustment for the spring, just make sure the

spring bolt (Item 2) [Figure 30-50-3] is tight.
Replacement
P-26582 Remove the belt shield.
Loosen the two stop mounting bolts (Item 1) [Figure 30-

Remove the belt shield from the drive belt housing
50-3].
[Figure 30-50-2].
Loosen the spring tension bolt (Item 2) [Figure 30-50-3].
Remove the fan drive belt from the tensioner pulley.
Remove the drive belt from the hydrostatic pump pulley

and flywheel pulley.
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DRIVE BELT (CONT’D) Figure 30-50-6
Replacement (Cont’d)
2
Figure 30-50-4
P5554
Remove the two stop mounting bolts (Item 1) [Figure 30-

P7894 50-6].
Remove the stop.

Remove the drive belt [Figure 30-50-4].
Remove the spring tension bolt (Item 2) [Figure 30-50-

Tensioner Pulley Removal And Installation 6].
1
1
P5552 P5548
Remove the belt shield clips (Item 1) [Figure 30-50-5]. Remove the end cap (Item 1) [Figure 30-50-7] from the
tensioner pulley arm.
Remove the belt shield (Item 2) [Figure 30-50-5].
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Tensioner Pulley Removal And Installation (Cont'd)
Figure 30-50-8
P5553
Check the arm seal (Item 1) [Figure 30-50-10]. Replace

P5555 the seal as needed.
Figure 30-50-11
Remove the mounting bolt (Item 1) [Figure 30-50-8] from
the tensioner pulley arm.

Figure 30-50-9
2
P5561
Remove the pulley mounting bolt [Figure 30-50-11].

P5560
Remove the pulley / arm assembly (Item 1) [Figure 30-

50-9] from the engine housing.
Remove the arm bushing (Item 2) [Figure 30-50-9].

Check for wear and replace as needed.
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Tensioner Pulley Removal And Installation (Cont'd)
Figure 30-50-12
1
P5563
Remove the end block (Item 1) [Figure 30-50-14] (both

P5559 ends) from the spring.
Check the spring for wear and etc. Replace the spring as
Disassemble the pulley and bearing as shown in [Figure needed.
30-50-12].

Check the spring end blocks for wear and replace as
Check the parts for wear and replace as needed. needed.
Tensioner Pulley Tension Spring
Figure 30-50-13
P5551
Remove the base end bolt (Item 1) [Figure 30-50-13]

from the spring block.
Remove the tension spring from the engine housing.
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OIL COOLER (SEAL TO CONNECT) (STC) Figure 30-60-3
Hydraulic Oil Cooler Removal And Installation
Figure 30-60-1
1
N-19545A
Install tool MEL1613 (Item 1) [Figure 30-60-2] & [Figure

P-31259 30-60-3] to the outside of the rubber sleeve.
Figure 30-60-4
Open the rear door of the loader.

Raise and remove the rear grill [Figure 30-60-1].
IMPORTANT
damage the system.
I-2003-0888
P-26760
Figure 30-60-2
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 30-60-4].
Repeat the procedure for the other hose and fitting on the
oil cooler.
NOTE: When installing the cooler hoses, the fittings

1 should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.

P-26761
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-10-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Front Chaincase Cover Removal And Installation . . . . . . . 40-40-1
Rear Chaincase Cover Removal And Installation . . . . . . . 40-40-1
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-30-1
Axle, Sprocket And Bearings Removal And Installation. . . 40-30-2 DRIVE
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-30-7 SYSTEM
HUB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-7
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

STEERING BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
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BRAKE Figure 40-10-3
Block Removal And Installation
Figure 40-10-1
1
1
1
1 1
1 2
P-34382

P-34378 40-10-3] from the brake solenoid.

Lift and block the loader. (See Procedure on Page 10-10- 40-10-3] from the two speed solenoid.
1.)

Figure 40-10-4
on Page 10-30-1.)
Mark all hydraulic hoses for proper installation.

1
Disconnect the six hydraulic hoses (Item 1) [Figure 40-
10-1] from the brake / two speed block.
Figure 40-10-2
1 P-34383
1
40-10-4] from the make-up valve solenoid.
P-34381
Disconnect the two hydraulic hoses (Item 1) [Figure 40-

10-2] from the brake / two speed block.
Cap and plug the hoses and the fittings.
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BRAKE (CONT’D) Block Disassembly And Assembly
Block Removal And Installation (Cont'd) Figure 40-10-7
Figure 40-10-5
1
1 1
1
1
P-34097
P-34384
Mark all hydraulic hoses and fittings for proper
installation.
5] from the brake / two-speed block. Remove the hydraulic fittings (Item 1) [Figure 40-10-7]

from the block.
Remove the brake / two-speed block from the loader.
Figure 40-10-8
Figure 40-10-6
1
2
2
P-34098
P-26340
Remove the check valve (Item 1) [Figure 40-10-8] from

Remove the AWS block mount bolts and nuts (Item 1) the two-speed valve.
[Figure 40-10-6].
Remove the check valve (Item 2) [Figure 40-10-8] from
Remove the brake / two-speed mount plate (Item 2) the brake valve.
[Figure 40-10-6] from the AWS block.
NOTE: The check valves (Items 1 & 2) [Figure 40-10-
8] are interchangeable.
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BRAKE (CONT’D) Figure 40-10-11
Block Disassembly And Assembly (Cont'd)
Figure 40-10-9
1
2
P-34112
Use a test meter and test the make-up valve solenoid

N-22580 (Item 1) [Figure 40-10-11] for resistance.
The resistance value for the solenoid coil can be found

Check the back-up washers (Item 1) [Figure 40-10-9] on the electrical schematic. (See Solenoid Test on Page
and O-rings (Item 2) [Figure 40-10-9] for wear and 60-10-5.)

replace as needed.
Figure 40-10-12
Figure 40-10-10
1 2 1
P-34111
P-34099
Use a test meter and test the brake solenoid (Item 1)

Remove the electrical solenoid nut (Item 1) [Figure 40- [Figure 40-10-12] from the block.
10-10] from the make-up valve solenoid.
Remove the electrical solenoid nut (Item 2) [Figure 40- on the electrical schematic. (See Solenoid Test on Page
10-10] from the brake solenoid. 60-10-5.)
Assembly: Tighten the solenoid nuts to 60 - 84 in.-lb.

(6,78 - 9,49 N•m) torque.
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Figure 40-10-13
P-34105
1
2
Check the O-rings [Figure 40-10-15] on the brake valve
P-34101 stem and replace as needed.
Tighten the solenoid valve to 20 ft.-lb. (27,1 N•m) torque.

Remove the make-up valve solenoid stem (Item 1)
[Figure 40-10-13] from the block Figure 40-10-16

Remove the brake solenoid stem (Item 2) [Figure 40-10-
13] from the block
Figure 40-10-14
P-34102
Remove the four plugs (Item 1) [Figure 40-10-16] from

the brake / two speed block.
N-22584
Assembly: Always install new O-rings and back-up

washers [Figure 40-10-14] on the make-up valve
solenoid. Tighten the solenoid valve to 20 ft.-lb. (27,1
N•m) torque.
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1
Figure 40-10-17
N-22610
1 Use a test meter and test the solenoid (Item 1) [Figure

P-34103 40-10-19] for resistance.

Check the O-rings (Item 1) [Figure 40-10-17] on the on the electrical schematic. (See Solenoid Test on Page
plugs and replace as needed. 60-10-5.)

Figure 40-10-18 Replace the O-rings (Item 2) [Figure 40-10-19].
Figure 40-10-20
1
P-34104
P-34589
Remove the two speed solenoid nut (Item 1) [Figure 40-
10-18].
Remove the solenoid valve (Item 1) [Figure 40-10-20]
Assembly: Tighten the nut to 60 - 84 in.-lb. (6,78 - 9,49 from the block.
N•m) torque.
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BRAKE (CONT’D)
Figure 40-10-21
N-22611
Check the O-rings [Figure 40-10-21] and replace as

needed.

Assembly: Tighten the solenoid valve to 20 ft.-lb. (27,1
N•m) torque.
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STEERING BLOCK
Wiring Diagram

P-26449
2
9 1
4
8 5
P-26439
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STEERING BLOCK (CONT’D)
Wiring Diagram (Cont’d)
SOLENOID NO. COLORED

FUNCTION CONNECTOR WIRING HARNESS NO.
TIE
1 Front Left Rod C443 Blue 4040 & 2890
2 Front Left Base C449 Red 4030 & 2940
3 Front Right Rod C461 White 4020 & 2950
4 Front Right Base C440 Purple 4010 & 2960
5 Left Rear Rod C447 Black 4170 & 2850
6 Left Rear Base C446 Pink 4160 & 2840
7 Right Rear Rod C445 Yellow 4070 & 2830
8 Right Rear Base C444 Green 4050 & 2820
9 Pressure Control Solenoid C448 Orange 4060 & 2870
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STEERING BLOCK (CONT’D) Disconnect the four hydraulic hoses (Item 1) [Figure 40-
20-2] from the steering block.
Removal And Installation Cap and plug the hydraulic hoses and fittings.
Figure 40-20-3
Figure 40-20-1
1
1
P-26343
P-26341
Mark all wire connector for proper installation.

Raise the lift arms and install an approved lift arm Disconnect the nine solenoid wire connectors (Item 1)
support device. [Figure 40-20-3].
Figure 40-20-4
on Page 10-30-1.)
Remove the brake / two speed block. (See Block 1

Removal And Installation on Page 40-10-1.)
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 1) [Figure 40-

20-1] from the steering block.
Cap and plug the hydraulic hoses and fittings.
Figure 40-20-2
P-26344

Remove the two hydraulic hoses (Item 1) [Figure 40-20-
4] that come from the pump.
1 1 Cap and plug the hydraulic hoses and fittings.
P-26342
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STEERING BLOCK (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 40-20-7
Figure 40-20-5
1
1
P-26439
P-26345
Mark all solenoids for proper installation.
Remove the two mount bolts and nuts (Item 1) [Figure Remove the solenoid nut (Item 1)[Figure 40-20-7].
40-20-5].

Installation: Tighten to 5 ft.-lb. (6,8 N•m) torque.
Remove the brake / two-speed mount plate.
Figure 40-20-8
Figure 40-20-6
P-26440
P-26346

Remove the steering block (Item 1) [Figure 40-20-6] solenoid nut.
from the loader.
Check the O-ring and replace as needed.
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STEERING BLOCK (CONT’D) Figure 40-20-11
Figure 40-20-9 2
P-26443
Remove the O-ring (Item 1) from the washer (Item 2)

P-26441 [Figure 40-20-11].

Remove the rod end solenoid (Item 1) [Figure 40-20-9]
from the right front wheel solenoid stem. Figure 40-20-12

Figure 40-20-10
1
P-26444
P-26442
Remove the base end solenoid (Item 1) [Figure 40-20-
12] from the right front wheel.
Remove the washer and O-ring (Item 1) [Figure 40-20-
10] from base end solenoid.
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1
Figure 40-20-13
1
P-26303
Check the five O-rings (Item 1) and six back-up washers

P-26445 (Item 2) [Figure 40-20-15] on the solenoid stem.
Replace the O-ring and back-up washers and as needed.

solenoid stem. Figure 40-20-16

1
Figure 40-20-14
3
2
1
P-26439
NOTE: The disassembly and assembly of the left

P-26446 front (Item 1), left rear (Item 2) and right rear
(Item 3) [Figure 40-20-16] solenoids can be
done by following the procedure for the right
Remove the solenoid stem (Item 1) [Figure 40-20-14]. front solenoid, starting on Page 40-20-5.
Installation: Tighten the solenoid stem to 12 ft.-lb. (16,3

N•m) torque.
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1
Figure 40-20-17
P-26451
Remove the solenoid (Item 1) [Figure 40-20-19] from the

P-26439 proportional pressure control valve.
Figure 40-20-20
Remove the nut (Item 1) [Figure 40-20-17] from make-
up valve solenoid.

Installation: Tighten to 7 ft.-lb. (9,5 N•m) torque.
Figure 40-20-18 1
P-26452

1 solenoid stem.
P-26450 Check the O-ring and replace as needed.
Remove the solenoid stem.

solenoid nut. Installation: Tighten the solenoid stem to 12 ft.-lb. (16,3
N•m) torque.
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Figure 40-20-21
1
2
1
P-26455
Do Not Adjust the screw (Item 1) [Figure 40-20-23].

P-26453 (This is preset from the factory.)
Figure 40-20-24
Check the two O-rings (Item 1) and back-up ring (Item 2)
[Figure 40-20-21].

Replace the O-rings and back-up ring as needed.
Figure 40-20-22
P-26456
1
P-26454
Check the screen (Item 1) [Figure 40-20-22] at the base

of the solenoid stem, and clean as needed.
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2
Figure 40-20-25
1
1 P-26458

P-26457 [Figure 40-20-27].

on the plug. Figure 40-20-28

Figure 40-20-26
P-26446
P-26446
Remove the upper left relief valve (Item 1) [Figure 40-20-
28].
Remove the upper right relief valve (Item 1) [Figure 40-
20-26].
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Figure 40-20-29 2
P-26458
1
P-26458 [Figure 40-20-31].

[Figure 40-20-29]. Figure 40-20-32

Figure 40-20-30
P-26460
Remove the left side relief valve (Item 1) [Figure 40-20-

P-26459 32].
Remove the right side relief valve (Item 1) [Figure 40-20-

30].
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STEERING BLOCK (CONT’D)
Figure 40-20-33
P-26458

[Figure 40-20-33].

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DRIVE COMPONENTS Figure 40-30-3
Axle Seal Removal And Installation
Figure 40-30-1
2
1
P-24945
Before installing the axle seal, pack the seal spring

P-24946 groove (Item 1) [Figure 40-30-3] with a high quality
lithium base grease.
Lift and block the loader. (See Procedure on Page 10-10- Also apply a light coat of grease to the seal surface (Item
1.) 2) [Figure 40-30-3] that contacts the hub yoke surface.

Remove the tire / wheel assembly. Figure 40-30-4
Installation: Tighten the wheel nuts to 105 - 115 ft.-lb.

(142 - 155 N•m) torque.
Remove the hub assembly. (See Removal on Page 40-

50-1.)

loader axle.
Figure 40-30-2
P-24947
1 Install the axle seal on the seal driver, MEL1604 [Figure

40-30-4].
P-24944
The axle seal must be installed with the metal side (Item
1) [Figure 40-30-2] facing the loader hub.
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DRIVE COMPONENTS (CONT’D) NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings
Axle Seal Removal And Installation (Cont'd) is for a front axle. This procedure will be the
same for the rear axle, after removal of some
Figure 40-30-5 hydraulic components.
DANGER
1
P-90328
P-24946
AVOID DEATH
Install the new seal in the loader axle (Item 1) [Figure 40- can cause lift arms to drop.
30-5]. • Keep out of this area when lift arms are raised

Install the loader hub on the axle, being careful not to support. Replace if damaged.
damage the axle seal. D-1009-0409
Axle, Sprocket And Bearings Removal And

Installation
Figure 40-30-6 WARNING

W-2059-0598
1
Page 10-20-1.)
1.)
P-26425 Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
The tools listed will be needed to do the following Remove the loader control panel. (See Removal And
procedure: Installation on Page 50-100-1.)
MEL1420 - Bearing Driver Remove the wheel tire assembly.

MEL1607 - Snap Ring Installer Remove the hub assembly. (See Removal on Page 40-
50-1.)
Remove the eight bolts (Item 1) [Figure 40-30-6] from
the front transmission cover
Remove the front transmission cover.
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DRIVE COMPONENTS (CONT’D) Figure 40-30-9

Installation (Cont'd)
Figure 40-30-7
P-34485
Loosen the axle bolt (Item 1) [Figure 40-30-9] and

washer.
P-34485
Figure 40-30-10
Remove the oil from the transmission (Item 1) [Figure

40-30-7] and washer.
Figure 40-30-8
P-34486
Install a spacer (Item 1) [Figure 40-30-10] between the

1
axle bolts, use a wrench and loosen the axle bolt pushing
P-26427 the axle from the bearing.
Remove the axle seal (Item 1) [Figure 40-30-8].
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1
Figure 40-30-11
1
P-26431
Remove the fiber spacer (Item 1) [Figure 40-30-13] and

replace as needed.
P-34487
Figure 40-30-14
Install a 3/4 in. x 16 (fine thread) (24 mm) adapter (Item

1) [Figure 40-30-11] into the outer end of the axle. Install
a slide hammer to the adapter and finish pulling the axle. 1
Figure 40-30-12
2
1
P-26432
Remove the snap ring (Item 1) [Figure 40-30-14].
P-26430
Remove the axle (Item 1) and spacer (Item 2) [Figure

40-30-12] from the axle tube.
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Figure 40-30-15
P-26436
Use MEL1420 Bearing Driver Tool and a threaded rod

[Figure 40-30-17].
P-26433
Figure 40-30-18
With a 3-13/16 bearing driver, come through the outer

end of the axle tube, drive the bearing out of the axle
tube [Figure 40-30-15].
Figure 40-30-16
P-26434
Install bearing driver and threaded rod in the

transmission end of the axle tube [Figure 40-30-18].
P-26433
Install the bearing in the axle. Be sure the bearing is

square in the axle tube (Item 1) [Figure 40-30-16].
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Figure 40-30-19
P-26437
Install axle and plastic axle bushing (Item 1) [Figure 40-

30-21] into axle tube.
P-26435
Figure 40-30-22
Install a plate (Item 1) and nut on the threaded rod at the

axle end [Figure 40-30-19].
Tighten the nuts and draw the bearing into the axle tube.
Figure 40-30-20
P-26438
Align the axle, sprocket and chain [Figure 40-30-22].

Using a pry bar hold the sprocket and chain in position.
Align the axle splines into the sprocket spline, and lightly
P-26432 drive the axle into place.
Install the snap ring (Item 1) [Figure 40-30-20].
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Axle, Sprocket And Bearings Removal And REAR CHAIN

Figure 40-30-23
FRONT CHAIN
P7866
Raise the loader lift arms and install an approved lift arm
1
P-26426 Device on Page 10-20-1.)

Install the axle washer and bolt [Figure 40-30-23]. 1.)

Installation: Tighten the bolts to 475 - 525 ft.-lb. (644 - Raise the loader operator cab. (See Raising The
710 N•m) torque. Operator Cab on Page 10-30-1.)
Replace the oil in the transmission. Drain the fluid from the chaincase. (See Replacing The
Oil on Page 10-130-1.)
Install the transmission cover.
Remove the front (or rear) chaincase cover.
Drive Chain Removal And Installation
Remove the front (or rear) axle and sprocket.
Remove the front (or rear) drive chain from the

DANGER chaincase.
P-90328
AVOID DEATH
D-1009-0409
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DRIVE COMPONENTS (CONT’D) Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-30-25]. Tighten the
Axle, Sprocket And Bearings Removal And threaded rod of the chain link tool to 180 ft.-lb. (176 N•m)
Installation (Cont'd) 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
WARNING

W-2059-0598
Figure 40-30-25
B-13504
The tool listed is needed for the following procedure:
MEL1037 - Chain Link Tool
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Install the new chain around the carrier shaft.
Use MEL1037 Chain Link Tool and #100 chain adapter.
Secure the tool and place the connector link and chain in
the tool as shown [Figure 40-30-25].
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CHAINCASE
Front Chaincase Cover Removal And Installation WARNING

Figure 40-40-1
W-2059-0598
Figure 40-40-2
P-26241
Remove the mounting bolts from the front chaincase

cover (Item 1) [Figure 40-40-1].

Remove the cover. 1
Rear Chaincase Cover Removal And Installation

P-26696
DANGER device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)

on Page 10-30-1.)
Disconnect the hydrostatic hoses [Figure 40-40-2].
Remove the eight mounting bolts from the rear chaincase

cover (Item 1) [Figure 40-40-2].
P-90328
NOTE: The auxiliary tubeline at the rear port of
AVOID DEATH
hydraulic control valve may need to be
disconnected to provide clearance for cover
front bolt removal.
D-1009-0409
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HUB Figure 40-50-3
Removal
Figure 40-50-1
P-24931

P-24816 the steering cylinder pin.
Figure 40-50-4
1.)

Remove the tire / wheel assembly [Figure 40-50-1].
1
Figure 40-50-2
P-24932
Remove the steering cylinder pin (Item 1) [Figure 40-50-

4].
P-24930
Attach a hook and hoist to the hub (Item 1) [Figure 40-

50-2].
Support the hub for removal.
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HUB (CONT’D) Figure 40-50-7
Removal (Cont'd)
1
Figure 40-50-5
P-24935
Remove the bearing seal (Item 1) [Figure 40-50-7] from

P-24933 the top and bottom king pins.
Figure 40-50-8
Remove the (4) bolts (Item 1) [Figure 40-50-5] from the
top and bottom king pins.

Remove the king pins from the hub assembly.
Figure 40-50-6 1
1
P-24936
Remove the bearing (Item 1) [Figure 40-50-8] from the

top and bottom king pins.
P-24934 Remove the wheel position sensor (Item 2) [Figure 40-

50-8]. Sensor Removal And Installation60-140-4 (From
the top king pin only.)
Slide the hub assembly (Item 1) [Figure 40-50-6] from
the loader axle.
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HUB (CONT’D) Installation
Removal (Cont'd) Figure 40-50-11
Figure 40-50-9
P-24940
P-34484
Install the race (Item 1) [Figure 40-50-11] in the top and
bottom king pins.
Figure 40-50-10
Figure 40-50-12

1
P-24940
P-24941
Remove the bearing race (Item 1) [Figure 40-50-9] &

[Figure 40-50-10] from the top and bottom king pins. Using a 2-13/16'' driver, seat the race (Item 1) [Figure
40-50-12] in the top and bottom king pins.
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2
Figure 40-50-13
1 2
P-24968
NOTE: Before installation, pack the internal splines

P-24936 in the hub (Item 1) [Figure 40-50-15] with
grease.
Install the wheel position sensor (Item 1) [Figure 40-50- Align the yoke (Item 1) on the hub assembly with the
13]. (See Sensor Removal And Installation on Page 60- loader axle (Item 2) [Figure 40-50-15].

140-4.) (In the top king pin only.)
Figure 40-50-16
Pack the bearings (Item 2) [Figure 40-50-13], and install
the bearings in the top and bottom races.
Figure 40-50-14
P-24967
Rotate the yoke (Item 1) [Figure 40-50-16] until the

P-24942 P-24935 splines on the yoke align with the splines on the loader
axle.
Install the seal (Item 1) [Figure 40-50-14] metal side Slide the hub assembly in until the king pin holes on the
towards the outside, in the top and bottom king pins. hub assembly align with the holes in the axle.
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Figure 40-50-17
P-24971
Figure 40-50-20
P-24969
Install the lower king pin (Item 1) [Figure 40-50-17], with

the grease fitting toward the loader.

Install the four mount bolts and finger tighten. 1
Figure 40-50-18
P-24972
1
Remove the wheel position indexing pin (Item 1) [Figure
40-50-19] & [Figure 40-50-20] from the upper king pin.
Figure 40-50-21
P-24970
Remove the plug (Item 1) [Figure 40-50-18] from the top 1

king pin.
P-24974
Install the upper king pin (Item 1) [Figure 40-50-21], with

the grease fitting toward the loader.
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2
1
Figure 40-50-22
3
P-24978A
3 3
P-24977A P-24976
Install the wheel position indexing pin (Item 1) [Figure

P-24975 40-50-23] in the upper king pin (Item 1) [Figure 40-50-
24].
Install the four mount bolts (Item 1) [Figure 40-50-22] in The fork (Item 2) [Figure 40-50-23] & [Figure 40-50-24]
the upper king pin. on the end of the indexing pin must align with the notches

(Item 3) [Figure 40-50-24] in the wheel position sensor.
Tighten the bolts to 70 ft.-lb. (95 N•m) torque. (Both upper
and lower king pin mount bolts.) Figure 40-50-25
Figure 40-50-23
1
1 1
P-24981
P-24973
Slightly turn the indexing pin until the positioning lobes on
the pin drops into the indexing grooves (Item 1) [Figure
40-50-25] in the king pin.
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Figure 40-50-26
P-26040
Check the O-ring (Item 1) [Figure 40-50-28] on the back

P-24933 side of the hub retainer washer, replace as needed.
Figure 40-50-29
Install the plug (Item 1) [Figure 40-50-26] in the upper
king pin, and tighten to 20 ft.-lb. (27 N•m) torque.

Install the tire / wheel assembly. 1
Remove the loader from jackstands.
Disassembly
Figure 40-50-27
P-26032
1
Remove the hub assembly (Item 1) [Figure 40-50-29]
from the spline shaft.
P-26031
Remove the hub retainer bolt and washer (Item 1)

[Figure 40-50-27].
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Figure 40-50-30
1
P-26035
Inspect the hub for any damage, to the splines (Item 1)

P-26033 [Figure 40-50-32], or to the bearing surface.
Figure 40-50-33
Remove the spacer (Item 1) [Figure 40-50-30] from the
back side of the hub.

Figure 40-50-31
1
P-26037
Using a dead blow hammer, remove the u-joint yoke

P-26034 assembly (Item 1) [Figure 40-50-33] from the housing.

hub.
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1
Figure 40-50-34
P-26045
Remove the inner seal (Item 1) [Figure 40-50-36] from

P-26038 the yoke assembly.
Figure 40-50-37
Remove the outer housing seal (Item 1) [Figure 40-50-
34].
3

Figure 40-50-35 2
1
1
1
1 1
1
P-26046
Remove the eight bolts (Item 1) and remove the male

P-26039 yoke (Item 2) and the female yoke (Item 3) [Figure 40-
50-37], from the U-joint.
Remove the bearing races (Item 1) [Figure 40-50-35]

from the housing.
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Inspection
Figure 40-50-38
P-26050
Check the U-joint [Figure 40-50-40].

P-26048
Figure 40-50-41
Before the hub is assembled, check the following items:

Check the female yoke [Figure 40-50-38].
Figure 40-50-39
P-26036
Inspect the bearings for any damage [Figure 40-50-41].
If the bearings need replacement, the bearing races must

P-26049 be replaced also.
Check the male yoke [Figure 40-50-39].
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Assembly
Figure 40-50-42 1
1
2
P-26039
1 3
Use MEL1605 and install new bearing races (Item 1)
P-26047 [Figure 40-50-44] in the housing.
Figure 40-50-45
Install the female yoke (Item 1) and the male yoke (Item
2) to the U-joint (Item 3) [Figure 40-50-42].

Figure 40-50-43
1 1
1
1 1
P-26051
Pack the bearing with lithium grease.

P-26046
Install the new bearing (Item 1) [Figure 40-50-45] in the
inside of the housing.
Install the eight mounting bolts (Item 1) [Figure 40-50-
43] and tighten to 90 - 110 ft.-lb. (122 - 149 N•m) torque.
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Assembly (Cont'd)
Figure 40-50-46
P-26053
Install the yoke assembly (Item 1) [Figure 40-50-48] into

P-26043 the seal.
Figure 40-50-49
Figure 40-50-47

1
1
P-26037
P-26052
Use MEL1606 and install the inner seal (Item 1) [Figure

40-50-46] & [Figure 40-50-47] with the metal side of the
seal away from the bearing.
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Assembly (Cont'd)
Figure 40-50-50
P-26033
Install the spacer (Item 1) [Figure 40-50-52] on the hub.

P-26041
Figure 40-50-53
Use MEL1606 and install the seal (Item 1) [Figure 40-50-

49] & [Figure 40-50-50] with the letter stamped side 1

away from the bearing.
Figure 40-50-51
1
P-26054
Install the hub assembly (Item 1) [Figure 40-50-53] on

the spline shaft in the housing.
P-26034
Pack the bearing with lithium grease.
Install the bearing (Item 1) [Figure 40-50-51] on the hub.
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HUB (CONT’D)
Assembly (Cont'd)
Figure 40-50-54
P-26040
Install the O-ring (Item 1) [Figure 40-50-54] on the back

side of the hub retainer washer.

Figure 40-50-55
P-26031
Install the hub retainer bolt and washer (Item 1) [Figure

40-50-55]. Tighten the bolt to 350 ft.-lb. (475 N•m)
torque.
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MAINFRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Joystick Boot Removal (Right & Left) . . . . . . . . . . . . . . . . 50-90-3
Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . 50-90-2
Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . 50-90-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 MAINFRAME
INSIDE ACCESS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Panel Removal (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-4

Panel Removal (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Installation Of Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-5
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . 50-50-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . 50-20-5
Gas Cylinder Removal And Installation (Early Models) . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-31-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-41-5
Power Bob-Tach Lever And Wedge. . . . . . . . . . . . . . . . . . 50-41-3
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MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Adjusting The Rear Door Latch . . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . 50-10-3
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SEAT BAR Figure 50-10-3
Figure 50-10-1
1 1
P-31288 P-31289
Loosen the nut (both sides) at the front corner of the

N-19225 operator cab [Figure 50-10-3].
Remove the nuts and plates [Figure 50-10-3] (both

Raise the seat bar (Item 1) [Figure 50-10-1]. sides).

N-18463 P-31267
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2] Lift on the grab handle and bottom of the operator cab
from the cab harness. slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].
Lower the seat bar.
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SEAT BAR (CONT’D) Assembling Components
Figure 50-10-5
5 6
4
7
1
3
8
1 9
2
10
N-19383
N-18572
Figure 50-10-8
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-5] (both sides).

4 5 9 8
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m)
torque. 6
3
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
2 10
Figure 50-10-6
1
1
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
N-19224 Seat Bar (Item 4)
Magnetic Busing Assembly (Item 5)
Remove the seat bar (Item 1) [Figure 50-10-6] from the Pivot Bushing (Item 6)
operator cab. Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Reverse the above procedure to install the seat bar into Sensor Mounting Bolt (Item 9)
the operator cab. Mounting Nut (Item 10)
Installation: Tighten the mounting bolt (Item 2) [Figure

50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
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SEAT BAR (CONT’D) Compression Spring Disassembly And Assembly
Assembling Components (Cont'd) Figure 50-10-11
Figure 50-10-9
1
4 5
6
3 7
N-19222
1
N-19340
Turn the bolt (Item 1) [Figure 50-10-11] & [Figure 50-10-
12] out of the clevis.
Figure 50-10-10
Assembly: Apply Loctite® #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
4 5 NOTE: For procedures requiring the use of Loctite®
3 #518 adhesive, thoroughly clean and dry
6 affected parts before the application of
2
Loctite® #518.
Figure 50-10-12
7
8 7
1
5 6
4
N-19220
3
Assemble the parts as shown for the right side of the seat
2
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
1 N-19384
10].
Seat Bar Mount (Item 1)

Disassemble and assemble the seat bar compression
Mounting Nut (Item 2)
spring and parts as shown in Fig. [Figure 50-10-12].
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Bolt (Item 1)
Seat Bar (Item 5) Bushing (Item 2)
Keyed Plastic Bushing (Item 6) Spring (Item 3)
Mounting Bolt (Item 7) Bushing (Item 4)
Clevis (Item 5)
Installation: Tighten the mounting bolt (Item 7) [Figure Retaining Pin (Item 6)
Bushing (Item 7)
50-10-9] & [Figure 50-10-10] to 50 - 70 in.-lb. (5,6 - 7,9 Pin (Item 8)
N•m) torque.
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OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation (Early

Models)
WARNING 1
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-31546
Install a chain (Item 1) [Figure 50-20-2] from the

operator cab to the loader main frame to prevent the cab
from tipping forward when the gas cylinder(s) are
removed.

1
Figure 50-20-3
P-31545
2
Remove the operator cab stop (Item 1) [Figure 50-20-1].
(Both sides.)
NOTE: Be careful not to break the rear window (if so

equipped) when the cab is raised after the cab 1
stops are removed.
Raise the operator cab. (See Raising The Operator Cab P-43444
on Page 10-30-1.)
Remove the bolt (Item 1) [Figure 50-20-3] from the gas
cylinder mounting bracket.
Loosen the mount bolt (Item 2) [Figure 50-20-3].
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Gas Cylinder Removal And Installation (Early

Models) (Cont'd)
Figure 50-20-4
1 2
P-43446
1
Installation: Mount the gas cylinder to the cab pivot pin.

Install the front mount bolt (Item 1). Use a locking pliers
P-43445 and turn the mount bracket to align the bracket with the
hole (Item 2) [Figure 50-20-6]. Install the bolt and tighten
the mount bolts to 15 - 20 ft.-lb. (20,3 - 27,1 N•m) torque.
Turn the mounting bracket forward to relieve any

remaining tension on the gas cylinder [Figure 50-20-4].
Remove the mount bolt (Item 1) [Figure 50-20-4].
Figure 50-20-5
N-19719
Remove the retainer clip (Item 1) [Figure 50-20-5] from

the top pivot pin.
Remove the gas cylinder from the cab.
Repeat the procedure for the opposite side.
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Gas Cylinder Removal And Installation (Later

Models)
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or 1
death.
W-2113-0288
P-31546
Figure 50-20-7

from tipping forward when the gas cylinder(s) are
removed.
Figure 50-20-9

1 1
P-31545
Remove the operator cab stop (Item 1) (Item 1) [Figure

50-20-7]. (Both sides.)
NOTE: Be careful not to break the rear window (if so

equipped) when the cab is raised after the cab
P-39601
stops are removed.
Raise the operator cab. (See Raising The Operator Cab Remove the retaining pins (Item 1) [Figure 50-20-9] from
on Page 10-30-1.) the cab pivot pins.
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OPERATOR CAB (CONT’D)
Gas Cylinder Removal And Installation (Later

Models) (Cont'd)
Figure 50-20-10
1
P-43354
Remove the retaining pins (Item 1) [Figure 50-20-10]

from the lower pivot pins.
Remove the gas cylinders (Item 2) [Figure 50-20-10]

from the operator cab.
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OPERATOR CAB (CONT’D) Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly Figure 50-20-13
Figure 50-20-11
2 P-31289
1
P1008
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-13] (both sides).
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-11] from the end of the gas cylinder. Installation: Tighten the nut to 40 - 50 ft.-lb. (54 - 68

N•m) torque.
Remove the gas cylinder from the outer housing.
Figure 50-20-12 on Page 10-30-1.)
Figure 50-20-14
P1006
P-31550
Assembly: Install a replacement cylinder inside the
cylinder housing.
Disconnect the two wiring harness connectors (Item 1 &
Apply a small amount of Loctite® on the threads of the 2) [Figure 50-20-14].
cylinder rod [Figure 50-20-12].
Remove the tie-straps (Item 3) [Figure 50-20-14] from
Reinstall the washer and clevis on the cylinder rod. the wiring harness.
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Figure 50-20-15
1
P-31546
P-31551
Disconnect the electrical connector (Item 1) [Figure 50- from tipping forward when the gas cylinders are
20-15]. removed.

Figure 50-20-16 Remove both gas cylinders. (See Gas Cylinder Removal
And Installation (Early Models) on Page 50-20-1.)
P-31552
Remove the mount bolt (Item 1) from the wire harness

mount bracket (Item 2) and ground strap (Item 3) [Figure
50-20-16].
Remove the tie-straps from the wiring harness.
Position the wiring harness, so that it does not get

damaged when the cab is removed.
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Figure 50-20-18
P-31554
Move the operator cab forward a small amount for

P-31553 clearance at the pivot mounting brackets [Figure 50-20-
20].
Connect a sling and chain hoist to the operator cab grab Install the pivot bolt, washer and nut (Item 1) [Figure 50-
handles and lower (or raise) the operator cab when the 20-20] in the cab pivot (both sides).

gas cylinders are disconnected [Figure 50-20-18].
Install the sling under the pivot bolt and pivot of the
Figure 50-20-19 operator cab [Figure 50-20-20].
Figure 50-20-21
1
2
P-31545
P-31555
Remove the operator cab stop (Item 1) [Figure 50-20-
19].
Connect the slings (Items 1 & 2) [Figure 50-20-21] to a
Remove the nut (Item 2) [Figure 50-20-19] from the pivot chain hoist.
bolt (both sides).
Remove the operator cab from the loader [Figure 50-20-
Installation: Tighten the pivot bolt and nut to 25 - 35 ft.- 21].
lb. (34 - 47 N•m) torque.
Remove the pivot bolt (both sides).
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OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1 1
2
1
N-20729
N-20729
on Page 10-30-1.)
on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation

(Items 1 & 2) [Figure 50-30-3] and peel back or cut
Remove the four seat mounting nuts (Item 1) [Figure 50- insulation to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Items 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) to 54 ft.-lb. (73 N•m)

torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lb.
P-31288 P-31289 (46 N•m) torque.
Repeat for other half of seat belt and guide.

Lower the cab and install one of the mounting washer
and nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.
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OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-31-2
1 N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P-31288 P-31289
Lower the cab and install one of the mounting washer

and nut [Figure 50-31-2].
NOTE: With the seat removed the cab will raise.

seat.
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OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-7
Slide Rail Removal And Installation 2

1 1
Figure 50-31-5
1
1
2 2
1
1
N-18582
1 Figure 50-31-8
N-18587

on Page 10-30-1.) 1

Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Remove the two slide rail mounting bolts (Item 1) [Figure

50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.
N-18581
seat slide rail.
Remove the cushion (Item 2) [Figure 50-31-7] from the
Cushion Removal And Installation seat frame (Item 1) [Figure 50-31-8].
Figure 50-31-6
N-18579
Press the two buttons (Item 1) [Figure 50-31-6] &

[Figure 50-31-7] and lift the seat cushion.
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Cushion Removal And Installation (Cont’d)
Figure 50-31-9
1 1
N-18578
Remove the two mounting screws (Item 1) [Figure 50-

N-18580 31-11] from the seat back and remove the back.

Inspect the seat ride adjustment [Figure 50-31-9]. seat back.

seat back.
Back Removal And Installation
Figure 50-31-10
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50-

31-10] and tilt the seat back all the way forward.
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Shock Removal And Installation
Figure 50-31-12 1
1
1
1
N-18586
2
NOTE: The seat block mounting studs (Item 1)

N-18584 [Figure 50-31-14] are replaceable.

Figure 50-31-13 seat shock.

1
2
N-18585

on Page 10-30-1.)
Remove the operator seat. (See Removal And

Remove the seat shock retaining pin (Item 1) [Figure 50-

31-12] & [Figure 50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-12] &

[Figure 50-31-13].
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BOB-TACH Figure 50-40-3
Figure 50-40-1
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-40-3] from the

P-31400 Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 in.) under each side of the Bob-

Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.
Remove the retainer nut (Item 1) [Figure 50-40-1] and

bolt from the tilt cylinder rod end pin (both sides).

Figure 50-40-2
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
P-31401
Remove the pivot pin (Item 1) [Figure 50-40-2] from the

tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
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BOB-TACH (CONT’D) Figure 50-40-7
Figure 50-40-5
P-31406
1
P-31405 the Bob-Tach pin.
Figure 50-40-8
Check and replace O-ring (Item 1) [Figure 50-40-5] on
the grease plug.

Figure 50-40-6
1
1
P-31407
With a 7/8” (.875 mm) drift (Item 1) [Figure 50-40-8] and

P-31403 a hammer, drive the pivot pin out of the lift arm & Bob-
Tach.
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-

Tach pivot pin retaining bolt (both sides).
Installation: Tighten the retainer nut and bolt to 190 ft.-

lb. (258 N•m) torque.
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BOB-TACH (CONT’D) Figure 50-40-11
Bob-Tach Lever And Wedge
Figure 50-40-9
P-31410
Use a punch and hammer, remove the roll pin (Item 1)

P-31408 [Figure 50-40-11] from the Bob-Tach wedge and spring
clevis.
Tilt the Bob-Tach forward, so it is parallel to the floor. Put Remove the spring / clevis (Item 2) [Figure 50-40-11]
blocks (approximately 3 in.) under each side of the Bob- assembly.

Tach [Figure 50-40-9].
Figure 50-40-12
Tach lever pivot bolt.
NOTE: Removal procedure is shown for the left side.

Right side procedure is the same.
1
Figure 50-40-10
P-31411
2
3
Remove the wedge (Item 1) [Figure 50-40-12] out of the
bottom of the Bob-Tach
Always replace bent or broken wedges.

P-31409
Remove the lever mounting washer (Item 1), spring (Item

2) and lever (Item 3) [Figure 50-40-10].

N•m) torque.
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BOB-TACH (CONT’D)
Bob-Tach Lever And Wedge (Cont’d)
Figure 50-40-13
4 3
2
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) [Figure 50-40-13] are damaged, put the

assembly in a vise.
Remove the bolt and replace the damaged parts as

needed,
Reverse the removal procedure to install the Bob-Tach

lever and wedge.
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POWER BOB-TACH Installation: Tighten the retainer nut to 18 - 20 ft.-lb. (24 -
27 N•m) torque.
Figure 50-41-3
Figure 50-41-1
2 1
1 2
P-31401
P-31379
Remove the pivot pin (Item 1) [Figure 50-41-3] from the

Tilt the Bob-Tach forward, so it is parallel to the floor. Put tilt cylinder rod end (both sides).
2x4 blocks under each side of the Bob-Tach [Figure 50-

41-1]. Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Lower the Bob-Tach onto the blocks.
Figure 50-41-4
Mark the hoses (Item 1) [Figure 50-41-1] for correct
installation.
Remove the hoses from the cylinder fittings.
Remove the mount bolt (Item 2) [Figure 50-41-1] from

the cylinder (both ends).
Remove the cylinder from the Bob-Tach.
Figure 50-41-2 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

Bob-Tach pivot pin grease plug (both sides).
P-31400
Remove the retainer nut and bolt (Item 1) [Figure 50-41-

2] from the tilt cylinder rod end pin (both sides).
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POWER BOB-TACH (CONT’D) Figure 50-41-7
Figure 50-41-5
P-31403
1
P-31404 Tach pivot pin retaining bolt (both sides).
Installation: Tighten the retainer nut and bolt to 190 ft.-

Use a grease gun and pump grease into the pivot pin lb. (258 N•m) torque.
forcing the grease plug out of the Bob-Tach (Item 1)

[Figure 50-41-5] (both sides). Figure 50-41-8
Figure 50-41-6
1
P-31406
P-31405
the Bob-Tach pivot pin (both sides).
on the grease plug.
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Figure 50-41-9
P-31408
1
Remove the lever mounting nut (Item 1) [Figure 50-41-
P-31407 11].

With a 7/8” (.875 mm) drift (Item 1) [Figure 50-41-9] and N•m) torque.
a hammer, drive the pivot pin out of the lift arm and Bob-

Tach (both sides). Figure 50-41-12
Remove the Bob-Tach from the loader.
Power Bob-Tach Lever And Wedge
Figure 50-41-10
1
P-31409
1
1 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-41-12].
P-31379
Remove the washers and bolts (Item 1) [Figure 50-41-

10] (both ends of the cylinder).
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the cylinder from the lever pivots.
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Power Bob-Tach Lever And Wedge (Cont'd)
Figure 50-41-13 4
1
3 2
2
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
P-31410 or clevis (Item 4) [Figure 50-41-15] are damaged, put the
assembly in a vise.
Use a punch and hammer to remove the roll pin (Item 1) Remove the bolt and replace the damaged parts as
[Figure 50-41-13] from the Bob-Tach Wedge and spring needed.

clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
Figure 50-41-14
P-31411
Remove the wedge (Item 1) [Figure 50-41-14] out of the

bottom of the Bob-Tach.
Always replace bent or broken wedges.
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POWER BOB-TACH (CONT’D)
Pivot Pin Bushing And Seal Replacement
Figure 50-41-16
2 1
N-18557
Remove the Power Bob-Tach. (See Removal And


Use a seal pick to remove seal (Item 1) [Figure 50-41-
16] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-16]

with a driver tool and hammer.
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LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation
Figure 50-50-1
1
1
P-31413
Remove the stabilizer bar, rear pivot pin (Item 1) [Figure

P-31412 50-50-3]
Remove the stabilizer bar from the loader.

on Page 10-30-1.)
Figure 50-50-4

NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.

1
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-
50-1].
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-31414

the stabilizer bar rear pivot pin at the lift arm.
Installation: Tighten the retainer bolt to 18 - 20 ft.-lb. (24

- 27 N•m) torque.
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LIFT ARMS (CONT’D) Figure 50-50-7
Link Removal And Installation
Figure 50-50-5
P-31562
Remove the lift arm pivot pin (Item 1) [Figure 50-50-7]

P-31415 (both sides).
Figure 50-50-8
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].

Figure 50-50-6
2
P-31563
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
P-31416 8] (both sides).
Remove the lift arm link from the loader.

Remove the retainer bolt and nut (Item 1) [Figure 50-50-
6] from the lift arm pivot pin (both sides).
Remove the retainer bolt and nut (Item 2) [Figure 50-50-

6] from the lift arm link pivot pin (both sides)
Installation: Tighten retainer bolt and nut to 18 - 20 ft.-lb.

(24 - 27 N•m) torque.
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LIFT ARMS (CONT’D) Disconnect the hydraulic hose (Item 1) [Figure 50-50-10]
from the filter that goes to the case drain on the auxiliary
Removal And Installation hydraulic coupler.
Figure 50-50-9 Cap and plug the hose and filter fittings.
Figure 50-50-11
1
2
P-31564
P-31572

WARNING Pull the hose (Item 1) [Figure 50-50-11] up and out of the
upright to allow for lift arm removal.
Lift arms must be fully lowered before removing the Mark the auxiliary hydraulic hoses and tubelines for
stabilizer link pins. Even with the approved lift arm proper installation.
support installed, the lift arms and links can
suddenly move if both link pins are removed with the Disconnect the two auxiliary hydraulic hoses (Item 2)
lift arms raised. [Figure 50-50-11].
W-2358-0999
Figure 50-50-12
on Page 10-30-1.)
Remove the left side access panel (Item 1) [Figure 50-

50-9].
Figure 50-50-10
1 1
P-31566
At the right side of the loader, mark the two tilt hoses and
tubelines. Disconnect the two tilt hoses (Item 1) [Figure
50-50-12] from the tubelines.
P-31565
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Figure 50-50-13
P-31571
Position the front sling in the middle of the Bob-Tach as

P-31567 shown in (Item 1) [Figure 50-50-15].
Support the lift arms with the chain hoist.

Install slings and a chain (Item 1) [Figure 50-50-13] on
the lift arms and connect to a chain hoist. Figure 50-50-16

Figure 50-50-14
P-31568
P-31570
With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-16]. (Both sides.)
NOTE: Be sure the slings on the lift arms are in a
position to balance the lift arms when being
remove. See (Item 1) [Figure 50-50-14].
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Figure 50-50-17
1
2
P-31569
Install pivot pin retainer bolt and nut (Item 1) [Figure 50-
P-31569 50-19] (both sides).

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (24 - 27 N•m) torque.
17] from the lift arm pivot pin (both sides).

Figure 50-50-20
Remove the lift arm pivot pin (Item 2) [Figure 50-50-17]
(both sides).
Using the chain hoist, remove the lift arms from the
loader.
Installation Of Lift Arms
Figure 50-50-18
P-31561
Remove the chain hoist and lift slings from the lift arms.
Support the front of the lift arms with a floor jack.
P-31570
Install lift arms.
Install the lift arm pivot pin (Item 1) [Figure 50-50-18].

(Both sides.)
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LIFT ARMS (CONT’D)
Installation Of Lift Arms (Cont’d)
Figure 50-50-21
P-31560
Reposition the lift straps and lower cab [Figure 50-50-

21].

Move the lift arms and link toward the rear of the
machine, using the chain hoist and floor jack until
stabilizer bar pins line up.
Figure 50-50-22
P-31414
Install the stabilizer pins (Item 1) [Figure 50-50-22] (both

sides).
Install the stabilizer pin retainer bolt and nut (Item 2)

[Figure 50-50-22] (both sides).

(24 - 27 N•m) torque.
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REAR GRILL Figure 50-60-3
Figure 50-60-1
P-31558
Lift and pull the rear grill and remove it from the loader
P-31556 [Figure 50-60-3].
Figure 50-60-4
Open the rear door (Item 1) [Figure 50-60-1].

Figure 50-60-2
2
1
P-31559
P-31557 Installation: Insert the tab on the rear grill (Item 1) into
the notch (Item 2) [Figure 50-60-4] on the loader frame.
(Both sides.)
Lift the rear grill assembly (Item 1) [Figure 50-60-2] over
the muffler.
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REAR DOOR Figure 50-70-3
Figure 50-70-1
1
1
N-19676
Remove the light housing (Item 1) [Figure 50-70-3] from

N-19674 the rear door. (Both sides).
Figure 50-70-4
Open the rear door.

Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the engine harness.
Figure 50-70-2
1
1
N-19678
Install a nylon sling (Item 1) [Figure 50-70-4] through the

holes for the light housings.
N-19675 Connect a chain hoist to the nylon sling.
Remove the light bulb (Item 1) [Figure 50-70-2] from the

light housing. (Both sides).
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REAR DOOR (CONT’D) Adjusting The Rear Door Latch
Figure 50-70-5
2 1
3
P-16367
P-31247
The door catch (Item 1) [Figure 50-70-6] can be adjusted

side to side for alignment with the door latch.
Figure 50-70-7

1
N-19677
1
Remove the nuts from the top and bottom hinge bolts
(Item 1) [Figure 50-70-5] and remove the hinge bolts.
Installation: Tighten the mounting bolts and nuts to 25 - P-31248

28 ft.-lb. (34 - 38 N•m) torque. The door stop (Item 2) is
installed in the top hinge bolt, above the stop retainer
(Item 3) [Figure 50-70-5]. The door latch (Item 1) [Figure 50-70-7] cannot be
adjusted.
Remove the rear door from the loader frame and lay it flat
on the floor.
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FUEL TANK Figure 50-80-3
Figure 50-80-1
1
1
N-19994
Disconnect the fuel fill hose (Item 1) [Figure 50-80-3].

P1616
Figure 50-80-4
Remove the cover (Item 1) [Figure 50-80-1] which is

installed over the drain plug.

Figure 50-80-2
1
N-19995
Disconnect the tank vent hose (Item 1) [Figure 50-80-4].
P1619 Remove the engine / hydrostatic pump assembly from

the loader. (See Removal And Installation on Page 70-
80-1.)
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.
Check the drain plug and replace if necessary.
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FUEL TANK (CONT’D) Figure 50-80-7
Figure 50-80-5
P5664
Lift the fuel tank and remove it from the loader frame
P5656 [Figure 50-80-7].
Fuel Level Sender

Remove the bolts (Item 1) [Figure 50-80-5] from the
battery holddown plate. Figure 50-80-8

Remove the holddown plate from the loader.
Figure 50-80-6
P5665
Loosen the fuel level sender in fuel tank.

P5661
Remove the fuel level sender (Item 1) [Figure 50-80-8].
Remove the mounting plate (Item 1) [Figure 50-80-6] for

the battery holddown plate.
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CONTROL Figure 50-90-3
Joystick Testing (Right & Left)

1
Figure 50-90-1
1 2
P-28312
Disconnect the joystick harness connector (Item 1) from

P-28301 the loader wiring harness (Item 2) [Figure 50-90-3].
Install the test harness (Item 3) [Figure 50-90-3]

The tools listed will be needed to do the following between the two connectors.
procedure:

Turn the remote start key to ON position without starting
MEL1608-Joystick Test Harness [Figure 50-90-1] the loader.
MEL1563-Remote Start Tool
Multimeter Check the voltage between pin 3 and pin 5 on the joystick
test harness (Item 3) [Figure 50-90-3].
Figure 50-90-2
The voltage should be between 2.45 and 2.55 volts.
Figure 50-90-4
P-28311
P-28310
Page 10-20-1.)
Repeat the procedure at the right joystick wiring harness
Raise the operator cab. (See Raising The Operator Cab connector (Item 1) [Figure 50-90-4]. (If needed.)
on Page 10-30-1.)
Connect the remote start tool to the loader. (See

REMOTE START on Page 10-60-1.)
At the back side of the control panel, locate the left
joystick wire connector (Item 1) [Figure 50-90-2].
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CONTROL (CONT’D) Figure 50-90-7
Joystick Removal (Right & Left)
Figure 50-90-5
1
P-26222
Remove the two outside joystick mount bolts (Item 1)

P-26220 [Figure 50-90-7].
Figure 50-90-8

Page 10-20-1.)

on Page 10-30-1.)
Roll the joystick rubber boot (Item 1) [Figure 50-90-5]

down from the joystick handle.
Figure 50-90-6
1
P-26223
Remove the joystick from the rubber boot [Figure 50-90-

8].
P-26221
Remove the two inside joystick mount bolts (Item 1)

[Figure 50-90-6].
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CONTROL (CONT’D) Lever Assembly Removal (Right & Left)
Joystick Removal (Right & Left) (Cont'd) Figure 50-90-11
Figure 50-90-9
1
1
P-26226
P-26224
Disconnect the electrical harness (Item 1) [Figure 50-90- Page 10-20-1.)
9] from the joystick.

Remove the joystick from the loader. on Page 10-30-1.)
Joystick Boot Removal (Right & Left) Remove the joystick. (See Joystick Removal (Right &
Left) on Page 50-90-2.)
Figure 50-90-10
Remove the joystick boot. (See Joystick Boot Removal
(Right & Left) on Page 50-90-3.)
Remove the joystick wiring grommet (Item 1) [Figure 50-

90-11]
Figure 50-90-12
P-26225
1
Page 10-20-1.)

P-26227
on Page 10-30-1.)
Remove the joystick. (See Joystick Removal (Right & Disconnect the joystick wiring harness connector (Item 1)
Left) on Page 50-90-2.) [Figure 50-90-12].
Remove the joystick boot from the control lever assembly

[Figure 50-90-10].
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CONTROL (CONT’D) Figure 50-90-15
Lever Assembly Removal (Right & Left) (Cont'd)
Figure 50-90-13
P-26230
Remove the two control lever mounting bolts (Item 1)

P-26228 [Figure 50-90-15].
Figure 50-90-16
Remove the wiring harness grommet (Item 1) [Figure
50-90-13] from the lower steering lever assembly.

Figure 50-90-14
P-26231
Remove the control lever from the loader [Figure 50-90-

P-26229 16].
Remove the wiring harness (Item 1) [Figure 50-90-14]

from the control lever assembly.
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CONTROL PANEL Figure 50-100-1
WARNING
1
W-2017-0286
P-31822
DANGER Raise the lift arms and install an approved lift arm support
Page 10-20-1.)
on Page 10-30-1.)
Remove the lift arm bypass control knob and washer

(Item 1) [Figure 50-100-1].
Figure 50-100-2
P-90328
AVOID DEATH 2
can cause lift arms to drop. 1
D-1009-0409
WARNING P-31824

the lift arms are secured by an approved lift arm Remove the control panel mount bolt (Item 1) [Figure 50-
support device. Failure to use an approved lift arm 100-2].
to fall and cause injury or death. Remove the two mount bolts (Item 2) [Figure 50-100-2]
W-2059-0598 from the engine speed control.
Remove the engine speed control linkage from the

engine speed control lever, and remove the lever from
the loader.
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CONTROL PANEL (CONT’D) Figure 50-100-5

1
Figure 50-100-3
P-26236
Remove the control panel mount bolt (Item1) [Figure 50-

P-26234 100-5] from the left side of the control panel.
Remove the two side panel mount bolts (Item 2) [Figure

Remove the two control panel mount bolts (Item 1) 50-100-5], to allow clearance for the removal of the
[Figure 50-100-3]. control panel.

Installation: Tighten the control panel mounting bolts to Installation: Tighten the control panel mounting bolts to
25 - 28 ft.-lb. (34 - 38 N•m) torque. 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Figure 50-100-4 Figure 50-100-6
1 1
P-26235 P-26237
Remove the fuse cover mount bolts (Item 1) [Figure 50- Remove the two side panel mount bolts (Item 1) [Figure
100-4]. 50-100-6], to allow clearance for the removal of the
control panel.
Remove the fuse cover.
Installation: Tighten the control panel mounting bolts to
25 - 28 ft.-lb. (34 - 38 N•m) torque.
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CONTROL PANEL (CONT’D) Figure 50-100-9
Figure 50-100-7
1
1
P-26239
Remove the two control panel mount bolts (Item 1)

P-26227 [Figure 50-100-9].
Remove the control panel from the loader.

Disconnect the right joystick wire harness connector
(Item 1) [Figure 50-100-7]. Figure 50-100-10

Figure 50-100-8
1 1
P-26240
P-26238
from the foot rests.
Disconnect the left joystick wire harness connector (Item
1) [Figure 50-100-8].
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CONTROL PANEL (CONT’D)
Figure 50-100-11
1 1
P-26241
Remove the front four mount bolts (Item 1) [Figure 50-

100-11] from the foot rests.

Remove the foot rests from the loader.
Figure 50-100-12
1
1
P-26242

from the lower fill panel.
Remove the panel from the loader.
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INSIDE ACCESS PANEL Figure 50-110-3
Panel Removal (Right)
Figure 50-110-1
1 1
P-34546
Disconnect the foot operated speed control linkage (Item

P-34544 1) [Figure 50-110-3] from the hand operated speed
control lever arm.
Raise the lift arms and install an approved lift arm support Remove the foot operated speed control assembly from
device. (See Installing The Lift Arm Support Device on the loader.

Page 10-20-1.)
Figure 50-110-4
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50-

110-1], from the right side foot rest. 2
Remove the foot rest, from the loader.

1
Figure 50-110-2
1
P-34547
2
Loosen the two mount bolts (Item 1) [Figure 50-110-4]
from the front inside access panel.

the front inside access panel.
P-34545 Remove the inside access panel from the loader.

the foot operated speed control assembly.
Loosen the two mount bolts (Item 2) [Figure 50-110-2]

from the foot operated speed control assembly.
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INSIDE ACCESS PANEL (CONT’D) Figure 50-110-7
Panel Removal (Right) (Cont’d)
Figure 50-110-5
1
1
1 2
P-34553
Lift the speed control pin (Item 1) from the notch (Item 2)
P-34548 [Figure 50-110-7] in throttle cable.
Figure 50-110-8
from the hand operated speed control lever.

Figure 50-110-6
P-34549
At the bottom right side of the control panel, remove the

P-34551 keeper and pin (Item 1) [Figure 50-110-8] that connects
the speed control linkage arm to the speed control cable.
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-110-6].
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Panel Removal (Right) (Cont’d)
Figure 50-110-9
1
1
1
2
P-34554
Remove the five mount bolts (Item 1) [Figure 50-110-11]

P-34550 from the access panel.

Remove the mount bolt and nut (Item 1) [Figure 50-110- the lever assembly. Move the lever assembly a slight
9] from the speed control linkage arm. amount toward the center of the loader, to allow

clearance for the panel to be removed.
Remove the speed control linkage arm (Item 1) [Figure
50-110-9] from the access panel. Remove the panel from the loader.
Figure 50-110-10
P-34555
At the bottom right side of the control panel, behind the

lift arm bypass valve, remove the two bolts and nuts (Item
1) [Figure 50-110-10] that mount the engine speed cable
to the access panel.
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Panel Removal (Left)
Figure 50-110-12
1
1
1
1
1
2
1
1
1
P-34653
Remove the nine mount bolts (Item 1) [Figure 50-110-

P-34651 14]

Raise the lift arms and install an approved lift arm support the lever assembly. Move the lever assembly a slight
device. (See Installing The Lift Arm Support Device on amount toward the center of the loader, to allow

Page 10-20-1.) clearance for the panel to be removed.
Raise the operator cab. (See Raising The Operator Cab Remove the inside access panel from the loader.
on Page 10-30-1.)

110-12], from the left foot rest.
Remove the foot rest from the loader.
Figure 50-110-13
1
1
P-34652

13].
Remove the front access panel from the loader.
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ELECTRICAL SYSTEM & ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6
Alternator Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-4
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-4
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
AWS CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-4

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1 ELECTRICAL
SYSTEM &
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1 ANALYSIS
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . .60-20-4
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)60-110-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . 60-110-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . 60-110-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
BOBCAT 2001 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-2
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1
Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-3
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . .60-170-2

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-170-2
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ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
ELECTRICAL SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . .60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-1

Deluxe Panel Removal And Installation (Right Side) . . . . . . . . . . 60-50-11
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-1
Option and Field Accessory Panels (If Equipped) . . . . . . . . . . . . .60-50-8
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . .60-50-3
Right Panel Set Up Display Options (Deluxe) . . . . . . . . . . . . . . . .60-50-4
Right Panel - (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . .60-50-2
Standard & Deluxe Panel Removal And Installation (Left Side). . 60-50-12
Standard Panel Removal And Installation (Right Side) . . . . . . . .60-50-10
LIFT AND TILT ACTUATOR CALIBRATION . . . . . . . . . . . . . . . . . . .60-160-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-1

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . .60-150-1

Connecting The Service PC To Remote Start Tool . . . . . . . . . . .60-150-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-3
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-10
STEERING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-100-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-100-1
A300 Bobcat Loader

392 of 772
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-1

Description Of The Control System . . . . . . . . . . . . . . . . . . . . . . .60-130-2
Inspecting The Control System . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-1
WHEEL POSITION SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
Wheel Alignment (Failed Sensor) . . . . . . . . . . . . . . . . . . . . . . . .60-140-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-3
Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . .60-140-4
Wheel Alignment (Field Adjustment) . . . . . . . . . . . . . . . . . . . . . .60-140-6
Wheel Alignment (Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-10
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
A300 Bobcat Loader

393 of 772
A300 Bobcat Loader

394 of 772
LEFT RIGHT LEFT PANEL REAR ROD
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
2910 G GROUND
WIRING SCHEMATIC
BROWN TIE STRAP 2430 B B 12V
9340 D HEADLIGHTS
B A A B 1210 E PROTECTED POWER
C434 C435 1910 F COMPUTER POWER
REAR BASE
C414
A300 (S/N 521111001 - 521111550) B A A B
9110 H SYSTEM Tx
WHITE TIE STRAP
4440
2440
A
B
A
B
7.5 ohm
12V
2750
6110
6120
2760
WIRES CONNECT BY 9210 K SYSTEM Rx
(PRINTED MAY 2004) LETTER ACROSS SEE FUSE/RELAY
H H
9300 A CLOCK/LATCH
C421
C407
CONNECTORS CENTER J J A 4370 DIVERTER
V-0145 9310 B DATA NOT
C416
A B (EUROPEAN A 6100 A A 6100 USED B 2370 4450 A A 7.5 ohm
B A LIGHTING) 9330 J START
12V
THIS PAGE M M 2900 YELLOW TIE STRAP 2450 B B
9320 C BUZZER
Printable Version Click Here SOME CONNECTOR C C 9340
C422
BODIES NOT SHOWN D D 9200 NOT A 4380
9320 +
FOR DRAWING CLARITY E E 9100 BUZZER USED B 2380
SEE ACS -
C408
SEE CONTROL 2930
CONNECTOR E MODULE J4
B 4500 F F 4500 1930 RIGHT PANEL
RED = RED BRAKE
THIS PAGE THIS PAGE 2740 S S 2740 2770
RNG = ORANGE SWITCH 9330 J START
BLK = BLACK P P 1900 HYD. LOCK VALVE REAR AUX RELIEF
LBL = LIGHT BLUE BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA
C417
C420
DBL = DARK BLUE GROUND 2000-2999 BLK R R 1200 9.8 ohm A A 4410 4480 A A 9.8 ohm
9300 A CLOCK/LATCH GREEN TIE STRAP
12V
LGN = LIGHT GREEN MONITORING 3000-3999 LBL B B 9350 12V B B 2410 2480 B B
DGN = DARK GREEN HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
YEL = YELLOW ATTACHMENT CONTROLS 5000-5999 YEL SEE ACS L L 3900
LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx
2530 GROUNDS
PNK = PINK
ACCESSORIES 7000-7999 WHT CONNECTOR D G G 3920
SENSOR
FRONT ROD HIGH FLOW / 900 LOAD SENSE
WHT = WHITE 1920 F COMPUTER POWER
C418
C415
ENGINE 8000-8999 TAN THIS PAGE K K A A A 4330 4460 A A
2480 BRN = BROWN 3910 3.3 ohm 7.5 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER
PWM 12V
2460 TAN = TAN N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
PUR = PURPLE
9110
9210
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 GRY = GRAY 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
FUEL SENDER 2750 2740
C419
2430 2760 3.3 ohm A A 4340
HARNESS - 6719422
2340 CAB HARNESS - 6727178 PWM
B B 2340
B3
B2
C3
B1
D2
D1
D3
A1
A2
A3
C2
C1
E3
E1
E2
F3
F2
F1
2330 TWO SPEED
C441
C406
2520 C C 4350 A A
J2 WHITE 5.5 ohm
C442
FUEL SENDER 3100 A A 3100 3100 B1 F1 4340 2350 B 12V
2100 A A PROTECTED
POWER
COMPUTER
POWER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR
SUPPLY
B
30-270 ohm
2490 B B 3110 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITION
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM Rx OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
2410 D J2 C K3 4420 A A 6.7 ohm

F2 E2 B2 A2
900 LOAD SENSE

12V
C405
WHITE
2 2
HIGH FLOW /
A 3700 E2
REAR AUX
A 3700 K2
DIVERTER
2420 B B
RELIEF
4460
2380 2390 AIR FILTER
4470
9350 9200 3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
GROUND OPEN OPEN OPEN
SWITCH B B 3710 3010 F2 SWITCH GROUND
F3 4360
2370 D C
F3 E3 B3 A3
D3 3 3 G2 4430
TWO SPEED
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
2900 9340 3910
4350
4420
4410
H3
H2
H1
2000
G1 4440
t J2 4450
TRACTION HOLD
2240
REAR BASE
REAR ROD
HYD TEMP SENDER
C
4200
4430
4440
3300 C 3300 B3 J3
G3
G2
G1
RESERVED
4480
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
500-3000 ohm
(hall)
F3
F2
F1
D
2800 +A
3310 D 3310
CONTROL MODULE J1 4460
C102
SPOOL LOCK
FRONT BASE
FRONT ROD
3400 A A 3400 C1 H3
FILTER SIGNAL
HYD CHARGE PRESS 4350
HYD CHARGE
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
C
3430
E3
E2
E1
2300 SENDER 0.5-7.5 V 3420 E E 3420 C2 H2 4420
3510
- B 3410 F F 3410 D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
HYD OIL FILTER
ENG OIL
B
ENG OIL
3430
3520
J4
B 3430 E3
3500
OPEN
C2 4830
D3
D2
D1
J1 BLACK
PRESSURE SWITCH
2110 SEE LEFT B2 4820
PWM SIGNAL
HYDRAULIC FILTER HARNESS - 6717247 HANDLE
PWM +
4300
PWM -
C A3
4320
4310
4640 A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
THIS PAGE B3 1400
2730 SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
RH SKI UP
HYD CHARGE ENG COOLANT
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A3 4500 B
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 THIS PAGE
C3
C2
C1
+ SEE
A D1 4940
2710 ENGINE OIL A A 3500 3500 D1
C107
CONTROL
PRESSURE C C1
RH SKI DOWN
4930
LH SKI DOWN
FUEL SENDER
EHC INPUT
3520 3520 D2
HYDRAULIC
2350 C C SPARE ACCESSORY UNSWITCHED
MODULE
9400
3300
3100
SIGNAL
4830
4930
3200
-
C3
C2
C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD
SENDER
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
0.5-7.5 V
B 3510
B1 4920
J1 THIS
B B K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
8800 1110
A1 4910 PAGE
LH AUX LEFT
9500 8000 8250 8210
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
HANDLE
4640
ATTACHMENT BRAKE PULL
SPARE
SPARE
REAR WKLT BRAKE PULL UNSWITCHED
FLOAT
4820
4920
C106
1400
OUT
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
SPEED A A 3600 3600 E1 J3
C
SENSOR K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
B B 3610
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
A3
A2
A1
C3
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104
4220
COOLANT A A 3200 3200 B2 D3 9410
SENDER BLAC
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
4930
500-3000 ohm B B 3210 G3 4200
ALTERNATOR SUPPLY K
H3
G1
G3
G2
H1
D3
D1
C1
C3
C2
B2
B3
D2
A3
A2
A1
H2
K1
K2
K3
B1
E3
E1
E2
F3
F2
F1
J1
J2
J3
1020
B D C G F E K J H A E H J A F G B C K D
C110
B B
A A 1800
C409 C410
B NOT USED NOT USED
4730
4110
8000
6320
6210
8550
8510
8250
8210
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
6510
6410
7200
4390
2360
2015
4 4
C101
3 3 A B
1015 STARTER 3.2 ohm
12V
1
2
1
2
2800
8100
Dealer Copy -- Not for Resale C458
M R
8250
FUEL SHUTOFF A B TWO-SPEED
MAKE-UP
B
S 5 ohm
8200
12V
GLOW PLUGS
TAILGATE / WORKLIGHTS 6716419 1.0 ohms Each
F F
2600 B B 2600 HR HR HR HR
RIGHT
2620 6200 6200 H H 6200
WORKLIGHT
C103
6210 6310 A A 6310
8590
8580
8570
8560
9410
9400
LEFT
2630 6210 E E 6400
WORKLIGHT SEE CAB
D D 6500 CONNECTOR
RIGHT (EUROPEAN
2610 6320 G G 6600
TAILLIGHT LIGHTING) B A
C404
BACKUP 7100 C C 7100 A TO ALL WHEEL THIS PAGE

LEFT
2640 6330 ALARM B STEER CONTROL C473
TAILLIGHT
2650 HARNESS C407 B A
A
J 2730 ACS
9420
2650
9420
P 6600 JUMPER
2640
6000
2630 2600 M 6500
2620 L 6400
2610 F 4730
D 4235
R
C488
C 4275 TRACTION LOCK

E 4550
TWO SPEED BRAKE
N 6300 WHT TO BLK =
C425
C425
4200 A A HOLD
0.26 ohm
A
S 1700
2200 C C RED TO BLK= B 9.8 ohm
A 1140 10.9 ohm
4100 B B PULL C
H 1150
B
G
TO OPTIONS
K (ALTERNATOR (ALL WHEEL
1800 & KITS) STEER CONTROLLER)
TO OPTIONS
(ACCESSORY CONNECTOR) FUSE 11
25A J
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 P
N
C489
B 2720 SWITCHED MARKER REAR GLOW FUEL TRACTION 1740 B

POWER LIGHT LIGHT PLUG STARTER PULL 4220 M
(COMPUTER)
A 1720 1720 LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A 4275 L
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1730
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D
C492
(HEATER SEE CONTROL R
) 1 FUSE 2 120 MODULE J2
FUSE FUSE 3 FUSE 6 FUSE 5 E 9210 G
15A 30A 30A OHM
25A 15A THIS PAGE
RESISTOR S
MAINFRAME HARNESS 6732227 1140
9520 C
1150 1160 2240 H
1070 SEE CONTROL
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12
MODULE J2 D 9110 F
ARE CONNECTED IN SERIES 25A 25A THIS PAGE
FUSE / RELAY CENTER (UNSWITCHED
POWER) (ACS)
1170 A
FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040
1080
30A 15A 25A
REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR
Printed in U.S.A.
1040 V-0145 (4-30-04)
BATTERY 1080
395 of 772
REAR BASE REAR ROD LOCK VALVE LOCK VALVE
LEFT RIGHT LEFT PANEL
FRONT
WORKLIGHTS 2910 G GROUND
WIRING SCHEMATIC B A
C434 C435
A B
9340
1210
1910
D
E
F
HEADLIGHTS
PROTECTED POWER
COMPUTER POWER C414A
B A
C413A
B A
C417A
B A A B
C416A
A300 (S/N 521111551 AND ABOVE) B A A B
9110 H SYSTEM Tx B A B A B A A B
2750
6110
6120
2760
WIRES CONNECT BY 9210 K SYSTEM Rx
(PRINTED MAY 2004)
2440
4440
2430
4430
4482
4452
2450
H H
2480
LETTER ACROSS SEE FUSE/RELAY 9300 A CLOCK/LATCH
C421
C407
CONNECTORS CENTER J J A 4370
V-0578 A B (EUROPEAN A 6100 A A 6100
9310 B DATA NOT
USED B 2370
REAR AUX.
J
HARNESS
LIGHTING) 9330 START
B A M M
6736011
2900
THIS PAGE 9320 C BUZZER
Printable Version Click Here SOME CONNECTOR C C 9340
C422
4481
D D
4451
BODIES NOT SHOWN 9200 NOT A 4380
9320 +
FOR DRAWING CLARITY E E 9100 BUZZER USED B 2380
SEE ACS -
C408
SEE CONTROL 2930
CONNECTOR E MODULE J4
B 4500 F F 4500 1930 RIGHT PANEL
RED = RED BRAKE
THIS PAGE THIS PAGE 2740 S S 2740 2770
RNG = ORANGE SWITCH 9330 J START
BLK = BLACK P P 1900 HYD. LOCK VALVE WHITE TIE STRAP BROWN TIE STRAP GREEN TIE STRAP YELLOW TIE STRAP
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA
2440
4440
LBL = LIGHT BLUE
C420
GROUND 2000-2999 BLK R R 1200 9.8 ohm A A 4410
2430
4430
4450
2450
DBL = DARK BLUE
2480
4480
9300 A CLOCK/LATCH
LGN = LIGHT GREEN MONITORING 3000-3999 LBL B B 9350 12V B B 2410
DGN = DARK GREEN HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
YEL = YELLOW ATTACHMENT CONTROLS 5000-5999 YEL SEE ACS L L 3900 B A
LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx B A B A A B
2530 GROUNDS
PNK = PINK
ACCESSORIES 7000-7999 WHT CONNECTOR D G G 3920
SENSOR
FRONT ROD
C414
WHT = WHITE 1920 F COMPUTER POWER
C418
THIS PAGE A
2480 BRN = BROWN
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
K K 3910
1220 E PROTECTED POWER
3.3 ohm A A 4330
B A C413 C417 C416
PWM
2460 TAN = TAN N N B B 2330
B A
2910 9350 D RUN/ENTER SWITCH B A A B
PUR = PURPLE
9110
9210
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2440
4440
2450 GRY = GRAY 2930
MAIN 2920 G GROUND
2430
4430
2770 CAB 2000 FRONT BASE
4450
2450
2480
4480
2440 2400 FRAME
FUEL SENDER 2750 2740 C OPEN
C419
2430 2760 3.3 ohm A A 4340
HARNESS - 6719422 WHITE TIE STRAP
2340 CAB HARNESS - 6727178 PWM
B B 2340 YELLOW TIE STRAP
B3
B2
C3
B1
D2
D1
D3
A1
A2
A3
C2
C1
E3
E1
E2
F3
F2
F1
BROWN TIE STRAP GREEN TIE STRAP
2330
C406
2520 C C
J2 WHITE
C442
2100 FUEL SENDER A A 3100 A A 3100 3100 B1 PROTECTED
POWER
COMPUTER
POWER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR
SUPPLY
F1 4340
30-270 ohm
2490 B B 3110 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 HIGH FLOW / 900 LOAD SENSE
K3
K2
K1
2420 KEY/ENTER
SYSTEM Rx OPEN OPEN
SEATBAR
OPEN BLUE TIE STRAP
C415
SWITCH SENSOR SIGNAL
2410 D J2 C K3 4460 A A 7.5 ohm

F2 E2 B2 A2
900 LOAD SENSE

C405
WHITE
2 2
HIGH FLOW /
A 3700 E2 12V
REAR AUX
A 3700 K2 B B
DIVERTER
2460
RELIEF
4460
2380 2390 AIR FILTER
4470
9350 9200 3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
GROUND OPEN OPEN OPEN
SWITCH B B 3710 3010 F2 SWITCH GROUND
F3 4360
2370 D C
F3 E3 B3 A3 TWO SPEED
D3 3 3 G1 4440
TWO SPEED
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
C441
2900 9340 3910
4350
4420
4410
A
H3
H2
H1
4350 A
2000
G2 4430 5.5 ohm
2350 B B 12V
t J3 4480
TRACTION HOLD
2240
REAR BASE
REAR ROD
HYD TEMP SENDER
C
4200
4430
4440
3300 C 3300 B3 J2
G3
G2
G1
RESERVED
4450
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
500-3000 ohm BUCKET POSITION
(hall)
F3
F2
F1
D
3310 D 3310
CONTROL MODULE J1 4460
C423
2800 +A 4420 A A 6.7 ohm
C102
SPOOL LOCK
FRONT BASE
FRONT ROD
3400 A A 3400 C1 H3
FILTER SIGNAL
HYD CHARGE PRESS 4350 12V
HYD CHARGE
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
F3
F2
F1
3610 2420 B B
3700
SIGNAL
3600
SIGNAL
C
3430
E3
E2
E1
2300 SENDER 0.5-7.5 V 3420 E E 3420 C2 H2 4420
3510
- B 3410 F F 3410 D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
HYD OIL FILTER
ENG OIL
B
ENG OIL
3430
3520
J4
B 3430 E3
3500
OPEN
C2 4830
D3
D2
D1
J1 BLACK
PRESSURE SWITCH
2110 SEE LEFT B2 4820
PWM SIGNAL
HYDRAULIC FILTER HARNESS - 6717247 HANDLE
PWM +
4300
PWM -
C A3
4320
4310
4640 A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
THIS PAGE B3 1400
2730 SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
RH SKI UP
HYD CHARGE ENG COOLANT
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A3 4500 B
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 THIS PAGE
C3
C2
C1
+ SEE
A D1 4940
2710 ENGINE OIL A A 3500 3500 D1
C107
CONTROL
PRESSURE C C1
RH SKI DOWN
4930
LH SKI DOWN
FUEL SENDER
EHC INPUT
3520 3520 D2
HYDRAULIC
2350 C C SPARE ACCESSORY UNSWITCHED
MODULE
9400
3300
3100
SIGNAL
4830
4930
3200
-
C3
C2
C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD
SENDER
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
0.5-7.5 V
B 3510
B1 4920
J1 THIS
B B K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
8800 1110
A1 4910 PAGE
LH AUX LEFT
9500 8000 8250 8210
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
HANDLE
4640
ATTACHMENT BRAKE PULL
SPARE
SPARE
REAR WKLT BRAKE PULL UNSWITCHED
FLOAT
4820
4920
C106
1400
OUT
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
SPEED A A 3600 3600 E1 J3
C
SENSOR K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
B B 3610
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
A3
A2
A1
C3
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104
4220
COOLANT A A 3200 3200 B2 D3 9410
SENDER BLAC
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
4930
500-3000 ohm B B 3210 G3 4200
ALTERNATOR SUPPLY K
H3
G1
G3
G2
H1
D3
D1
C1
C3
C2
B2
B3
D2
A3
A2
A1
H2
K1
K2
K3
B1
E3
E1
E2
F3
F2
F1
J1
J2
J3
1020
B D C G F E K J H A E H J A F G B C K D
C110
B B
A A 1800
C409 C410
B NOT USED NOT USED
4730
4110
8000
6320
6210
8550
8510
8250
8210
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
6510
6410
7200
4390
2360
2015
4 4
C101
3 3 A B
1015 STARTER 3.2 ohm
12V
1
2
1
2
2800
8100
Dealer Copy -- Not for Resale C458
M R
8250
FUEL SHUTOFF A B TWO-SPEED
MAKE-UP
B
S 5 ohm
8200
12V
GLOW PLUGS
TAILGATE / WORKLIGHTS 6716419 1.0 ohms Each
F F
2600 B B 2600 HR HR HR HR
RIGHT
2620 6200 6200 H H 6200
WORKLIGHT
C103
6210 6310 A A 6310
8590
8580
8570
8560
9410
9400
LEFT
2630 6210 E E 6400
WORKLIGHT SEE CAB
D D 6500 CONNECTOR
RIGHT (EUROPEAN
2610 6320 G G 6600
TAILLIGHT LIGHTING) B A
C404
BACKUP 7100 C C 7100 A TO ALL WHEEL THIS PAGE

LEFT
2640 6330 ALARM B STEER CONTROL C473
TAILLIGHT
2650 HARNESS C407 B A
A
J 2730 ACS
9420
2650
9420
P 6600 JUMPER
2640
6000
2630 2600 M 6500
2620 L 6400
2610 F 4730
D 4235
R
C488
C 4275 TRACTION LOCK

E 4550
TWO SPEED BRAKE
N 6300 WHT TO BLK =
C425
C425
4200 A A HOLD
0.26 ohm
A
S 1700
2200 C C RED TO BLK= B 9.8 ohm
A 1140 10.9 ohm
4100 B B PULL C
H 1150
B
G
TO OPTIONS
K (ALTERNATOR (ALL WHEEL
1800 & KITS) STEER CONTROLLER)
TO OPTIONS
(ACCESSORY CONNECTOR) FUSE 11
25A J
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 P
N
C489
B 2720 SWITCHED MARKER REAR GLOW FUEL TRACTION 1740 B

POWER LIGHT LIGHT PLUG STARTER PULL 4220 M
(COMPUTER)
A 1720 1720 LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A 4275 L
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1730
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D
C492
(HEATER SEE CONTROL R
) 1 FUSE 2 120 MODULE J2
FUSE FUSE 3 FUSE 6 FUSE 5 E 9210 G
15A 30A 30A OHM
25A 15A THIS PAGE
RESISTOR S
MAINFRAME HARNESS 6732227 1140
9520 C
1150 1160 2240 H
1070 SEE CONTROL
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12
MODULE J2 D 9110 F
ARE CONNECTED IN SERIES 25A 25A THIS PAGE
FUSE / RELAY CENTER (UNSWITCHED
POWER) (ACS)
1170 A

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040
1080
30A 15A 25A
REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR
Printed in U.S.A.
1040 V-0578 (4-30-04)
BATTERY 1080
396 of 772
WIRING SCHEMATIC
RED = RED
RNG = ORANGE BATTERY FEED 1000-1999 RED, RED/WHT, RNG
WIRES CONNECT BY BLK = BLACK GROUND 2000-2999 BLK
LETTER ACROSS LBL = LIGHT BLUE MONITORING 3000-3999 LBL
DBL = DARK BLUE HYDRAULIC 4000-4999 LGN
A300 (S/N 521111001 AND ABOVE) CONNECTORS
A B
LGN = LIGHT GREEN
DGN = DARK GREEN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
B A YEL = YELLOW
(PRINTED MAY 2004) PNK = PINK
WHT = WHITE
COMMUNICATION 9000-9999 PUR
SOME CONNECTOR
V-0153 BODIES NOT SHOWN
BRN = BROWN
TAN = TAN
FOR DRAWING CLARITY PUR = PURPLE
Printable Version Click Here GRY = GRAY
ALL WHEEL STEER CONTROL HARNESS - 6726663 or 6733293
TO ALL WHEEL TO ALL WHEEL TO ALL WHEEL

J3
TO ALL WHEEL
STEER CONTROLLER J2 STEER CONTROLLER J1 STEER CONTROLLER J4 STEER CONTROLLER
K G P E R F N M D L C B J A H S SH GA B D C P F E R N M L K J A B K J G F C D E H
D E F R C B J H S A K L M N P G
3130
4250
2690
2680
4260
4270
2670
2660
4280
9520
9620
1180
1190
2250
2500
2980
2880
2970
2810
2870
1500
1740
2260
1590
1555
2650
1 2 3 A B C D A B C D
C456 C451 C452

A B C D A B C D
1 2 3
RED
DGN
BLK
RIGHT RIGHT LEFT LEFT
1 2 3 DRIVE DRIVE DRIVE DRIVE
REVERSE FORWAR REVERSE FORWARD
D ohm
20 ohm 16 20 ohm 16 ohm
DRIVE COILS
Dealer Copy -- Not for Resale Right Rear
Wheel
Position
C497
TO C B A
1520
4530
9010
4540
2080
4520
1510
4510
9000
2070
OPTIONS
ORANGE TIE STRAP

YELLOW TIE STRAP
401 TIE STRAP
405TIE STRAP
123 4 56 1 23 4 5 6
BLACK TIE STRAP
NOTE *
WHITE TIE STRAP
BLACK TIE STRAP
WHITE TIE STRAP

BLUE TIE STRAP
PINK TIE STRAP

403STRAP
9420 *
SEE
C449 C450
9000
4950
7200
6410
9620
9010
1170
6510
9520
1740
2240
1580
2630
2180
1240
3060
2620
1570
1230
2170
3050
4070
404
402
416
123 4 56 123 4 56
4170
4060
2640
1565
3140
2560
1560
PURPLE
3040
2550
1550
3030
RED TIE
2940
0
0
0
2960
2950
2890
2830
0
0
2840
2820
GREEN
2850
1530
3020
2570
1540
2580
3000
3070
3080
J P N B C D E A H K F G R L M S 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 JOYSTICK JOYSTICK
710
0
C492 LIFT ACTUATOR 3 2 1 3 2 1 3 2 1 HARNESS - HARNESS -
WHT
WHT
RED
BRN
RED
BRN
LGN
LGN
TO MAINFRAME
BLK
BLK
TILT ACTUATOR
HARNESS 6729397 6729397
A B A B B A A B B A A B B A A B B A A B C429 C428 1 2 3 4 1 2 3 4 C457 C498 C455
C404 C440 C461 C499 C443 C444 C445 C446 C447 C448 LIFT ACTUATOR TILT ACTUATOR 3 4 5 6 27 1 3 4 5 6 27 1
TO A B B A A B B A A B B A A B B A A B 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C454 C453 3 2 1 3 2 1 3 2 1
MAINFRAME C459 C460
* NOTE: Wire 9420 on HARNESS 1 2 3 4 1 2 3 4
DGN
RED
BLK 3 4 5 6 27 1 3 4 5 6 27 1
RED
RED
RED
DGN
DGN
DGN
RED
DGN
RED
BLK
BLK
BLK
BLK
BLK
RED
BLK
connector C492 on Front Front Front Front Right Right Left Left Pressure
Left A B C
harness 6733293 ONLY. Right
Base
Right
Rod
Left
Base Rod
Rear
Base
Rear
Rod
Rear
Base
Rear
Rod
Control A B C
3 2 1 3 2 1 3 2 1
7 ohms
10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms LEFT HANDLE RIGHT HANDLE
HALL HALL
M M EFFECT
STEERING SOLENOIDS SENSOR
EFFECT
SENSOR
Left Front Left Rear Right
2070
Wheel Wheel Front
2080 Left Side Right Position Position Steering
SENSOR GROUND (5V)
Wheel Side Sensor
2570
Speed Wheel
2580 2500 Speed
2550 SENSOR POWER (5V)
1510 SENSOR POWER (5V) 1550 SUPPLY #2
2560 SUPPLY #1
1520 1555 1590
2620 1500
1530 1560
2630
1540 1565
2650
1570
2640
1580
Printed in U.S.A. V-0153 (4-30-04)
397 of 772
WIRING SCHEMATIC POWER BOB-TACH
OPTIONS TO OPTIONS
(POWER BOB-TACH) TO OPTIONS
SOLENOID
Printable Version Click Here STROBE OR
C606
POWER BOB-TACH 2770 E A 7000 A A
BEACON
A300 (S/N 521111001 AND ABOVE) FLASHER SWITCH
2760 D D 2760 B B
C601
C601
1 C
(PRINTED MAY 2004) 7000 A
BEACON SWITCH 2
C607
C B 7010 B B POWER BOB-TACH
V-0146 2 1 6 SOLENOID
5 HAZARD SWITCH 7010 B E 2770 A A
LEFT RIGHT C609 3
4
WIRES CONNECT BY FLASHER FLASHER 2 1
TO 1130 6010 6430 4
LETTER ACROSS LIGHT LIGHT 2 1 L 5
STROBE/BEACON 3 X 3
CONNECTORS 1180
1 2
A B TO OPTIONS TO OPTIONS
(EXTERIOR CAB)
5
4
6530
6 POWER BOB-TACH HARNESS -
B A 6700 E 6 2750
E 6700 TO MAINFRAME
6730770
2775
TO OPTIONS 2755 AWS SWITCH
TO OPTIONS A D 2780
SOME CONNECTOR
2790
2795
(EXTERIOR CAB) 1
C670
4550 E
C670
BODIES NOT SHOWN (4 WAY FLASHER) C
B 6540 2 3
FOR DRAWING CLARITY 6440 1 2 2785 2780 D 2745 R
C669
F
C669
6440 4
2785 2 1 6440 F 2755 4235 D
A 5
6540 3 4275 C
3 6540 B 6
C K
C488
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
4 WAY FLASHER EXTERIOR CAB HARNESS - G
B
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN HARNESS - 6718873 6718872 2730 J
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
1700 S FRONT WIPER
ACCESSORIES 7000-7999 WHT 6400 L M BOTTLE AND TANK
COMMUNICATION 9000-9999 PUR 6500 M FRONT WIPER
1150 H MOTOR
N V
P M
RED = RED
F
RNG = ORANGE
BLK = BLACK A C622
7200 or YEL
7150 or DGN
2765 or BRN
LBL = LIGHT BLUE
DBL = DARK BLUE STANDARD ACCESSORY HARNESS - 6727468 L X
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW TO OPTIONS
C617 OR C642
PNK = PINK (HVAC OR HVAC/ACCESSORY) TO OPTIONS
2745
WHT = WHITE (DELUXE ACCESSORY)
BRN = BROWN 1140 B
C 7310
TAN = TAN 1740 A
PUR = PURPLE B 2735 2755 B B
C610
C667
GRY = GRAY 2740 C
E 7150 7160 C C DOOR SENSOR
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR A 7210 A A
LIGHT SWITCH POWER BOB-TACH 2770 E F 7190 2 7180 2
BEACON SWITCH V 2 2
SWITCH D 4710
1 2760 D M 1 1 4720 1 1
2745 6420
C601
6 5 2 1 REAR WIPER 1710
7000 A
4
1130 6010 HAZARD SWITCH
6520
2
C
SWITCH
TRAVEL CONTROL
WIPER HARNESS - 6730885
3 X L 1 3
1180 6430 7010 B 1720 LOCKOUT SWITCH
1 2 2 1 FRONT WIPER
2 4 3 7220
3 5 SWITCH
1 FRONT WIPER
4 5 4
6530 3
1730
2 M BOTTLE AND TANK
TO OPTIONS 5 2750 6 2 1
6
(EXTERIOR CAB) 6 4 1750 FRONT WIPER
5 4730
E 6700 2725 3 2715 MOTOR
3 4
D 2780 6 5 V
4
C670
7310
B 6540 5 M
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A C622
7200 or YEL
C608
7150 or DGN
2710 B
2765 or BRN
C 6300 1110 A L X
TO OPTIONS (AWS HORN/
BLINKER HARNESS) 2 1190
6410 D 1 2700
TO OPTIONS TO OPTIONS
2745
6510 A POWER 2790
C411
(FRONT WIPER) (DELUXE ACCESSORY)
PLUG
6000 B C C 7310
C F B 2735 2755 B B
C610
C667
E
C667
7210 A E 7160 C C
AWS SWITCH TO MAINFRAME 4710 D A 7210 A A
1
1770 4550 E 1760 E D
2 3 R 2735 B F
2755
5
4
4235 D WIPER HARNESS - 6729739
4275 C
6
K
G
B TO HORN
C488
2730 J CONNECTOR
6400
C412
L 2750 B
6500 M HORN RELAY 1730 A
1150 H
6300 N 85 86
2770 7200
6600 P 87
2750 30
TO EUR0. LIGHTS
CONNECTOR
4730
1140
F
A
Dealer Copy -- Not for Resale TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A 2760 ADDITIONAL POWER
CONNECTOR
C490
E 85 86 2740 B
1700 S 2780 6415
87
D 6410 6410 30 1740 A
C411
87A 6020
C
B 6000
TO AWS TO MAINFRAME
DELUXE ACCESSORY HARNESS - 6727190 A 6510
RIGHT BLINKER CONTROLS B C A
C489
2720 B
RELAY C497
1720 A
85 86
2790 6515
87
6510 30
87A 6010
TO ATTACHMENT
(BOOM
TO
MAINFRAME
AWS HORN/BLINKER HARNESS - 6726662
CONNECTOR) DOME LIGHT
TO OPTIONS SWITCH
A 9500 A
C608
B 9600 B A RED
C 9700 C B BLK
C666
C426
D 9800 D
1 1710 E
DOME LIGHT
AIR CONDITIONER SWITCH
2 1160 F
THERMOSTAT
3 2710 G 3100 A A
C630
C612
OFF A 7010 B B
BOOM HARNESS - 6718426 LOW B 2310 2205 C C
2100
MEDIUM TO OPTIONS (AC)
HIGH
TAILGATE HARNESS - 6716419
F HERE OR TO OPTIONS
SSL 7-PIN
C426 To Mainframe
2600 B
(HVAC JUMPER) HEATER VALVE
Harness RIGHT DBL A A 3200 1300 A A RED 10
CAN CONNECTOR D F C E A B G 2620 6200 6200
C613
WORKLIGHT H
C103
6210 6310 A
WHT B B 7200 D D WHT 8 M
C614
7000
LEFT
2630 6210 C BLK C C 2110 2130 C C BLK 7
WORKLIGHT E 1110
9800
1160
9700
1710
9500
9600
2710
POTENTIOMETER B B
D
RIGHT
2610 6320 B E E
TAILLIGHT G 1000
KEY "RUN" D 9800 C705 J1 - 8-PIN BACKUP 7100 C
F F
LEFT ALARM
UNSW POWER 2 1160 2720 H GROUND
TAILLIGHT
2640 6330 2650 L BLOWER MOTOR
5000 3 3 YEL
CAN SHIELD C 9710 9710 F CAN SHIELD M
1200 2 2 RED
C611
SW POWER 1 1730 1720 B SW POWER 2650 H M
1010 1 1 RNG
CAN LOW B 9620 9610 E CAN LOW 2640 2200 4 4 BLK
CAN HIGH A 9520 9510 D CAN HIGH BLOWER SWITCH POWER RELAY
2630 2600 5 5 TO OPTIONS
GROUND 3 2730 C OPEN (HVAC or DELUXE ACCESSORY)
2620 6 6 85 86
7-PIN A OPEN 1740 2210
C617 or
A
C666 ATTACHMENT 2610 87
C636
30
CONNECTOR G OPEN 87A 1190 B
J
BOOM-MOUNTED
HVAC HARNESS - 6725933 2740 C
N ACD CONNECTORS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
TO ENGINE OR MAINFRAME TO OPTIONS (HVAC)
F OUTPUT F 5350 5350 H F OUTPUT
C631
C612
G OUTPUT G 5400 5400 J G OUTPUT 7100 C B B 2310 2300 B
2650 F A A 7030 A
H OUTPUT H 5050 5050 B H OUTPUT
C103
C OUTPUT C 5300 5300 G C OUTPUT 6600 G
D OUTPUT D 5150 5150 D D OUTPUT BACK-UP
6400 E DIODE
AIR CONDITIONER
A OUTPUT A 5250 5250 F A OUTPUT ALARM 6310 A CLUTCH SOLENOID
M OUTPUT M 5200 5200 E B OUTPUT 6500 D
ID (K TO L) L 5910 5000 A J OUTPUT 6200 H
ID (K TO P) P 5510 5450 K K OUTPUT 2600 B
7020
7010
C506 14-PIN
C704
6340
ATTACHMENT J3 - 10-PIN GRAY
2620
2610
6610
6320
6620
6330
2640
CONNECTOR
5900 J ID #1 TO OPTIONS TO OPTIONS
5500 A ID #2 (HVAC) (DELUXE ACCESSORY)
B A
B ID #3
F E D C B A 2630 6210 C 2740 C
C636
C642
E F C A B D C632
C ID #4 B 1140 B
C604 C605 REGISTRATION LEFT WORK RIGHT WORK B A
D ID #0 A 1740 A
E F C A B D F E D C B A LAMP
E OPEN
HVAC/ACCESSORY AIR CONDITIONER
F OPEN
G OPEN
HARNESS - HARNESS -
H OPEN DELUXE EUROPEAN 6719630
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K 6725390 EVAPORATOR (AC)
OPEN
LEFT TAILLIGHT RIGHT TAILLIGHT
TAILLIGHT HARNESS - 6718198 PRESSURE SWITCH
V-0146 (4-30-04)
Printed in U.S.A.
398 of 772
ELECTRICAL SYSTEM INFORMATION
WIRING SCHEMATIC
A300 (S/N 521111001 - 521111550)
(PRINTED MAY 2004)
V-0145
WIRING SCHEMATIC
A300 (S/N 521111551 AND ABOVE)
(PRINTED MAY 2004)
V-0578
WIRING SCHEMATIC
A300 (S/N 521111001 AND ABOVE)
(PRINTED MAY 2004)
V-0153
WIRING SCHEMATIC
OPTIONS
A300 (S/N 521111001 AND ABOVE)
(PRINTED MAY 2004)
V-0146
A300 Bobcat Loader

399 of 772
A300 Bobcat Loader

400 of 772
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Troubleshooting WARNING
assistance in locating and correcting BICS system AVOID INJURY OR DEATH
problems. It is recommended that these procedures be Instructions are necessary before operating or
done by authorized Bobcat Service Personnel only. servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
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 the solenoid is damaged.
9. Check the fuses.
A300 Bobcat Loader

401 of 772
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Description
Figure 60-10-1
P-26235
The electrical system is also protected by fuses and

P-13848A relays under the fuse panel cover (Item 1) [Figure 60-10-
3] located in the cab on the steering control panel.
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by a

100 amp master fuse (Item 1) [Figure 60-10-1] to protect
against serious system overloads that could lead to
burned up harness or loader damage.
IMPORTANT
Do Not use silicone base sprays and/or sealants on
Figure 60-10-2
harness connectors or components.
I-2123-0397
Figure 60-10-4
1 1
P-24811
The fuse holder is located in the engine compartment

(Item 1) [Figure 60-10-2]. N-19661
The fuse panel cover (Item 1) [Figure 60-10-3] & [Figure

60-10-4] has a decal inside to show the location and amp
ratings.
A300 Bobcat Loader

402 of 772
ELECTRICAL SYSTEM INFORMATION (CONT’D) Remove the cover to check or replace the fuses.
Fuse Location The location and sizes are shown in [Figure 60-10-5] &
[Figure 60-10-6].
Figure 60-10-5
Ref Description Amp. Ref Description Amp.
F1 Heater 25 F9 Unswitched Attch. 25
F2 Front & Marker Lights 15 F10 Switched Attach. 25
F3 Rear Lights 15 F11 Alternator & Kits 25
F4 Bobcat Controller 25 F12 AHC Power 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
F8 Not Used --
Relay Switch Location
Remove the cover to check or replace the relays.
The location is shown in [Figure 60-10-5] & [Figure 60-

P-26239
10-6].
Ref Description Ref Description
B Switch Power F Glow Plugs
C Rear Lights G Fuel Shutoff
E D C B D Front & Marker Lights H Traction

E Not Used J Starter
Solenoid Test
Figure 60-10-7
F G H J
6718774
Figure 60-10-6
P9175

for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
N-19661
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A300 Bobcat Loader

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BATTERY Figure 60-20-2
WARNING
AVOID INJURY OR DEATH 1
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-31294
and wash eye with clean, cool water for at least 15
minutes.
Remove the battery holddown clamp (Item 1) [Figure 60-
If electrolyte is taken internally drink large quantities 20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Figure 60-20-3
W-2065-0807

Figure 60-20-1
1
1
P-31295
Disconnect the positive (+) cable (Item 1) [Figure 60-20-

P-31293 3] from the battery.
Open the rear door.
Disconnect the negative (-) cable (Item 1) [Figure 60-20-

1] from the battery.
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BATTERY (CONT’D) Always clean the terminals and cable ends when
installing a battery [Figure 60-20-5] & [Figure 60-20-6].
When installing the battery in the loader, do not touch any
Figure 60-20-4 metal parts with the battery terminals.
Connect and tighten the battery cables.
Figure 60-20-7
P-31296
Remove the battery from the loader [Figure 60-20-4].

P-31297

Figure 60-20-5
Connect the negative (-) cable (Item 1) [Figure 60-20-7]

last to prevent sparks.
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
P9589 Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
Figure 60-20-6
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-0705
P9590
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BATTERY (CONT’D) Figure 60-20-9
Servicing The Electrical System
WARNING

In case of eye contact get prompt medical attention P9590
minutes.
Clean the terminals and cable ends as shown in [Figure
If electrolyte is taken internally drink large quantities 60-20-8] & [Figure 60-20-9].
prompt medical attention. Figure 60-20-10
W-2065-0807

Figure 60-20-8
P9588
The battery cables must be clean and the connections

P9589 tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-10].
Check the electrolyte level in the battery. Add distilled

water as needed.
Put Battery Saver or grease on the battery terminals and

cable ends to prevent corrosion.
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BATTERY (CONT’D) Figure 60-20-11
Using A Booster Battery (Jump Starting)
WARNING 4


In case of eye contact get prompt medical attention P9618
minutes.
If electrolyte is taken internally drink large quantities

prompt medical attention. 3
W-2065-0807

WARNING
1
AVOID INJURY OR DEATH P9615
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Do not jump start or charge a frozen or damaged operator's seat and one person to connect and
battery. Warm battery to 60°F (16°C) before disconnect the battery cables.
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never The ignition must be in the OFF position. The booster
lean over battery while boosting, testing or charging. battery to be used must be 12 volt.
Battery gas can explode and cause serious injury. Connect the end of the first cable (Item 1) [Figure 60-20-
W-2066-0705 11] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-11] to the positive terminal on the starter.
Connect the end of the second cable (Item 3) [Figure 60-

20-11] to the negative (-) terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-11] to the engine frame.
Keep cables away from moving parts. Start the engine

(See Cold Temperature Starting Condition, Operation &
Maintenance Manual.)
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-11] first.
Remove the cable from the starter.
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ALTERNATOR The black cover has been removed to show alternator
rectifier / regulator assembly. The alternator contains field
Adjusting The Alternator Belt coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
Figure 60-30-1
60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] &
2 [Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] &
[Figure 60-30-3], and four pair of large power diodes
(Item 1) [Figure 60-30-3] on the underside of the rectifier.
Figure 60-30-3
4
1 1
3
P-26602
Stop the engine.
Raise the operator cab. (See Raising The Operator Cab 1 1

1

on Page 10-30-1.) 2 P-24542
Loosen the alternator adjustment bolts (Item 1) [Figure

60-30-1].
NOTE: The rectifier / regulator assembly has been
At the front side of the alternator, loosen the alternator removed from the alternator and flipped over
mounting bolt (Item 2) [Figure 60-30-1]. for component identification [Figure 60-30-3].
Move the alternator until the belt has 5/16 in. (8,0 mm)
movement at the middle of the belt span with 15 lb. (66
N) of force.
Tighten the adjustment bolts and mounting bolt.

Cab on Page 10-30-2.)
Alternator Identification
Figure 60-30-2
2
1
P-24416
4
1
3
P-24417
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ALTERNATOR (CONT’D) Figure 60-30-4
Charging System Check
WARNING
Batteries contain acid which burns eyes and skin on 2

In case of eye contact get prompt medical attention P-34325
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities Check the condition and tension of the alternator belt.
of water or milk! DO NOT induce vomiting. Get (See Adjusting The Alternator Belt on Page 60-30-1.) If
prompt medical attention. belt is worn or deteriorated replace.
W-2065-0807
Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
WARNING Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair / replace. If fuse is in
doubt, remove it and check for continuity.
Keep arcs, sparks flames and lighted tobacco away Check the electrolyte level in the battery. Add distilled
from batteries. When jumping from booster battery water as needed. (Does not apply to maintenance free
make final connection (negative) at machine frame. batteries.)
Verify the charge of the battery. Make sure battery is fully
Do not jump start or charge a frozen or damaged
charged.
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before Disconnect the battery cables (negative first, then
connecting or disconnecting cables to battery. Never positive). Inspect the cable clamps and battery posts for
lean over battery while boosting, testing or charging. corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
Battery gas can explode and cause serious injury. grease on the cable ends and battery terminals to
W-2066-0705 prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect a test light between the
negative battery post and the disconnected negative
cable clamp.
IMPORTANT 1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Below.)
Damage to the alternator can occur if:
• Engine is operated with battery cables 2. If the test light lights up, there is a short (drain) in the
disconnected. electrical system of the loader. The short must be
• Battery cables are connected when using a fast repaired before the charging system can be checked.
charger or when welding on the loader. (Remove 3. Disconnect the alternator B+ terminal (Item 1) [Figure
both cables from the battery.) 60-30-4] and L & S terminal connector (Item 2)
• Extra battery cables (booster cables) are [Figure 60-30-4] and if the test light goes out, the
connected wrong. alternator is faulty. If the test light stays on, find the
I-2023-1285
short in the system and repair it.
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ALTERNATOR (CONT’D) Low Voltage Test
Alternator Voltage Test Figure 60-30-6
Figure 60-30-5
P-34325
P-24560
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Open rear door.
Turn the remote start tool key to the ON position.

REMOTE START on Page 10-60-1.) Figure 60-30-7
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature). 1 P-24566
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5 2
volts, proceed with the following low voltage test.
P-24565
Check the voltage across the “L” terminal (Item 1)

[Figure 60-30-7] and ground (Item 2) [Figure 60-30-7].
The voltage should be what the battery voltage is. If not,
check wire harness, relay and fuses. If the wire harness,
relay and fuses are OK then remove alternator for
replacement or repair.
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ALTERNATOR (CONT’D)
High Voltage Test WARNING

Figure 60-30-8
1 the lift arms are secured by an approved lift arm
W-2059-0598
P-24568
2 IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
P-24569 P-24567 disconnected.
• Battery cables are connected when using a fast
Turn engine OFF and remove the L & S Terminal charger or when welding on the loader. (Remove
connector (Item 1) [Figure 60-30-6] off the alternator. both cables from the battery.)
• Extra battery cables (booster cables) are

Check the continuity between the “S” terminal (Item 1) connected wrong.
I-2023-1285
[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 Figure 60-30-9
harness.
If voltage is still above 14.7 volts at 70° F (Alternator

Temperature), then remove alternator for replacement or
repair. 1
2
DANGER
P-34325
Place jackstands under the rear corners of the loader.
P-90328
Page 10-20-1.)
AVOID DEATH
on Page 10-30-1.)
can cause lift arms to drop. Disconnect the negative (-) cable from the battery.
unless supported by an approved lift arm Disconnect the red wire (Item 1) [Figure 60-30-9] from
support. Replace if damaged. the alternator which comes from the battery.
D-1009-0409 Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator.
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ALTERNATOR (CONT’D) NOTE: In the diode tests there should be continuity
in one direction only. Meter readings should
Removal And Installation (Cont’d) be different when probes are reversed. If the
diode being tested shows no continuity or
Figure 60-30-10 continuity in both directions, replace the
rectifier assembly.
2
Figure 60-30-12
1 1
P-26602
Remove the adjustment bolts (Item 1) [Figure 60-30-10]

P-24532
from the mounting bracket.

Remove the alternator belt (Item 2) [Figure 60-30-10] NOTE: Use the diode function (Item 1) [Figure 60-30-
from the alternator pulley. 12] on the multimeter.
At the front of the alternator, remove the mounting bolt Figure 60-30-13
(Item 3) [Figure 60-30-10].
Remove the alternator from the loader.

1
Rectifier Continuity (Diode) Test
Figure 60-30-11
1
2
3
1
P-24527
1
Touch the probes to the terminals (Item 1) [Figure 60-30-
13] of each diode and read the meter.
1
Reverse the probes to check the diode in the other
P-24416 direction.
Meter readings should be different when probes are

Remove the two screws (Item 1), nut / washer (Item 2) reversed.
and the plastic cover (Item 3) [Figure 60-30-11] from the
alternator.
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ALTERNATOR (CONT’D) Figure 60-30-16
Rectifier Continuity (Diode) Test (Cont’d)
Figure 60-30-14
1
P-24535
Reverse the probes to check in the other direction

P-24558 [Figure 60-30-16].
There should be continuity in one direction only. Meter

Touch one probe to the diode (Item 1) [Figure 60-30-14] readings should be different when probes are reversed. If
and the other probe to each heat sink and read the meter. there is no continuity or continuity in both directions,

replace regulator.
Reverse the probes to check the diode in the other
direction.
Meter readings should be different when probes are

reversed.
Alternator Regulator Test
Figure 60-30-15
P-24533
Touch one probe to the “L” terminal (Item 1) [Figure 60-

30-15] and the other probe to the ground (Item 2) [Figure
60-30-15].
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ALTERNATOR (CONT’D) Stator Continuity Test
Disassembly Figure 60-30-18
Figure 60-30-17
1. Alternator 11. Bearing
2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1 6
P-24537
4 7 13 14
3
2 12 5 Use an ohmmeter to test the stator.
11 Touch the probes to two of the bare stator wires [Figure

10 60-30-18].

9
8 Move one of the probes to the third wire.
The readings should be the same.

19
18
If there is no continuity, replace the stator.
17 Stator Ground Test
16 Figure 60-30-19
15
C-3529B
Disassemble the alternator [Figure 60-30-17].
Remove the regulator cover.
Remove the four bolts holding halves together.
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley

nut.
Remove front case half from the rotor using a plastic P-24538
hammer or press.
Unsolder the stator leads from the rectifier. Remove the Touch one probe to a bare stator lead and the other
stator. probe to the bare metal surface of the stator [Figure 60-
30-19].
Unsolder the two leads between the rectifier and
regulator. Remove the regulator from rectifier. There should be no continuity.
Replace the stator if there is continuity.
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ALTERNATOR (CONT’D) Assembly
Rotor Continuity Test Figure 60-30-22
Figure 60-30-20
P-24557
P-24524
Reverse the order of disassembly.
Touch the probes to the slip rings [Figure 60-30-20]. Do not assemble the rear case half.

The ohmmeter should read between 3.0-4.0 ohms. Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-30-22]. Tighten to 72 ± 14.5 ft.-lb. (98
If there is no continuity replace the rotor. ± 20 N•m) torque.
Rotor Ground Test Install the rear case half and the remaining parts.
Figure 60-30-21
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-21].
There should be no continuity.
Replace the rotor if there is continuity.
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STARTER If the starter does not turn, the starter is defective.
Checking Removal And Installation
Bat
S
M
Cranking 1
Motor
A-1992 P-34326
The key switch must be in the OFF position. Open the rear door.

The battery must be at full charge. Disconnect the negative(-) cable from the battery.
The cable connections on the battery must be clean and Disconnect the wires and positive (+) cable (Item 1)
tight. [Figure 60-40-3] from the starter solenoid.
Connect a jumper wire between S terminal and BAT Installation: Tighten the nut to 18 - 24 ft. lb. (24,4 - 32,5
terminal [Figure 60-40-1]. N•m) torque.
If the starter turns but does not turn the engine, the Figure 60-40-4
starter drive has a defect.
Figure 60-40-2
Bat 2
S
M
1
Cranking
Motor
P-34328
A-1991 Disconnect the tan wire (Item 1) [Figure 60-40-4] from

the R terminal on the starter solenoid.
Connect a jumper wire (of at least 4 gauge in size) Disconnect the brown wire (Item 2) [Figure 60-40-4]
between the M terminal and the BAT terminal [Figure 60- from the S terminal on the starter solenoid.
40-2].
If the starter turns, the defect is in the solenoid.
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STARTER (CONT’D)
Figure 60-40-5
P-34327
Remove the three mounting bolts (Item 1) [Figure 60-40-

5].

Installation: Tighten the three mounting bolts to 25 - 28
Remove the starter from the engine.
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STARTER (CONT’D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
11 23. Seal
12. Seal 9
10 24. Yoke
31
32 7
21
15
14 19

16 20
17
19 18
5 8
14
6
29
1 4
3
28
2
27
35
25. Holder
26. Bracket
26 27. Ring
22
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
24 35. Boot
36. Bracket
B-16488
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STARTER (CONT’D) Figure 60-40-8
Figure 60-40-6
1
1
1
2
P-34596
Remove the bolts (Item 1) from the brush cover (Item 2)

P-34594 [Figure 60-40-8].
Remove the cover (Item 2) [Figure 60-40-8].

Remove the cable (Item 1) [Figure 60-40-6] from the
magnetic switch. Figure 60-40-9

Remove the bolts (Item 2) [Figure 60-40-6].
Installation: Tighten the bolts to 63 - 129 ft.-lb. (7,1 - 2

14,6 N•m) torque.
Figure 60-40-7
1
1 2
4
3
3
N-00980
Using a needle nose pliers, pull the brush springs (Item

1) back and remove the brushes (Item 2) [Figure 60-40-
9].
P-34595 NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
Remove the armature, yoke, brush holder and rear positive brushes).
bracket assemblies (Item 1) from the front assembly
(Item 2) [Figure 60-40-7]. Remove the brush holder (Item 3) [Figure 60-40-9] from
the end of the armature.
NOTE: When separating the parts there will be a steel
ball (Item 3) located at the end of the armature
shaft (Item 4) [Figure 60-40-7].
Installation: Apply grease to the steel ball (Item 3) and

install into the end of the armature shaft (Item 4) [Figure
60-40-7].
A300 Bobcat Loader

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1
Figure 60-40-10
2
3
2 P-34600
Inspect the magnetic switch (Item 1), the spring (Item

P-34598 2),and the plunger (Item 3) [Figure 60-40-12] for wear
Remove the armature (Item 1) [Figure 60-40-10] from Figure 60-40-13

the frame.

end of the armature.
Figure 60-40-11
3 2
1
P-34601
Remove the center bracket (Item 1) [Figure 60-40-13].
P-34599

magnetic switch.
Installation: Tighten bolts to 34 - 69 ft.-lb. (3,8 - 7,8 N•m)

torque.
Remove the front assembly (Item 2) from the magnetic

switch (Item 3) [Figure 60-40-11].
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Figure 60-40-14
1
3
2
2 2 4
P-34604
1 Remove the snap ring (Item 3) [Figure 60-40-15] &

P-34602 [Figure 60-40-16]
Remove the retainer (Item 2) [Figure 60-40-15] &

Remove the rubber retainer (Item 1) [Figure 60-40-14]. [Figure 60-40-16] and pinion (Item 1) [Figure 60-40-15]
& [Figure 60-40-16].

Remove the planetary gears (Item 2) [Figure 60-40-14]
and inspect for damage. Remove the spring (Item 4) [Figure 60-40-16].
Figure 60-40-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Press down on the pinion (Item 1) [Figure 60-40-15] &

[Figure 60-40-16] and retainer (Item 2) [Figure 60-40-
15] & [Figure 60-40-16].
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Inspection And Repair
Figure 60-40-17
N-00997
Armature Winding Continuity Test: Use a circuit tester,

B-14455 touch the probes to two commutator segments [Figure
60-40-19]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.

Figure 60-40-20
Inspect the pinion teeth for wear and damage.
Armature Short-Circuit Test: Use a growler tester, put the

armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-17]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-40-18
B-14458
Commutator Run-Out Test: check the commutator run-

out as shown in [Figure 60-40-20].
Service Limit - 0.002 in. (0,07 mm)
If the commutator exceeds the service limit, repair as

needed.
N-00996
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-18]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.
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Inspection And Repair (Cont'd)
Figure 60-40-21
N-00999
Check the field windings for wear and damage.

B-14460
Check all the connections for clean and tight solder
joints.
Measure the segment mica depth (Item 1) [Figure 60-40-
21]. Field Winding Ground Test: Use a circuit tester, touch

one probe to the field winding end of the brush and the
Service Limit - 0.012 in. (0,3 mm) other probe to the surface of the frame [Figure 60-40-
22]. There should be no continuity. If there is continuity,
If it is worn, replace the armature. the field windings are grounded.
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-23
N-15005
Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush
[Figure 60-40-23]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Replace the frame.
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Inspection And Repair (Cont'd)

1
Figure 60-40-24
2
P-34675
P-34674
Pull-In Test: Use circuit tester, touch one probe to the

N-15006 starter motor terminal (Item 1 and one probe to the S
terminal (Item 2) [Figure 60-40-26].
Inspect the brushes for wear and damage.

Replace the brush holder and yoke if the brushes need
replacement.
Check brush spring, for damage or rust. Replace as

needed.
Brush Holder Insulation Test: Use a circuit tester, touch

one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-40-24]. There
should be no continuity. If there is continuity, replace or
repair.
Figure 60-40-25
1
2
P-34673
Hold-In Test: Use circuit tester, touch one probe to the

mounting bolt (Item 1) and one probe to the S terminal
(Item 2) [Figure 60-40-25] on the magnetic switch.
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STARTER (CONT’D)
No Load Test
Figure 60-40-27
Ammeter
50
M.T.
Starter B-14440
The following test should be done after reassembling the

starter:

Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the terminal [Figure 60-40-27]. Connect the
negative wire to the starter body. Using a jumper wire,
connect the 50 terminal to the main terminal.
The starter should show smooth and steady rotation

immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit - 1470 Amp. at Stall Condition
Clean all parts and apply high temperature grease to the

armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
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INSTRUMENT PANEL
Left Panel Figure 60-50-1
The left instrument panel is the same for both Standard and the 2
Deluxe Instrument Panels [Figure 60-50-1].
1
3
The table below shows the DESCRIPTION and FUNCTION /
4 5 6 7 8
OPERATION for each of the components of the left panel.
Press and hold LIGHTS Button (Item 4) [Figure 60-50-1]

for two seconds to view SERVICE CODES in the
HOURMETER / CODE DISPLAY (Item 2) [Figure 60-50-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER / CODE DISPLAY.
13 10 11 12
* See ELECTRICAL SYSTEM Service Manual for further 9
description of
14
B-15551
◆ SHUTDOWN feature only in Deluxe Right Panel or
Factory Option with Standard Panel.
Ref. No Description Function / Operation

1 TEMPERATURE GAUGE Shows the engine coolant temperature.

2 HOURMETER / CODE DISPLAY / GLOW PLUG HOURMETER- Records operating hours of loader. CODE DISPLAY- Displays numeric
COUNTDOWN SERVICE CODES* relating to the loader monitoring system. COUNTDOWN- Glow Plug time
remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS- Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights.
Press a third time to turn all lights off. HOLD FOR CODES- Press and hold two seconds for
display of SERVICE CODES* [Figure 60-50-1]. (CODES* show only when there is an error
found by loader monitoring system).
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and
hold 2 seconds to view BASE or SHTDN (◆ SHUTDOWN) feature in HOURMETER / CODE
DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS

6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics.Press again to disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to
engage MAXIMUM FLOW. Press a third time to disengage all auxiliary hydraulics.[VARIABLE
FLOW allows for slow-to-fast movement of auxiliary functions (The farther you move the switch,
the faster the movement of the auxiliary functions.) MAXIMUM FLOW allows for only fast
movement.
8 AUXILIARY PRESSURE RELEASE Press and hold for two seconds.The engine will stop. Hydraulic pressure will be released in the
rear auxiliary (If so equipped) or right side front auxiliary circuit (If so equipped).
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

(See Troubleshooting Guide. on Page 60-110-3 for trouble shooting.)
9 PRESS TO OPERATE LOADER Press to activate BICS™ System when the Seat Bar is down and operator is seated in the
operating position.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is
pressed. The lift and tilt functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is
released. The loader can be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the
brakes. Allows you to use the control levers to move the loader forward or backward when using
the backhoe attachment or for the loader service.(See TRACTION LOCK on Page
60-130-1.). Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.
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INSTRUMENT PANEL (CONT’D) The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
Right Panel - (Standard) (With Key Switch)
The table below shows the Icons and other components
Figure 60-50-2 of the Right Standard Panel
15 17 19 21 23 25 27
* These functions are monitored and have SERVICE
CODES associated with them. (See DIAGNOSTICS
SERVICE CODES on Page 60-90-1.) for descriptions of
DIAGNOSTICS SERVICE CODES.
16 18 20 22 24 26 28
29
B-15552B
ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT

Advanced ON 3 Beeps * Error Error with Advanced Control System (ACS)
Control System
15
(ACS)
Attachment FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
16 Control
Device (ACD)
General ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning ON 3 Beeps * WARNING Engine speed high or in shutdown.
FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
18 NOT USED
Fuel ON 3 Beeps * Error Fuel level sender system fault.
19 Level FLASHING 3 Beeps * WARNING Fuel level low.
Glow ON --- - --- Glow plugs are energized.

20 Plugs FLAHSING 3 Beeps * Error Error with glow plugs
System Voltage ON 3 Beeps * WARNING Voltage low, high or very high.

21
Seat Belt ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure ON 3 Beeps * WARNING Engine oil level low.
FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Engine coolant sender out of range
25 Coolant ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter FLASHING 3 Beeps * WARNING Air filter switch not connected.
Hydraulic ON 3 Beeps * Error Hydraulic filter with high restriction.

Filter FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch - - - - Used to start and stop the engine.
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INSTRUMENT PANEL (CONT’D) Figure 60-50-3
Right Panel - (Deluxe) (With Keyless Start)
1.Display Panel: The Display Panel is where all system 1
setup, monitoring, troubleshooting, and error conditions 3
are displayed.
2
2.Function Icons: The lower left area of the Deluxe Panel

has the same Icons as the Standard Panel (See Right
Panel - (Standard) (With Key Switch) on Page 60-50-2.)
These Icons are only visible when the monitoring 4
system has detected an error.
3.Selection Buttons: The four Selection Buttons allow you

to select items from the Display Panel and scroll through 6 5 B-15553B
screens.
4.Keypad: The numeric keypad (Item 4) [Figure 60-50-3] Figure 60-50-4

has two functions:
(a)To enter a number code (password) to allow

starting the engine (Keyless Start).

(b)To enter a number as directed for further use of the
Display Panel.
The first screen you will see on your new loader will be as
shown in [Figure 60-50-4].
When this screen is on the display you can enter the

password and start the engine or change the Display
Panel setup features.
B-16656
NOTE: Your new loader (with Deluxe Instrument
Panel) will have a Owner Password. Your
dealer will provide you with this password. Figure 60-50-5
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See ELECTRICAL SYSTEM
SERVICE MANUAL.). Keep your password in a
safe place for future needs.
Start Engine: Use the Keypad to enter the numbers

(letters) of your password and press the RUN / ENTER
key (Item 5) [Figure 60-50-3].
Press and hold the START Button (Item 6) [Figure 60-

50-3] until the engine starts.
Change Language: Press the Selection Button at the end

of the arrow [Figure 60-50-4] to go to the next screen. B-16655
Use the Keypad to select the number of the language

[Figure 60-50-5].
Press EXIT. The screen will return to [Figure 60-50-4].

You can then enter the password and start the engine.
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INSTRUMENT PANEL (CONT’D)
Right Panel Set Up Display Options (Deluxe)
Icon Identification
ICON Description
Make selection by pressing SELECTION BUTTON LOCK / UNLOCK: Allows machine to
opposite the Icon. be locked. You must lock machine to
activate security system.
When system is unlocked, the user can
press RUN / ENTER then press START
to begin operation.
A valid password will need to be entered
at startup to run a locked machine.
TOOL / SETUP: Access system
options.
Use to set clock, check system warnings,
select language, set passwords, etc.
HELP: Access help on current menu
? item.
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or
lock job clock; TOOL / SETUP to set time.

0.0
UP ARROW: Goes backward one
screen. DOWN ARROW: Goes forward
one screen.
OUTLINE ARROWS: No screen avail-
able (backward / forward).
SELECTION ARROW: USE TO

SELECT MENU ITEM.
Goes to the NEXT screen series.

NEXT EXAMPLE: The next Active Warning
screen.
INFO Goes to more information about an
attachment.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.
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INSTRUMENT PANEL INDENTIFICATION (CONT’D)
Right Panel Setup Display Options (Deluxe) (Cont’d)

Deluxe Panel Setup
Press
TOOL/SETUP
Press
LOADER
FEATURES

Press
DISPAY
OPTIONS
Press
ADJUST
CONTRAST
Press
UP or Down
Arrow to
Change
Contrast
Press EXIT to
return to
previous level
menu .
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All new machines with Deluxe Instruments arrive at

Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.
Passwords
For security purposes, your dealer may change the

password and set it in the locked mode. Your dealer
will provide you with the password.
Enter Password on
Keypad
Owner Password: Allows for the full use of the loader
and to setup the Deluxe Panel. Owner can select a
password to allow starting & operating the loader and Press Enter to
modify the setup if the Deluxe Panel. Owner should Continue
change the password as soon as possible for security
of the loader.
Re-enter new
User Password: Allows starting and operating the password. Press
loader; cannot change password or any of the other Enter to Continue
setup features. (See left)

Changing the Password Right Instrument Pane
Display Screen
Press Enter to
Press
Continue
TOOL / SETUP
(See left)
Press More EXAMPLES:

PASSWORD Clocks
UTILITIES TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press RESET JOB CLOCK (Password required).
MODIFY OWNER Press CLEAR to reset job clock to zero.
or Press LOCK / UNLOCK to unlock.
MODIFY USER Enter Password and Press Run / Enter.
Languages
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER
Press EXIT to return to previous level menu.
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Vitals (Monitor engine, hydraulic / hydrostatic,

electrical functions when engine is running.)
TOOL / SETUP
LOADER FEATURES
VITALS
Press SELECTION ARROW to select METRIC
or ENGLISH (M/E) readouts
You can monitor real-time readouts of:

Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature
System Voltage
Engine Speed

The Display Panel is easy to use. Continue to set
your own preferences for running / monitoring your
Bobcat Loader.
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Option and Field Accessory Panels (If Equipped) Figure 60-50-7
Figure 60-50-6 SIDE ACCESSORY PANEL
SIDE ACCESSORY PANEL
7 8 9
N-22284B
1 2 3 4 5 6
N-22284A

Side Accessory Panel [Figure 60-50-6] and [Figure 60-50-7]
Ref. No. Description Function / Operation

1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED ---
3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for
wiper fluid). Press the bottom of the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of
the switch to provide washer fluid to clean the rear window.
5 NOT USED ---
6 NOT USED ---
7 FAN MOTOR Turn clockwise To increase fan speed; counterclockwise to decrease.
There are four positions: OFF -1 -2 -3.
8 AIR CONDITIONING Press the top of the switch to start; press the bottom to stop. (Fan
switch must be on for A/C to operate.)
9 TEMPERATURE CONTROL Turn clockwise to increase the temperature’ counterclockwise to
decrease.
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Option and Field Accessory Panels (If Equipped)

(Cont’d)
Figure 60-50-8
FRONT ACCESSORY PANEL
10 11 12 13 14 15 16 17
B-15891C
Front Accessory Panel [Figure 60-50-8]

Ref. No. Description Function / Operation
10 ALL WHEEL STEER / SKID- Press top of switch to select ALL WHEEL STEER; bottom for
STEER SELECTOR SKID-STEER
11 NOT USED ---
12 POWER BOB-TACH Press and hold the left side to disengage the Bob-Tach wedges.
Press and hold the right side to engage the wedges into the mounting
frame holes.
13 PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
14 TURN SIGNAL INDICATORS Indicates left or right TURN SINGALS are ON.
15 HAZARD LIGHTS Press the top of the switch to turn the HAZARD LIGHTS ON; press
the bottom of the switch to turn OFF.
16 ROTATING BEACON Press the top of the switch to turn the ROTATING BEACON ON;
press the bottom of the switch to turn OFF.
17 NOT USED ---
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Standard Panel Removal And Installation (Right Side)
Figure 60-50-9
1
1
N-20140
Ignition Switch Removal and Installation (Standard

N-18410 Panel)
Disconnect the key switch wiring harness (Item 1)

Remove the three mounting bolts (Item 1) [Figure 60-50- [Figure 60-50-11] from the back of the control panel.
9].

Figure 60-50-12
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-10
1
1
N-18410
Remove the ignition key (Item 1) from the switch.

Remove the ignition switch retaining nut (Item 2) [Figure
N-20158 60-50-12] from the switch.
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-10] from
the panel.
Remove the panel from the loader cab.
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Standard Panel Removal And Installation (Right Side)

(Cont’d)
Figure 60-50-13
N-20163
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-15] from
N-20141 the panel.
Remove the panel from the loader cab.

Ignition Switch Removal And Installation Standard Panel

(Cont'd) Figure 60-50-16
Remove the ignition switch (Item 1) [Figure 60-50-13]

from the control panel.
Deluxe Panel Removal And Installation (Right Side)
Figure 60-50-14
1
N-20142
1
NOTE: The instrument panel (Item 1) [Figure 60-50-
16] must be replaced as a complete unit.
N-20103

14].

panel mounting bolts to prevent stripping of the threaded
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Standard & Deluxe Panel Removal And Installation

(Left Side)
Figure 60-50-17
1
1
1
N-20144
Alarm Removal and Installation
N-18409 Remove the left side instrument panel.
Remove the retaining nut (Item 1) [Figure 60-50-19]

Remove the three mounting bolts (Item 1) [Figure 60-50- from the loader alarm.

17].
Remove the alarm from the loader instrument panel.
panel mounting bolts to prevent stripping of the threaded Bulb Removal And Installation
Figure 60-50-20
Figure 60-50-18
3
2
1
2
1
N-20145
N-20165
Remove the left side instrument panel. (See Standard &

Pull the left instrument panel down and disconnect the Deluxe Panel Removal And Installation (Left Side) on
wire harness connector (Item 1) [Figure 60-50-18] from Page 60-50-12.)
the loader alarm.
Remove the two light bulb covers (Item 1) [Figure 60-50-
Disconnect the wire harness connector (Item 2) [Figure 20] from the back of the instrument panel.
60-50-18] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-18]

is an optional accessory harness.
Remove the instrument panel from the loader.
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INSTRUMENT PANEL (CONT’D)
Standard & Deluxe Panel Removal And Installation

(Left Side) (Cont'd)
Figure 60-50-21
N-20146
With a flat blade screw driver, turn the light bulb

counterclockwise [Figure 60-50-21] and remove from
the panel.
Figure 60-50-22
N-20147
To install the bulbs, place them in the sockets and turn

clockwise [Figure 60-50-22].
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LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1
1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the

N-19348 socket.
Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative (-) cable from the battery. (See
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.
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LIGHTS (CONT”D)
Rear Removal And Installation
Figure 60-60-4
1
2
N-19655
Remove the bulb assembly (Items 1 & 2) from the light

housing (Item 3) [Figure 60-60-4] by turning bulb

assembly a 1/4 turn.
Figure 60-60-5
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
Reverse this procedure for installation.
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BOBCAT 2001 CONTROLLER Figure 60-70-2
WARNING
W-2059-0598
P-26165
Figure 60-70-1
Unplug the individual harness connectors from the

1 controller [Figure 60-70-2].
1
NOTE: The connectors are keyed and will only plug
in one way.

Figure 60-70-3
P-26164
Page 10-20-1.)

on Page 10-30-1.) P-26166
Remove the inside access panel (left side). (See Panel

Removal (Left) on Page 50-110-4.) Loosen the three controller mount bolts (Item 1) [Figure
60-70-3].
Remove the four connector mount bolts (Item 1) [Figure
60-70-1] from the harness connectors. Installation: Tighten the mounting bolts to 12 - 14 ft.-lb.
(16 - 19 N•m) torque.
Installation: Tighten the connector bolts to 30 - 35 in.-lb.
(3,39 - 3,96 N•m) torque.
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BOBCAT 2001 CONTROLLER (CONT'D)
Figure 60-70-4
TS-01941
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BOBCAT 2001 CONTROLLER (CONT'D)
Identification Chart (Cont'd)
Figure 60-70-5
J1 J2
BLACK 18 PIN CONNECTOR WHITE 18 PIN CONNECTOR
(ALL BLUE WIRES) (MOSTLY BLUE AND PURPLE WIRES)
3520
3500 OPEN
3400 9200
3600 9100 9210
3100
1900
OPEN 3900
O PEN
F E D C B A F E D C B A
1200
1 OPEN 1 3920
3010 2 OPEN 2
3 3
4640
OPEN
3300 2900 3910
3700
J1

3430
OPEN
3200
OPEN
9350 J2 9110
OPEN
9340 OPEN
3420 OPEN
OPEN
VIEWED FROM MATING END
X = NO CONNECTION VIEWED FROM MATING END
X = NO CONNECTION
J3 J4
BLACK 30 PIN CONNECTOR WHITE 30 PIN CONNECTOR
(MULTI COLOR WIRES) (MOSTLY GREEN WIRES)
6210 8250 4330 4300
OPEN 4340
OPEN 8210 4440 4940
8000 OPEN 4410 4930

7200 4920
OPEN 4460
2110 4820
K J H G F E D C B A 1110
K J H GF E D C B A 4910
9500 OPEN
1 1120 1 4810
9600 2 1130 OPEN 2 4500
3 3
9700 OPEN
2100 1400
OPEN 4450
4390
9800
J3 8150
8110 4800
4420
J4 9400
4830
8510 9410
4730 4110 4350 4840
6410 8550 4430 4320
6510 4150 4200 4310
6320 4360
VIEWED FROM MATING END VIEWED FROM MATING END

X = NO CONNECTION X = NO CONNECTION
V-0097
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AWS CONTROLLER Figure 60-71-2
Removal
Figure 60-71-1
1
P-26160
Press in on the connector release, (toward the connector

P-26158 [Figure 60-71-2] to release the connector.
Figure 60-71-3
WARNING

1
W-2059-0598
Page 10-20-1.) P-26159

on Page 10-30-1.) Loosen the three control mounting bolts (Item 1) [Figure
60-71-3] on the right side fender.
Remove the engine speed control. (See Removal on
Page 70-20-1.) Installation: Tighten the mounting bolts to 12 - 14 ft.-lb.
(16 - 19 N•m) torque.
Remove the inside access panel (right side). (See Panel
Removal (Right) on Page 50-110-1.) Lift and remove the controller from the fender.
Disconnect the four electrical connectors (Item 1) [Figure

60-71-1].
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AWS CONTROLLER (CONT’D) Figure 60-71-5
Removal (Cont’d)
Figure 60-71-4
A H
J2
J3
J4
J1 P-26886
Figure 60-71-6
P-26161
Remove the AWS controller [Figure 60-71-4].

J S
P-26885A
The wire location (Item 1) [Figure 60-71-5] & [Figure 60-

71-6], are printed on the individual wire connectors, in the
locations shown.
NOTE: The wire location letters (A,H,J,&S) have been

made larger to show there location on the
wiring connector. The actual letters on the
connectors are smaller.
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AWS CONTROLLER (CONT'D)
J1 J2

J4 J3
V-0103
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AWS CONTROLLER (CONT'D)
Identification Chart (Cont'd)
LEFT WHEEL LEFT WHEEL RIGHT WHEEL RIGHT WHEEL BUCKET BUCKET TILT LIFT
SPEED (1ST DIRECTION DIRECTION SPEED (1ST LEVEL LEVEL POSITION POSITION
INPUT) (2ND INPUT) (2ND INPUT) INPUT) ANALOG 1 ANALOG 2 FEEDBACK FEEDBACK
A B C D E F G H
3020 3080 3070 3000 OPEN OPEN 3050 3060
J1 RIGHT
JOYSTICK
RIGHT
JOYSTICK
LEFT
JOYSTICK Y
LEFT
JOYSTICK X
FRONT RIGHT FRONT LEFT REAR LEFT
WHEEL WHEEL WHEEL STEERING
Y AXIS X AXIS AXIS AXIS POSITION POSITION POSITION MODE SELECT
J K L M N P R S
4520 4510 4540 4530 3140 3040 3030 4950
FRONT
REAR LEFT FRONT LEFT BACKUP
LIFT SPOOL SENSOR STEERING RIGHT TILT SPOOL
SOL. SOL. ALARM
FORWARD SUPPLY PRESS. CNTRL SOL. REVERSE
EXTEND RETRACT
RETRACT
A B C D E F G H
1240 1590 4060 4160 4020 4040 7100 2170
REAR
J2

REAR LEFT REAR RIGHT RIGHT FRONT LEFT
FRONT RIGHT TILT SPOOL
LIFT SPOOL SOL. SOL. SOL. SOL.
GROUND SOL. EXTEND FORWARD
REVERSE RETRACT RETRACT EXTEND EXTEND
J K L M N P R S
2180 2260 4170 4070 4050 4010 4030 1230
RIGHT FWD RIGHT FORWARD BUCKET

RIGHT REV LOW LOW LEFT FWD HIGH HIGH SIDE LEVEL DIGITAL
SIDE OUTPUT SIDE OUTPUT SIDE OUTPUT OUTPUT 2
K J H G F
2690 2680 4110 4090 OPEN
J4 LEFT FWD LOW LEFT REV LOW LEFT REV HIGH RIGHT REV HIGH
REAR RIGHT
WHEEL POSITION
SIDE OUTPUT SIDE OUTPUT SIDE OUTPUT
SIDE OUTPUT
A
E D C B
3130
2660 2670 4270 4250
REAR LEFT REAR RIGHT UNSWITCHED

SWITCHED PRESSURE SOL. SOL. FRONT LEFT FRONT RIGHT
GROUND BATTERY IN (2)
BATTERY IN CNTRL RTRN RETURN RETURN SOL. RETURN
SOL. RETURN
S R P N M L K J
2250 1740 2870 2810 2970 2880 2980 1180
J3
BUCKET UNSWITCHED
SENSOR HIGH FLOW
HIGH FLOW LEVEL SENSOR BATTERY IN (1)
GROUND CAN LOW CAN HIGH
OUTPUT OUTPUT DIGITAL 1 SUPPLY
A B C D E F G H
2500 9620 9520 OPEN OPEN 3145 1500 1190
Connectors are Viewed From the Wire Side.
V-0111 (6-14-01)
V-0111
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SPEED SENSOR Figure 60-80-3
Testing
Figure 60-80-1
2
1
3
P-28307
Locate the speed sensor (Item 1) [Figure 60-80-3] on the

P-28302
left side hydrostatic motor carrier.
The tools listed will be needed to do the following Disconnect the speed sensor wire connector (Item 2)
procedure: from the loader harness wire connector (Item 3) [Figure
MEL1609-Wheel Speed Sensor Test Harness 60-80-3].

[Figure 60-80-1] Figure 60-80-4
Multimeter
1
Figure 60-80-2
P-28309
1
Connect the speed sensor test harness (Item 1) [Figure
60-80-4] in line, between the loader wiring harness and
P-28306
the speed sensor harness.
Raise the lift arms and install an approved lift arm support Turn the remote start key to ON position without starting
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab Take a voltage reading, with the multimeter, at the speed
on Page 10-30-1.) sensor test harness, between pin 1 and pin 3 (Item 1)
[Figure 60-80-4].
Connect the remote start tool to the loader. ((See
REMOTE START on Page 10-60-1.) The voltage should be between 5 volts.
Locate the speed sensor (Item 1) [Figure 60-80-2] on the Repeat the procedure for the opposite side speed
right side hydrostatic motor carrier. sensor. (If needed.)
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SPEED SENSOR (CONT'D) Figure 60-80-7
Removal
Figure 60-80-5 1
P-26290
2 Lift the speed sensor (Item 1) [Figure 60-80-7] out from

P-26288 the motor carrier.
Figure 60-80-8

Page 10-20-1.)

on Page 10-30-1.)
Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
P-26291
1
Remove the speed sensor [Figure 60-80-8].
P-26289
Disconnect the speed sensor electrical harness

connector (Item 1) [Figure 60-80-6].
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SPEED SENSOR (CONT'D) Figure 60-80-11
Removal (Cont'd)
Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
1
2
P-26295
Installation: The alignment pin (Item 1) at the bottom of

the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
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DIAGNOSTICS SERVICE CODES
Display
Figure 60-90-1

B-15551
Press and hold the LIGHTS Button (Item 1) for two

seconds to view SERVICE CODES in the HOURMETER
/ CODE DISPLAY (Item 2) [Figure 60-90-1]. If more than
one SERVICE CODE is present, the codes will scroll on
the HOURMETER / CODE DISPLAY.
NOTE: Corroded or loose grounds can cause

multiple service codes and/or abnormal
symptoms. All dash lights flashing, buzzer
going off, headlights and taillights flashing,
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.
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DIAGNOSTICS SERVICE CODES (CONT’D) The following word errors may be displayed.
Display (Cont’d) REPLY One or both instrument panel(s) not

communicating with the controller.
Figure 60-90-2
INPUT The controller not communicating with the left
1 instrument panel.
CODE The controller is asking for a password.

(Deluxe instrument panel only.)
ERROR The wrong password was entered. (Deluxe

instrument panel only.)
NOTE: The following troubleshooting procedures are

intended for active codes only - those
displayed on the hourmeter.
If a code is active (displayed) and the operator

keys OFF, then back ON and the code does
not reappear - ‘NONE’ displayed, we no longer
have an active code. This is referred to as an
intermittent fault.

In this situation the following troubleshooting
B-15551A procedures may be inaccurate.
The troubleshooting procedures can be

Figure 60-90-3 followed on intermittent codes, but the
harness and connectors should be inspected
1 carefully and moved back and forth during
voltage and continuity tests. It is not
recommended to replace the controller if the
code is not active (intermittent) and no other
causes for the error code are found.
Replacing the controller for active and
intermittent codes is a last effort in the
troubleshooting procedures only, when no
1
other problem can be found.
B-15551B
Service Codes may be either a word (Item 1) [Figure 60-

90-2] or a number (Item 1) [Figure 60-90-3]. (See the
following pages for the number codes and trouble
shooting trees.)
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DIAGNOSTICS SERVICE CODE (CONT’D)
NOTE: For Service Codes listed on Pages (60-90-3 - 60-90-6), See the Loader Electrical System Service Manual
for Troubleshooting Trees.
Number Codes List
CODE CODE
01-16 Air filter not connected 09-09 Fuel level low
01-17 Air filter plugged 09-21 Fuel level out of range high
09-22 Fuel level out of range low
02-16 Hydraulic charge filter not connected
02-17 Hydraulic charge filter plugged 11-05 Seat bar sensor short to battery
11-06 Seat bar sensor short to ground
03-09 Battery voltage low
03-10 Battery voltage high 12-21 Front auxiliary PWM switch out of range high
03-11 Battery voltage extremely high 12-22 Front auxiliary PWM switch out of range low
03-14 Battery voltage extremely low 12-23 Front auxiliary PWM switch not calibrated
03-22 Battery voltage out of range low
13-05 Fuel shut-off solenoid secondary short to battery
04-09 Engine oil pressure low 13-06 Fuel shot-off solenoid secondary short to ground
04-14 Engine oil pressure extremely low 13-07 Fuel shut-off solenoid secondary open circuit

04-15 Engine oil pressure shutdown level
04-21 Engine oil pressure out of range high 14-02 Fuel shut-off solenoid primary error ON
04-22 Engine oil pressure out of range low 14-03 Fuel shut-off solenoid primary error OFF
05-09 Hydraulic charge pressure low 15-02 Traction lock solenoid primary error ON
05-14 Hydraulic charge pressure extremely low 15-03 Traction lock solenoid primary error OFF
05-15 Hydraulic charge pressure shutdown level
05-21 Hydraulic charge pressure out of range high 16-05 Traction lock solenoid secondary short to battery
05-22 Hydraulic charge pressure of range low 16-06 Traction lock solenoid secondary short to ground
16-07 Traction lock solenoid secondary open circuit
06-10 Engine speed high
06-11 Engine speed extremely high 17-05 Hydraulic lock valve solenoid short to battery
06-13 Engine speed no signal 17-06 Hydraulic lock valve solenoid short to ground
06-15 Engine speed shutdown level 17-07 Hydraulic lock valve solenoid open circuit
06-18 Engine speed out of range
18-05 Spool lock solenoid short to battery
07-10 Hydraulic oil temperature high 18-06 Spool lock solenoid short to ground
07-11 Hydraulic oil temperature extremely high 18-07 Spool lock solenoid open circuit
07-15 Hydraulic oil temperature shut level
07-21 Hydraulic oil temperature out of range high 19-02 Bucket position solenoid error ON
07-22 Hydraulic oil temperature out of range low 19-03 Bucket position solenoid error OFF
08-10 Engine coolant temperature high 20-02 Two-speed solenoid error ON
08-11 Engine coolant temperature extremely high 20-03 Two-speed solenoid error OFF
08-15 Engine coolant temperature shutdown level

08-21 Engine coolant temperature out of range high 21-02 Glow plug error ON
08-22 Engine coolant temperature out of range low 21-03 Glow plugs error OFF
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Number Codes List (Cont’d)
CODE CODE
22-02 Starter output error ON 33-23 Constant data not calibrated
22-03 Starer output error OFF
34-04 Deluxe not downgraded in error
23-02 Rear base solenoid error ON
23-03 Rear base solenoid error OFF 36-48 ACD multiple controllers present
24-02 Rear rod solenoid error ON 37-02 Two-speed secondary error ON

24-03 Rear rod solenoid error OFF 37-03 Two-speed secondary error OFF
25-02 Rear auxiliary relief solenoid error ON 80-02 ACD output ‘A’ error ON
25-03 Rear auxiliary relief solenoid error Off 80-03 ACD output ‘A’ error Off
26-02 Front base solenoid error ON 81-02 ACD output ‘B’ error ON

26-03 Front base solenoid error OFF 81-03 ACD output’ B’ error OFF
27-02 Front rod solenoid error ON 82-02 ACD output ‘C’ error ON
27-03 Front rod solenoid error OFF 82-03 ACD output ‘C’ error OFF
28-02 Diverter solenoid error ON 83-02 ACD output ‘D’ error ON

28-03 Diverter solenoid error OFF 83-03 ACD output ‘D’ error OFF
29-02 High flow solenoid error ON 84-02 ACD output ‘E’ error ON
29-03 High flow solenoid error OFF 84-03 ACD output ‘E’ error OFF
30-28 Watchdog failure (internal)
31-28 Recovery mode failure (internal)
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Number Codes List (Cont’d)
CODE CODE
38-04 AWS controller in error 38-52 AWS back-up alarm error ON
38-05 AWS left joystick X axis not calibrated 38-53 AWS left forward drive solenoid error OFF
38-06 AWS right joystick X axis not calibrated 38-54 AWS left reverse drive solenoid error OFF
38-07 AWS left joystick Y axis not calibrated 38-55 AWS right forward drive solenoid error OFF
38-08 AWS right joystick Y axis not calibrated 38-56 AWS right reverse drive solenoid error OFF
38-09 Not Used 38-57 AWS front right extend steering solenoid error OFF
38-10 Not Used 38-58 AWS front right retract steering solenoid error OFF
38-11 AWS lift actuator not calibrated 38-59 AWS front left extend steering solenoid error OFF
38-12 AWS tilt actuator not calibrated 38-60 AWS front left retract steering solenoid error OFF
38-13 AWS lift actuator wiring fault 38-61 AWS rear right extend steering solenoid error OFF
38-14 AWS tilt actuator wiring fault 38-62 AWS rear right retract steering solenoid error OFF
38-15 AWS right wheel speed wiring fault 38-63 AWS rear left extend steering solenoid error OFF
38-16 AWS left wheel speed wiring fault 38-64 AWS rear left retract steering solenoid error OFF
38-17 AWS tilt actuator reduced performance 38-65 AWS steering pressure solenoid error OFF
38-18 AWS lift actuator reduced performance 38-66 AWS back-up alarm error OFF

38-19 AWS left joystick X axis out of range high 38-67 AWS CAN communication time out
38-20 AWS right joystick X axis out of range high 38-68 AWS wheel angles (alignment) not calibrated
38-21 AWS left joystick Y axis out of range high 38-69 AWS lift & tilt actuators calibration fault
38-22 AWS right joystick Y axis out of range high 38-70 AWS recovery mode failure
38-23 AWS front right steering sensor out of range high 38-71 AWS battery out of range
38-24 AWS front left steering sensor out of range high 38-72 AWS drive pump not calibrated
38-25 AWS rear right steering sensor out of range high 38-73 AWS steering mode switch flipped while operating
38-26 AWS rear left steering sensor out of range high 38-74 AWS uncommanded right wheel speed error ON
38-27 AWS lift actuator short to battery 38-75 AWS uncommanded left wheel speed error ON
38-28 AWS tilt actuator short to battery 38-76 AWS undercurrent-steer pressure solenoid
38-29 AWS left joystick X axis out of range low 38-77 AWS undercurrent-front right extend steer solenoid
38-30 AWS right joystick X axis out of range low 38-78 AWS undercurrent-front right retract steer solenoid
38-31 AWS left joystick Y axis out of range low 38-79 AWS undercurrent-front left extend steer solenoid
38-32 AWS left joystick Y axis out of range low 38-80 AWS undercurrent-front left retract steer solenoid
38-33 AWS front right steering sensor out of range low 38-81 AWS undercurrent-rear right extend steer solenoid
38-34 AWS front left steering sensor out of range low 38-82 AWS undercurrent-rear right retract steer solenoid
38-35 AWS rear right steering sensor out of range low 38-83 AWS undercurrent-rear left extend steer solenoid
38-36 AWS rear left steering sensor out of range low 38-84 AWS undercurrent-rear left retract steer solenoid
38-37 AWS 5 volt sensor supply 1 out of range low 38-85 AWS 5 Volt sensor supply 1 out of range high
38-38 AWS 5 Volt sensor supply 2 out of range low 38-86 AWS 5 Volt sensor supply 2 out of range high
38-39 AWS lift actuator short to ground 38-87 AWS front right steering error
38-40 AWS tilt actuator short to ground 38-88 AWS front left steering error
38-41 AWS tilt actuator wrong direction 38-89 AWS rear right steering error
38-42 AWS lift actuator wrong direction 38-90 AWS rear left steering error
38-43 AWS left forward drive solenoid error ON 38-91 AWS right speed sensor missing pulses
38-44 AWS left reverse drive solenoid error ON 38-92 AWS left speed sensor missing pulses
38-45 AWS right forward drive solenoid error ON 38-93 AWS unresponsive right speed sensor
38-46 AWS right reverse drive solenoid error ON 38-94 AWS unresponsive left speed sensor
38-47 AWS front right steering solenoid error ON 38-98 AWS controller in drive calibration mode
38-48 AWS front left steering solenoid error ON 38-99 AWS controller in wheel position calibration mode
38-49 AWS rear right steering solenoid error ON
38-50 AWS rear left steering solenoid error OFF
38-51 AWS steering pressure solenoid error ON
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NOTE: For Service Codes listed on Pages (60-90-3 - 60-90-6), See the Loader Electrical System Service Manual for
Troubleshooting Trees.
Number Codes List (Cont'd)
CODE CODE
39-04 Left smart grip in error 85-02 ACD output ‘F’ ON
85-03 ACD output ‘F’ OFF
40-04 Right smart grip in error
86-02 ACD output ‘G’ ON
44-02 Horn error ON 86-03 ACD output ‘G’ OFF
44-03 Horn error OFF
87-02 ACD output ‘H’ ON
45-02 Right blinker error ON 87-03 ACD output ‘H’ OFF
45-03 Right blinker error OFF
90-02 Service tool output ‘C’ error ON
46-02 Left blinker error ON 90-03 Service tool output ‘C’ error OFF
46-03 Left blinker error OFF
91-02 Service tool output ‘D’ error ON

47-21 8 volt reference out of range high 91-03 Service tool output ‘D’ error OFF
47-22 8 volt reference out of range low
92-02 Service tool output ‘E’ error ON
48-05 Front light output short to battery 92-03 Service tool output ‘E; error OFF
48-06 Front light output short to ground
93-02 Service tool output ‘F’ error ON
49-05 Rear light output short to battery 93-03 Service tool output ‘F’ error OFF
49-06 Rear light output short to ground
80-02 ACD output ‘A’ error ON

80-03 ACD output ‘A’ error OFF
81-02 ACD output ‘B’ error ON

81-03 ACD output ‘B’ error OFF
82-02 ACD output ‘C’ error ON

82-03 ACD output ‘C’ error OFF
83-02 ACD output ‘D’ error On

83-03 ACD output ‘D’ error OFF
84-02 ACD output ‘E’ error ON

84-03 ACD output ‘E’ error OFF
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STEERING SOLENOID Figure 60-100-3
Removal
Figure 60-100-1
1
1
3
4 2
P-26299
Remove the nut from the solenoid stem (Item 1) [Figure

60-100-3].
P-26297
Installation: Tighten to 60 - 84 in.-lb. (6,8 - 9,5 N•m)

Remove the control panel. (See Removal And Installation torque.
on Page 50-100-1.)

Figure 60-100-4
List of steering block and solenoid location [Figure 60-
100-1]:
1 Left Front Wheel

2 Left Rear Wheel
3 Right Front Wheel
4 Right Rear Wheel
Figure 60-100-2
P-26300
1
Mark the solenoids for proper installation [Figure 60-100-
4].
Remove the solenoids from the stem.
P-26298
Remove the two wiring connectors (Item 1) [Figure 60-

100-2] from the solenoids.
NOTE: The wiring harness have color sta-straps for

proper installation. If sta-straps are missing
mark the connectors for proper installation.
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STEERING SOLENOID (CONT'D) Figure 60-100-7
Removal (Cont'd) 1
Figure 60-100-5
1
2
P-26303
Check and replace the five O-rings (Item 1) and six back-
P-26301 up washers (Item 2) [Figure 60-100-7] on the solenoid
stem.
Check the solenoid O-rings (Item 1) [Figure 60-100-5].

Figure 60-100-6
P-26302
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BICS™ SYSTEM 2. Raise the Seat Bar fully. All four BICS™ lights (Items
1, 2, 3, & 4) [Figure 60-110-1] [PRESS TO
Inspecting The BICS™ Controller (Engine STOPPED - OPERATE LOADER, SEAT BAR, LIFT & TILT
Key ON) VALVE and TRACTION*] on left instrument panel
should be OFF [Figure 60-110-1].
NOTE: Record what lights are blinking (if any) and

WARNING number of light flashes. (See Troubleshooting
Guide. on Page 60-110-3.)
AVOID INJURY OR DEATH Inspecting Deactivation Of The Auxiliary Hydraulics

The Bobcat Interlock Control System (BICS) must System (Engine STOPPED - Key ON)
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT 3. Sit in the operator's seat, lower the Seat Bar, and
modify the system. press the PRESS TO OPERATE LOADER Button.
W-2151-0394 Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Figure 60-110-1 Seat Bar. The light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in the operator's seat, lower the seat bar, engage

the parking brake switch and fasten the seat belt.
5. Start the engine and operate at low idle. Press the

PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten the seat belt, disengage the parking brake

switch, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
joystick slowly forward and backward. The
TRACTION lock should be engaged. Lower the Seat
Bar. Press the PRESS TO OPERATE LOADER
Button.
7. Engage the parking switch pedal and move the
control joystick slowly forward and backward. The
TRACTION lock should be engaged.
NOTE: * The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
1 2 3 4 Button is pressed and the parking brake
switch is disengaged.
B-15551 8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
1. Sit in the operator's seat. Turn key ON (Standard Turn the lift arm bypass control knob clockwise 1/4
Panel), press RUN / ENTER Button (Deluxe Panel), turn. Pull up and hold the lift arm bypass control knob
lower the Seat Bar and disengage the parking brake until the lift arms slowly lower.
switch. Press the PRESS TO OPERATE LOADER
Button. Three BICS™ lights (Items 1, 2, & 3) [Figure
60-110-1] [PRESS TO OPERATE LOADER, SEAT
BAR, and LIFT & TILT VALVE] on left instrument
panel should be ON [Figure 60-110-1].
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BICS™ SYSTEM (CONT’D)

The following troubleshooting guide is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
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 guide. (See Troubleshooting Guide. on Page 60-110-3.)

2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.

4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
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BICS™ SYSTEM (CONT’D) The following chart shows the effects which can happen
to the loader, and the probable causes when the BICS™
Troubleshooting Guide. System lights are off or flashing and associated service
codes. (See DIAGNOSTICS SERVICE CODES on Page
60-90-1.) for service codes.
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms
Effect on can be caused by corroded or loose ground. Check
Operation grounds and both battery connections.
of Loader
Indicator When Light ERROR OFF = shorted to ground or bad fuse, faulty wir-
Light Light ON Light Off is OFF ing,
faulty open relay, no voltage from relay to controller.
1 ERROR ON = shorted to battery voltage, faulty wiring,
PRESS TO PRESS TO faulty closed relay.
Lift, tilt, and
OPERATE OPERATE
traction func-
LOADER LOADER *Normal BiCS™ operating voltage is less that the electri-
tions will not
Button is Button is not cal system voltage.
operate.
pressed. pressed. SERVICE CODE Means System Error
2 (See Your Bobcat Dealer for Service
No. of Service
Flashes Code Causes

Lift and tilt
Seat Bar is Seat Bar is Seat Bar sensor circuit shorted
functions will
down. up. 2 11-05 to battery voltage*.
not operate.
Seat Bar sensor circuit shorted
3 11-06 to ground.
3
Valve output circuit is open.
1 17-07
Lift, tilt and Valve output circuit shorted to
Control Control valve
traction func- 2 17-05 battery voltage*.
valve can cannot be
tions will not Valve output circuit shorted to
be used. used.
operate. 3 17-06 ground.
Controller not grounded or inter-
4 3 17-06 mittent ground.
Traction lock hold solenoid cir-
1 16-07 cuit is open.
Traction lock hold solenoid cir-
Loader can- 2 16-05 cuit shorted to battery voltage*.
Loader can Loader can-
not be Traction lock hold solenoid cir-
be moved not be moved
moved for- 3 16-06 cuit shorted to ground.
forward & forward and
ward and traction lock pull solenoid circuit
backward backward
backward. is shorted to battery voltage* -
5 15-02 ERROR ON (Should be OFF).
Traction low pull solenoid circuit
6 15-03 ERROR OFF (Should be ON).
2 3 4
Continuous 03-09 System voltage low.
SEAT BAR LIFT & TILT VALVE TRACTION
Flashing 03-10 System voltage high.
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SEAT BAR SENSOR

W-2004-1285
PROBLEM SOLUTION#
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor
controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.

5. Check magnet collar magnets for contamination such as metal particles.
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SEAT BAR SENSOR (CONT’D) Figure 60-120-3
Test
Figure 60-120-1
1
P-4698
The toggle switch (Item 2) [Figure 60-120-3] can be in

N-18463 either the Absent or Present position.
If there is no power light (Item 1) [Figure 60-120-3] on

Use Sensor Tester (MEL1428) and seat bar sensor tester the sensor tester, check the tester or wiring harness.
adapter (MEL1567) for the following procedure:

Figure 60-120-4
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-120-1].
1
Figure 60-120-2
1
P-4699
N-19557
Lower the seat bar. The Sensor Test light (Item 1)
[Figure 60-120-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
N-19558 60-120-4] should go off.
If the above test fails, there is a problem with the seat bar
Connect the Sensor Tester (Item 1) online, to the seat bar sensor.
sensor connectors. See inset [Figure 60-120-2].
Disconnect the Sensor Tester.
Turn the key to the ON position. DO NOT START THE
ENGINE. Replace the Seat Bar Sensor. (See Removal And
If the above test passes, run the seat bar sensor BICS™
circuit test. (See BICS™ Circuit Test on Page 60-120-4.)
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SEAT BAR SENSOR (CONT’D) Figure 60-120-7

2
Figure 60-120-5 1
3
N-19383
P-26615
IMPORTANT
Remove the seat bar (Item 1) [Figure 60-120-5] from the
loader. (See Removal And Installation on Page 50-10-1.) Be careful to not overtighten the sensor mounting

bolt and nut to prevent breakage of the sensor.
Figure 60-120-6 I-2088-1095
Remove the keyed plastic bushing (Item 1), magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)
[Figure 60-120-7].
3 Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [Figure 60-120-7]
of the seat bar
1
Inspect all parts for damage and wear and replace if
necessary.
Reverse the removal procedure to install the seat bar

sensor.
2
N-19219
Remove the mounting bolt (Item 1) from the seat bar

mount (Item 2) [Figure 60-120-6].
Installation: Tighten the mounting bolt to 50 - 70 in.-lb.

(5,6 - 7,9 N•m) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

120-6] and nut.
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SEAT BAR SENSOR (CONT’D) When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-120-9] on the sensor tester to
BICS™ Circuit Test the Present position.
Figure 60-120-8 NOTE: The sensor test light (Item 3) [Figure 60-120-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Figure 60-120-10
N-18463
1
Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL 1567) for the following procedure:

N-18409
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
The BICS™ seat bar indicator light (Item 1)[Figure 60-
Disconnect the seat bar sensor connector (Item 1) 120-10] should illuminate.
[Figure 60-120-8].
Figure 60-120-11
Figure 60-120-9
1
2
P-4699
P-4703
Move the toggle switch (Item 1) [Figure 60-120-11] on

Connect Sensor Tester (Item 1) [Figure 60-120-9] online the sensor tester to the Absent position.
to the seat bar sensor connectors.
The Seat Bar light (Item 1) [Figure 60-120-10] should go
Turn the key to the ON position. DO NOT START THE off.
ENGINE.
If the above test fails, there is a problem with the Bobcat
If there is no power light on the sensor tester, check the controller or the wiring harness.
tester or wiring harness.
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TRACTION LOCK

W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6
Intermittent activation of traction lock. 4, 5, 6,
1. Make sure brake switch is not engaged.

2. If all lights indicate the brake should be released, but it doesn’t check the brake 25 amp. fuse.
3. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of
fuse. (See Fuse Location on Page 60-10-5.)
4. Check wire connections for loose connector body.
5. Check for loose or bent pins in connectors

6. Check for loose spade connectors in fuse holder.
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TRACTION LOCK (CONT’D) Figure 60-130-2
Description Of The Control System
Figure 60-130-1
P9440
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the BICS™ System.
Inspecting The Control System

Fasten the seat belt, disengage the parking brake pedal,
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
2) should be engaged. Lower the Seat Bar. Press the
PRESS TO OPERATE LOADER Button (Item 3) [Figure
60-130-1].
1 2 3 4
Engage the parking brake switch and move the steering
levers slowly forward and backward. The TRACTION
B-15551 lock (Item 4) [Figure 60-130-1] should be engaged.
NOTE: * The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.
Check the wire connections at the engine speed sensor

(Item 1) [Figure 60-130-2].
NOTE: When the Traction Lock Override Button is

activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if
the engine stops.
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WHEEL POSITION SENSORS Figure 60-140-3
Operation
Figure 60-140-1 1
3
2
P-24825
B-15552
1
Figure 60-140-4
P-24924

and remove the wheel position sensor / steering cylinder

Figure 60-140-2 3
1 2
Cover Removed
B-15551M
B-15551N
1 The Icon light in the right instrument panel (Item 1)

[Figure 60-140-3] will be ON, an alarm (Item 1) [Figure
60-140-4] will sound with three (3) beeps, and an
ERROR CODE will appear in the hourmeter display (Item
2) [Figure 60-140-4] (left instrument panel).
P-24925
NOTE: All Wheel Steer light (Item 3) [Figure 60-140-3]
will be ON, but the loader will ONLY OPERATE
There is a sensor on each wheel, located inside each IN SKID STEER MODE until the sensor
axle tube (Item 1) [Figure 60-140-2], to monitor wheel problem is corrected.
position. The sensors are associated with the selected
steering mode (Skid Steer, All Wheel Steer). If there is an Stop the engine and restart. Select Skid Steer Mode
electrical interruption to the wheel position sensor(s) or (Item 2) [Figure 60-140-3]. Press the PRESS TO
other system problem, the affected wheel(s) will stay in OPERATE button (Item 3) [Figure 60-140-4]. Move the
the same position it was in when the problem occurred. left joystick to the left or right and all wheels except the
one(s) affected will align straight ahead and you can
NOTE: If the wheels are in a turned position when the operate in Skid Steer Mode for a 30-second period to
problem occurs, all wheels will STOP. move the loader to a service area. Repeat, if necessary,
to operate for another 30-second period.
Perform the Wheel Alignment procedure, (See Wheel

Alignment (Field Adjustment) on Page 60-140-6.) before
operating the loader again.
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WHEEL POSITION SENSORS (CONT’D) This indicates that the wheel has now been manually
“Aligned".
Wheel Alignment (Failed Sensor)
• If the four BICS™ lights are ON, the wheels have
Figure 60-140-5 been aligned and you can now operate the loader in
Skid Steer Mode only.
• If the four BICS™ lights are NOT ON, then there will
be another alarm sound and an Alignment Code in the
hourmeter display. Continue aligning the wheels until
all four wheels are corrected.
You can continue to use the loader in Skid Steer Mode

1 only, but each time the engine is stopped, the wheels
may need to be aligned again to resume operation. See
3 your Bobcat dealer to get the sensor corrected as soon
2
as possible. Do not continue to repeat the alignment
procedure and operate with an ERROR CODE.
B-15551N
Wheel alignment is necessary to allow the machine to be

operated in skid Steer Mode only to load onto a transport

vehicle for service or to finish the work shift.
Aligning the wheels:
• Sit in the operator's seat with the seat bar down. Start
the engine and press the PRESS TO OPERATE
LOADER and TRACTION LOCK OVERRIDE buttons
(Items 1 & 2) [Figure 60-140-5] at the same time.
You will hear the alarm sound once and one or more of
the following Alignment Codes will appear in the
hourmeter display (Item 3) [Figure 60-140-5]. Use the
code to locate the wheel that is out of alignment.
Alignment Codes:
FL (Front Left Wheel)

FR (Front Right Wheel)
rL (Rear Left Wheel)
rr (Rear Right Wheel)
• When the Alignment Code appears, move the left

joystick to the left or right to align the disabled wheel.
• When the wheel is aligned straight ahead, press the

PRESS TO OPERATE LOADER button (Item 1)
[Figure 60-140-5]. The hourmeter display (Item 3)
[Figure 60-140-5] will now show the corresponding
Alignment Code with the letter “A“behind it: FL-A, Fr-
A, rL-A, rr-A
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WHEEL POSITION SENSORS (CONT'D) Remove the two mount bolts (Item 1) [Figure 60-140-7]
Testing cover from the loader.
Figure 60-140-6 Figure 60-140-8
P-28303 P-24925
The tools listed will be needed to do the following Disconnect the wheel position sensor wire connector
procedure: (Item 1) [Figure 60-140-8] from the loader harness.

MEL1603-Wheel Angle Sensor Test Harness [Figure 60- Figure 60-140-9
140-6].

Multimeter
2
Figure 60-140-7 1
P-28304
Connect one end of the test harness to the loader

harness (Item 1) [Figure 60-140-9].
1
Connect the other end of the test harness to the wheel
P-24924 position sensor wiring harness (Item 2) [Figure 60-140-
9].
Raise the lift arms and install an approved lift arm support Turn the remote start key to ON position without starting
Page 10-20-1.)

on Page 10-30-1.)
Connect the Remote Start Tool to the loader. (See

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WHEEL POSITION SENSORS (CONT'D) Figure 60-140-12
Testing (Cont'd)
Figure 60-140-10
P-28238
Disconnect the wheel sensor wire connector (Item 1)

P-28305 [Figure 60-140-12] from the loader wiring harness.
Figure 60-140-13
With a multimeter,) do a voltage check on pins 2 (Item 1)
and pins 3 (Item 2) [Figure 60-140-10] of the test

harness.
The voltage should be 5 volts. 1
(See DIAGNOSTICS SERVICE CODES on Page 60-90-

1.) for the diagnostics codes that apply to the four wheel
position sensors.
Sensor Removal And Installation
Figure 60-140-11
P-24926
With a needle nose plier, remove the wedge (Item 1)

[Figure 60-140-13] from the wheel sensor wire
1 connector.
P-28239
Remove the loader hub. (See Removal on Page 40-50-

1.)

cover form the loader.
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WHEEL POSITION SENSORS (CONT’D) Figure 60-140-16
Sensor Removal And Installation (Cont'd)
Figure 60-140-14
P-34482

P-24927 16] from the wheel sensor.
Installation: Tighten mounting bolts to 25 - 30 in.-lb.

With a pointed screw driver lightly press in on the tabs (2,85 - 3,39 N•m) torque.
and remove the individual wires from the connector

[Figure 60-140-14]. Figure 60-140-17
Installation:
Number of Connector Wire Color

1 Red 1
2 Black
3 Blue
Figure 60-140-15
P-34483
1
Lift the wheel sensor up and lightly pull on the sensor
while pushing the wires (Item 1) [Figure 60-140-17] thru
the face of the casting.
Remove the wheel position sensor from the loader.
P-24928
Remove the wire retainer (Item 1) [Figure 60-140-15]

from the wires.
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Wheel Alignment (Field Adjustment)
Figure 60-140-18
P-28612
Press the Diagnose / Calibrate button (Item 1) [Figure

P-28612 60-140-19].
Figure 60-140-20
procedure:

MEL1563 - Remote Start Tool
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software)
Straight Edge 6 ft. long
NOTE: This procedure must be performed with two

people.

REMOTE START on Page 10-60-1.) P-28608
Connect the Service PC to the Remote Start Tool. (See

Connecting The Service PC To Remote Start Tool on The Diagnostics Screen [Figure 60-140-20] will be
Page 60-150-1.) displayed.
Enter the Bobcat Service Analyzer screen [Figure 60-

140-18].
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Wheel Alignment (Field Adjustment) (Cont’d)
Figure 60-140-21
1
P-24825
The AWS switch and the position of the left joystick

P-28608 determine the side of the loader and the wheel that is
to be aligned.
With one person in the operator cab, the second person With the AWS switch (Item 1) [Figure 60-140-23] in the
start the loader, using the Remote Start Tool. AWS Mode, the left front wheel and left rear wheel can be

aligned.
NOTE: If at any time during the procedure, the power
to the loader is turned OFF before the wheels Figure 60-140-24
are aligned, the complete procedure must be
repeated to insure correct alignment of the
wheels.
Click the Enter Align Mode button (Item 1) [Figure 60-

140-21] on the Service Analyzer Screen.
Figure 60-140-22
P-26474
Move the left joystick [Figure 60-140-24] forward and

backward to align the left rear wheel.
1
P-28609
The bottom of the Service Analyzer Screen (Item 1)

[Figure 60-140-22] will display AWS Controller Ready
For Programing.
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Wheel Alignment (Field Adjustment) (Cont'd)
Figure 60-140-25
P-26474
Move the left joystick [Figure 60-140-27] forward and

P-26474 backward to align the right rear wheel.
Figure 60-140-28
Move the left joystick [Figure 60-140-25] from side to
side to align the left front wheel.

Figure 60-140-26
1 P-26474
Move the left joystick [Figure 60-140-28] from side to

P-24825 side to align the right front wheel.
Press the AWS switch (Item 1) [Figure 60-140-26] into

the Skid Mode, the right front wheel and right rear wheel
can be aligned.
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Figure 60-140-29
P-28586
Place a straight edge along both tires as shown in

P-28584 [Figure 60-140-30].
Use the left joystick to move the position of the wheel

Place a straight edge along both tires as shown in (front or rear) until aligned.
[Figure 60-140-29].

NOTE: Allow the joystick to go to neutral before
Use the AWS switch to select the left or right side. pushing the Set Alignment button.
Use the left joystick to move the position of the wheel Figure 60-140-31
(front or rear) to be aligned.
Move the position of the tires.
Alternate between the front and the rear tires, on the

same side, until they are aligned with the straight edge
[Figure 60-140-29].
If one or both wheels need to be aligned on the opposite

side, move the AWS switch.
P-28610
Have the person with the Service Analyzer (Lap Top

Computer) click the Set Alignment button (Item 1)
[Figure 60-140-31] on the Service Analyzer Screen.
NOTE: When the Set Alignment button is pushed, all

four wheel positions are recorded at the same
time. All four wheels must be checked to be
straight before the Set Alignment button is
pushed to ensure proper alignment.
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WHEEL POSITION SENSORS (CONT'D) The tools listed will be needed to do the following
procedure:
Figure 60-140-32 MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software)
Straight Edge 6ft. Long

10-10-1.)
Remove the four wheel / tire assemblies from the loader.

(See TIRE MAINTENANCE on Page 10-170-1.)
Remove the four steering cylinder pins at the hub. (See

1 Disassembly on Page 40-50-7.)

P-28611 REMOTE START on Page 10-60-1.)
Connect the Service PC to the Remote Start Tool. (See

The Screen will display Wheel Alignment Successful Connecting The Service PC To Remote Start Tool on
(Item 1) [Figure 60-140-32]. Page 60-150-1.)

The procedure is completed for both sides of the loader. Turn the Remote Start Tool key to the ON position without
starting the loader.
Shut loader Off.
NOTE: If at any time during the procedure, the power
Remove the Service Analyzer and Remote Start Tool. to the loader is turned OFF before the wheels
are aligned, the complete procedure must be
Wheel Alignment (Calibration) repeated to insure correct alignment of the
wheels.
Figure 60-140-33
Enter the Bobcat Service Analyzer screen [Figure 60-
140-33] on the Service PC.
Figure 60-140-34
P-28612
NOTE: A calibration procedure must be followed

when replacing a wheel position sensor, or
P-28612
AWS controller. Failure to calibrate after
component replacement may result in poor
performance. Press the Diagnose / Calibrate button (Item 1) [Figure
60-140-34].
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Wheel Alignment (Calibration) (Cont'd)
Figure 60-140-35
P-28609
The bottom of the Service Analyzer Screen (Item 1)

P-28608 [Figure 60-140-37] will display AWS Controller Ready
For Programing.
The Diagnostics Screen [Figure 60-140-35] will be Figure 60-140-38

displayed.

Figure 60-140-36
P-28588
P-28608 NOTE: When the Set Alignment button is pushed, all

four wheel positions are recorded at the same
time. All four wheels must be checked to be
Click the Enter Align Mode button (Item 1) [Figure 60- straight before the Set Alignment button is
140-36] on the Service Analyzer Screen. pushed to assure proper alignment.
Place a straight edge along both hubs as shown in

[Figure 60-140-38].
Use the straight edge as a reference to ensure that the

two wheel hubs are “In Line” with each other.
NOTE: The straight edge must contact the whole

surface of each hub.
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Figure 60-140-39
P-28611
The Screen will display Wheel Alignment Successful

P-28589 [Figure 60-140-41].
The procedure is competed.

Move to the other side of the loader and place a straight
edge along both hubs, and place them in alignment Install the steering cylinder pins in the hubs of the loader.

[Figure 60-140-39].
NOTE: When the steering cylinder pins are
Figure 60-140-40 reinstalled in the hub, the wheels may be out
of alignment. This will be corrected as soon
as the loader is started, the Press To Operate
button is pushed, and the Left Joystick is
moved.
Remove the Service Analyzer and Remote Start Tool.
P-28610
Click the Set Alignment button (Item 1) [Figure 60-140-

40] on the Service Analyzer Screen.
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WHEEL POSITION SENSORS (CONT'D)
Figure 60-140-42
P-26477
With an operator in the cab, seat bar down, start the

loader and press the Press To Operate button (Item 1)

[Figure 60-140-42].
Move the left joystick and the four wheels will move into
alignment.
Shut loader off.
Remove the loader from jackstands.
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SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
Figure 60-150-1
1 2
P16119
Tools that will be needed to complete the following steps

are:

MEL1565 - Service Tool Harness Control
MEL1566 -Service Tool Harness Communicator
(Computer Interface)
NOTE: Make all connections with the key in the OFF

position.
The Service PC (Item 1) with the remote start tool (Item

2) [Figure 60-150-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostic and
load software.
Connect the Service Tool Harness Communicator

(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC.
NOTE: The recommended serial cable length should

not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the remote

start tool.

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LIFT AND TILT ACTUATOR CALIBRATION Figure 60-160-2
Procedure
Figure 60-160-1
P-26475
Figure 60-160-3
P-28063
NOTE: This calibration procedure must be followed

when replacing the lift or tilt actuator or AWS

controller. 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.
Move the right joystick to the full forward position and 1

toward the side screen [Figure 60-160-1] and hold in
position.
P-26480
Turn the key (Item 1) [Figure 60-160-2] to the RUN

position or press the RUN / ENTER button (Item 1)
[Figure 60-160-3] for power, without starting the loader.
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LIFT AND TILT ACTUATOR CALIBRATION (CONT’D)
Figure 60-160-4
1
P-26477A
At the left panel, press the PRESS TO OPERATE Button

(Item 1) [Figure 60-160-4].

Release the joystick.
An audible beep will sound and an error code (Item 2)

[Figure 60-160-4] (38-06 & 38-08) will be displayed if the
operator presses the PRESS FOR CODES, (LIGHTS)
switch.
The AWS controller will cycle the actuators.
The calibration is complete.
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ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
RIGHT HAND
17 18
2 1
8
10 1. Front Aux.
2. Front Aux.
3. Auxiliary Detent
11 8. Right Ski (Up) 3
9
9. Right Ski (Down)
16 10. Right Blink
11. Left Blink

16. Float (Yellow in Color)
17. Future Function
P-24802
18. Future Function
P-28316
LEFT HAND
19 20
4 5
4. Rear Aux. (Side Shift
5. Rear Aux. (Side Shift)
12
6. Left Skit (Up)
6 7. Left Ski (Down)
12. Two-Speed (High)
13. Two-Speed (Low)
13 7
14. Horn
15. Inching Control
14
15 (Grey in Color)
19. Future Function
20. Future Function
P-24820
P-28317
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ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (CONT’D)
Controls Identification Chart (Cont’d)
xxxxxxxxx Attachment Right Side

Left Side
Control Handle Switch Solenoid Number Activated Harness Control Handle
Switches Number Terminal Switches
Activated
STD RH HFH HRH 8
1 1 1 1, 6 1, 6 K
5 2 2 2 2 2 K
4 6
3 1 1 1, 6 1, 6 K 9
1
4 2 3, 5 2 3, 5 K, A, D 2
5 1 3, 4 1 3, 4 K, A, C
7 6 1 3, 4 1 3, 4 K, E
7 1 3, 4 1 3, 4 K, F
8 1 3, 4 1 3, 4 K, G
3
9 1 3, 4 1 3, 4 K, H
Attachment Harness Connector

Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader. 1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.

HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
HRH - Loaders with High Flow and Rear Hydraulics Option.
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ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (CONT’D)
Controls Identification Chart (Cont’d)
Figure 60-170-1
STANDARD FLOW (EARLY) STANDARD FLOW (EARLY)
SOLENOID Hydraulic Coupler Wiring

NUMBER Number
1 4 A
1 Front Female (Rod) 4330
2 3
3 Front Male (Base) 4340
0 2
0 Diverter 4450
3 (TOP)
Bleed - Rear 4480
4 (BOTTOM)
Male & Female
STANDARD FLOW (LATER)

STANDARD FLOW
STANDARD FLOW (LATER)
(LATER)
9 8
SOLENOID Hydraulic Coupler Wiring
A NUMBER Number
2 1 A
14 7 3 1 Front Female (Base) 4340
2 3 0

6 0 0 2 Front Male (Rod) 4330
3
5 0
Diverter & Bleed 4450/
5 3
3 4480
4 Rear Aux. Base 4440
MC-2314A
5 Rear Aux. Rod 4430
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 4 on the Standard Flow Loader
(diverter valve), or solenoid 9 on the High Flow Loader (select valve). It will also shut down the loader, and
bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so equipped.)
The Hi-Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 8 on
the select valve.
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ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .70-40-1
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Blower Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-5
Drive Tension Pulley Removal And Installation . . . . . . . . . . . . . . . 70-60-1
Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-12
Gearbox/Blower Housing Removal And Installation . . . . . . . . . . . 70-60-2
Gearbox, Checking Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-17
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE COMPONENTS AND TESTS. . . . . . . . . . . . . . . . . . . . . . . .70-70-1

Engine Compression, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-1
Fuel Shut-Off Solenoid Checking. . . . . . . . . . . . . . . . . . . . . . . . . .70-70-4

Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . . .70-70-5
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-8
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-7
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-13
Fuel Injector, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11 ENGINE
Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11 SERVICE
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-70-10
Glow Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Thermostat, Oil Pressure Control Valves & Heater Connections.70-70-30
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Timing Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Timing Belt, Replacement In The Loader . . . . . . . . . . . . . . . . . .70-70-21
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-27
Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-28
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1
Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-4
FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . . 70-90-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
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ENGINE SERVICE (CONT’D)
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-50-1
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-6
Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-22
Camshaft Bearing, Removal And Installation. . . . . . . . . . . . . . .70-100-23
Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-33
Control Rod Guide Bushing Installation . . . . . . . . . . . . . . . . . . .70-100-26
Control Rod Guide Bushing Removal . . . . . . . . . . . . . . . . . . . .70-100-24
Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-31
Crankshaft Gear Mounting Bolt Torque Procedure . . . . . . . . . .70-100-61
Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-22
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-42
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-40
Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . . . . . . .70-100-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-2
Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-49
Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-44
Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-35
Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-36
Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-37
Piston Installation On The Connecting Rod . . . . . . . . . . . . . . . .70-100-38
Rear Cover Seal Removal And Installation . . . . . . . . . . . . . . . .70-100-30
Rocker Arm And Bracket, Checking . . . . . . . . . . . . . . . . . . . . .70-100-43
Turbo Charger Removal and Installation . . . . . . . . . . . . . . . . . .70-100-59
Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-40
Valve Seats, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-41
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
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TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 3, 7, 8, 9, 11, 12,13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power to engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
Engine is mis-firing. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
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, 47, 46
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 48
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
Vibration. 2, 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, 32, 40, 44, 47
Too much crankcase pressure. 22, 27, 29, 46
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
Start and stop. 9, 10, 11
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TROUBLESHOOTING (CONT’D)
Chart (Cont’d)

1. Battery capacity low. 26. Incorrect high pressure fuel pipes.
2. Bad electrical connection. 27. Worn cylinder bores.
3. Faulty starter motor. 28. Worn valve and seats.
4. Incorrect grade of oil. 29. Broken, worn, or sticking piston rings.
5. Low cranking oil. 30. Worn valve stems or guides.
6. Fuel tank empty. 31. Worn or damaged bearings.
7. Faulty stop control operation. 32. Not enough oil in the oil pan.
8. Plugged fuel line. 33. Switch / sensor in defective.
9. Plugged fuel filter. 34. Oil pump worn.
10. Restriction in air cleaner. 35. Pressure relief valve is sticking open.
11. Air in the fuel system. 36. Pressure relief valve is sticking closed.
12. Faulty fuel injection pump. 37. Broken relief valve spring.
13. Faulty fuel injectors. 38. Faulty suction pipe.
14. Broken injection pump drive. 39. Plugged oil filter.
15. Incorrect injection pump timing. 40. Piston seizure.
16. Incorrect valve timing. 41. Incorrect piston height.

17. Poor compression. 42. Faulty engine mounting.
18. Plugged fuel tank vent. 43. Incorrect alignment of flywheel.
19. Incorrect grade of fuel. 44. Faulty thermostat.
20. Exhaust pipe restriction. 45. Plugged oil cooler.
21. Cylinder head gasket leaking. 46. Plugged PCV System.
22. Overheating. 47. Damaged valve stem oil deflectors.
23. Cold running. 48. Plugged oil pump pipe strainer.
24. Incorrect tappet adjustment. 49. Broken valve spring.
25. Sticking valves.
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ENGINE SPEED CONTROL Figure 70-20-3
Removal
Figure 70-20-1
1 1
P-34546
Disconnect the foot speed control linkage (Item 1)

P-34544 [Figure 70-20-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

device. (See Installing The Lift Arm Support Device on Figure 70-20-4

Page 10-20-1.)

on Page 10-30-1.)

1], from the right side foot rest.
Remove the foot rest, from the loader. 1
Figure 70-20-2
2 P-34550
Remove the bolt and nut (Item 1) [Figure 70-20-4] from

the hand speed control pivot arm.
1
P-34545
Loosen the two lower access panel mount bolts (Item 1)

[Figure 70-20-2]
Remove the upper mount bolt (Item 2) [Figure 70-20-2]
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ENGINE SPEED CONTROL (CONT’D) Figure 70-20-7
Removal (Cont'd)
Figure 70-20-5
1
1
P-34548

P-34549 hand speed control lever assembly.
Figure 70-20-8
Remove the keeper and pin (Item 1) [Figure 70-20-5]
that attaches the pivot arm to the speed control cable.

Remove the speed control pivot arm from the loader. 1
Figure 70-20-6
2 4 4
6
P-34551
At the bottom side of the control panel, move the speed

3 5 3 control linkage toward the rear of the loader.
P-34654 Slide the hand speed control lever (Item 1) [Figure 70-
20-8] forward and lift, and disconnect the assembly from
the speed control cable.
The parts that go into the pivot arm (Item 1) are the bolt
(Item 2), washers (Items 3), fiber washers (Items 4),
spacer (Item 5) and nut (Item 6) [Figure 70-20-6].
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ENGINE SPEED CONTROL (CONT’D) Figure 70-20-11
Removal (Cont'd)
Figure 70-20-9
2 P-34656
Remove the bushing / nut (Item 1) [Figure 70-20-11]

P-34553 from the pedal lever.
Figure 70-20-12
Installation: When installing the hand speed control to
the speed control cable, be sure the speed control lever

(Item 1) fits in the notch (Item 2) [Figure 70-20-9] of the
speed control cable clevis.
Disassembly
2
Figure 70-20-10
3
P-34657
Remove the fiber washer (Item 1) [Figure 70-20-12] from

the bushing / nut.
Remove the foot pedal lever (Item 2) and linkage rod

(Item 3) [Figure 70-20-12].
P-34655
Remove the spring (Item 1) [Figure 70-20-10] from the

foot speed control assembly.
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ENGINE SPEED CONTROL (CONT’D) Speed Control Cable
Disassembly Figure 70-20-15
Figure 70-20-13
P-34555
P-34658
Raise the lift arm and install an approved lift arm support
Remove the fiber washer (Item 1) and washer (Item 2) Page 10-20-1.)
[Figure 70-20-13] from the pivot bolt.

Figure 70-20-14 on Page 10-30-1.)
Remove the speed control lever assembly. (See

Removal on Page 70-20-1.)
1
At the lower right side of the control panel, remove the
two mounting bolts (Item 1) [Figure 70-20-15] from the
speed control cable mount bracket.
Figure 70-20-16
P-34659
Remove the pivot bolt (Item 1) [Figure 70-20-14] from

the speed control.
P-26154
At the right side of the engine compartment remove the

nut (Item 1) [Figure 70-20-16] from the speed control
cable.
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ENGINE SPEED CONTROL (CONT’D)
Speed Control Cable (Cont’d)
Figure 70-20-17
P-26153
Remove the two nuts (Item 1) [Figure 70-20-17] from the

speed control cable U-bolt.

Remove the U-bolt from the mount plate and the cable.
Remove the speed control cable from the loader.
NOTE: Remove all sta-straps and note proper cable

routing for proper installation. Install all sta-
straps on the new speed control cable to
prevent interference with moving parts.
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MUFFLER Figure 70-30-3
Figure 70-30-1
P7899
1
Remove the two bolts and nuts (Item 1) [Figure 70-30-3]

P7898 from the muffler mounting bracket.
Remove the muffler.

Open the rear door.

Raise the rear grill.
Remove the four bolts and nuts (Item 1) [Figure 70-30-1]

from the engine muffler mounting bracket.
Remove the bracket.
Figure 70-30-2
P7900
Remove the three bolts and nuts (Item 1) [Figure 70-30-

2] from the muffler exhaust flange.
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AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Figure 70-40-1
1
P-26593
Disconnect the sensor wiring harness connector (Item 1)

2 [Figure 70-40-3] from the air cleaner.
N-19671
Remove the air cleaner housing from the loader.

Loosen the hose clamp (Item 1) [Figure 70-40-1] and
disconnect the inlet hose from the air cleaner.

Loosen the hose clamp (Item 2) [Figure 70-40-1] and
disconnect the hose from the air cleaner to the turbo
charger.
Figure 70-40-2
N-19672

2].
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RADIATOR Figure 70-50-3
Figure 70-50-1
1 1
P7906
1 1
2 2
Lift the oil cooler from the loader frame [Figure 70-50-3].
P7904
Figure 70-50-4
Raise the rear grill.

Remove the hydraulic oil cooler. (See Hydraulic Oil
Cooler Removal And Installation on Page 30-60-1.) 1

1] from the oil cooler. 1
Disconnect the tubelines (Item 2) [Figure 70-50-1] from

the bulkhead fittings.
Figure 70-50-2
P7909
Before installing the oil cooler, check the seals (Item 1)

1 [Figure 70-50-4] at both sides of the oil cooler mounting
1
frame. Replace the seals as needed.
2 2
P7907
Loosen the tubeline fittings (Item 1) and raise the

tubelines (Item 2) [Figure 70-50-2] (both sides) as
shown and tighten the fittings so they can be used as
handles when removing or installing the oil cooler.
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COOLING FAN Figure 70-60-3
Drive Tension Pulley Removal And Installation
Figure 70-60-1
P5551
Remove the bolt (Item 1) [Figure 70-60-3] & [Figure 70-

P5550 60-4].
Figure 70-60-4
Remove the fan drive belt (Item 1) [Figure 70-60-1].

Remove the idler pulley bolt (Item 2) [Figure 70-60-1]. 3
Figure 70-60-2
1 3
4 2
1
N-00303
Remove the thrust washer (Item 2), O-rings (Item 3) and

spring (Item 4) [Figure 70-60-4].
P4956
Check all parts for damage or wear and replace them as
needed.
Remove the spacers, bolt and washers from the arm
[Figure 70-60-2]. NOTE: When making any repairs, replace the bronze
bushing (Item 5) [Figure 70-60-4] with a new
Installation: Put a small amount of grease around the style nylon bushing. Clean all parts and
outside edge on the grease rings (Item 1) [Figure 70-60- assemble dry. Do not lubricate. (See Parts
2] between ring and bearing. Mircofiche for correct part numbers.)
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COOLING FAN (CONT’D) Figure 70-60-6
Gearbox / Blower Housing Removal And Installation

2
Figure 70-60-5
P7966

Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab N-19623
on Page 10-30-1.)
Remove the mounting bolts (Item 1) [Figure 70-60-5]

from the gas cylinder mounting bracket. (See Gas
Cylinder Bracket Disassembly And Assembly on Page
50-20-5.)
Installation: Tighten the mounting bolts to 80 - 90 in.-lb.

(9 - 10 N•m) torque.
Remove the hydraulic fluid reservoir. (See Removal And Disconnect the wiring harness connectors (Item 1)
Installation on Page 20-80-1.) [Figure 70-60-6].
Remove the harness clamp (Item 2) [Figure 70-60-6].
Move the electrical harness down for clearance at the

blower housing.
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(Cont'd) 1
Figure 70-60-7
Oil Level
1 P7936
Remove the sealant from the blower housing and loader

frame (Item 1) [Figure 70-60-9].
N-19736
Remove fuel fill hose (Item 2) [Figure 70-60-9] and the
fuel vent hose.
Remove the belt shield (Item 1) [Figure 70-60-7] from

the fan drive. Figure 70-60-10
Disconnect the breather hose (Item 2) [Figure 70-60-7]

from the fan drive housing.
Installation: When checking the fan gearbox oil level,

make sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use 90W gear
lube oil if the level is low.
Figure 70-60-8
1
P7775

10] and spacer tubes (two outside housing and two
inside housing).
1
NOTE: Remove the two rear mounting bolts first.
Installation: Use sealant on each end of the inside

P7774 spacer tubes to prevent the tubes from falling out of the
housing during installation. Tighten the mounting bolts to
25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the fan drive belt (Item 1) [Figure 70-60-8].
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(Cont'd)
Figure 70-60-11
P7776
The blower housing must be moved away from the loader

frame if the side grills need to be replaced [Figure 70-60-
P7773 12].
To replace the side grill, remove the four mounting

Slide the blower housing forward and remove the fan / screws (Item 1) [Figure 70-60-12] from the blower

fan gearbox assembly. Remove the blower housing housing.
[Figure 70-60-11].
Install the new grill and replace the screws.
Installation: Use R.T.V. sealant to re-seal the blower
housing to the loader frame (Item 1) [Figure 70-60-9].
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Blower Removal And Installation
Figure 70-60-13
CD-9953
Remove the fan from the tapered shaft [Figure 70-60-

CD-9952 15].
Figure 70-60-16
Remove the lock nut and spacer [Figure 70-60-13].

N•m) torque.
1
Figure 70-60-14
2 1
CD-9954
To remove the blower housing mounting plate, remove

1
the six bolts (Item 1) [Figure 70-60-16].
P3006
Use the following procedure to remove the fan from the

shaft:
Install the nut (Item 1) [Figure 70-60-14] on the tapered

shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-60-14].
As the center bolt (Item 2) [Figure 70-60-14] is tightened,

periodically strike the bolt head to loosen the fan from the
shaft.
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COOLING FAN (CONT’D)
Gearbox Parts Identification
* Individual Parts not available

1
18
6
1
2 3
4 4
7
5
22

4
12 9
13
14
10
11
*16
1. Seal
2. Snap Ring (Small) 15 21
20
3. Shims (1.0 in. O.D.)
4. Bearing 17
5. Shaft (Long) 12
6. Shims (2.0 in. O.D.)
7. Long Key
8. Shaft (Short)
9. Short Key 3
10. Long Housing
11. Nut
12. Gear 4
13. Washer
14. Screw
13
15. Square Shim
16. Short Housing*
17. Bolt
18. Snap Ring (Large) 14
19. Cap
20. Long Housing Assy.
21. Short Housing Assy. 18
22. Fill Plug
*Individual Part not available 19 TS-1002
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Gearbox Disassembly
Figure 70-60-17
Part Number
2 Tag
P2983
3 Remove the four mounting bolts and the part number tag
P-37891 [Figure 70-60-18].
NOTE: When repairing the gearbox order the

following as needed: WARNING

1. Complete Assembly
2. Long Housing Assembly AVOID INJURY OR DEATH
3. Long Housing Wear safety goggles to prevent eye injury when
4. Short Housing Assembly (See Note Below) drilling or grinding.
5. Internal Parts W-2108-1186
NOTE: The short housing is only available as an Figure 70-60-19

assembly. (See Gearbox Parts Identification
on Page 70-60-6.)for reference. (Order parts
from Bobcat Parts Sales.)
NOTE: Be sure to count the number and thickness of

shims during disassembly. Install the shims
in the original location during assembly.
Remove the fan and blower housing mounting plate.

(See Gearbox / Blower Housing Removal And Installation
on Page 70-60-2.)
Long Housing
Loosen the set screws (Item 1) and remove the pulley P2999
(Item 2) [Figure 70-60-17].
Remove the long key (Item 3) [Figure 70-60-17]. Remove the oil from the gearbox.
Drill an 1/8 in. (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [Figure 70-60-19].
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Gearbox Disassembly (Cont'd)
Figure 70-60-20
P2966
Remove the screw and washer from the shaft [Figure

P2964 70-60-22].
Figure 70-60-23
Remove the small snap ring [Figure 70-60-20].

Figure 70-60-21
P3004
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-23].
Remove the small shims [Figure 70-60-21]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
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Figure 70-60-24
P2996
Drill an 1/8 in. (3 mm) hole in the seal. Use a slide

P3298 hammer tool to remove the seal [Figure 70-60-26].
Figure 70-60-27
Support the bearing and press the shaft from the bearing
[Figure 70-60-24].

Short Housing
WARNING
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186
P2970
Figure 70-60-25
Remove the large snap ring from the flange end of the
housing [Figure 70-60-27].
P2997
Remove the end cap [Figure 70-60-25].
Use care not to damage the housing.
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Figure 70-60-28
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-30].
Figure 70-60-31
Remove the large shims from the housing [Figure 70-60-
28].

NOTE: Use the same size and thickness of shims
during assembly.
Figure 70-60-29
P2998
1 Press the shaft from the housing [Figure 70-60-31].
NOTE: Both bearings may come out of the housing

with the shaft. If one bearing remains in the
P2978 housing, use a non metal object to tap the
bearing from the housing.
Remove the screw and washer (Item 1) [Figure 70-60-

29] from the shaft.
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Figure 70-60-32
P2972
Remove the key (Item 1) [Figure 70-60-34] from the

P3088 shaft.
Press the bearing from the tapered end of the shaft

[Figure 70-60-32].

Figure 70-60-33
P3001
Press the bearing, shims and gear from the shaft [Figure
70-60-33].
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Gearbox Assembly
Figure 70-60-35
P2960
Install the long housing on the shaft [Figure 70-60-36].

P2961
Be sure the bearing is seated in the bore at the lower end
of the housing.
NOTE: See Note Page 70-60-7 when ordering parts
for the Fan Gearbox. Always replace seals Figure 70-60-37

during assembly. Replace the parts in the
gearbox as needed.
NOTE: Do not install the seals and cap in the housing

until after the backlash has been checked.
NOTE: Use care when pressing the bearings into the

aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of #242

Loctite® adhesive, thoroughly clean and dry
affected parts before the application of #242
Loctite®.
P2962
Long Housing
Press a bearing on the short keyed end of the long shaft Install a bearing on the long keyed end of the shaft
[Figure 70-60-35]. [Figure 70-60-37].
Support the lower bearing and press the other bearing in

the housing until the bearings seat in the housing [Figure
70-60-37].
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Gearbox Assembly (Cont'd)
Figure 70-60-38
P2965
Install the gear key in the flange end of the shaft [Figure
P2963 70-60-40].
Figure 70-60-41
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-60-

38].
Figure 70-60-39
P2967
Align the key and gear. While supporting the bearing on

the other end, press the gear on the shaft until it seats
P2964 against the bearing [Figure 70-60-41].
Install the small snap ring in the groove above the shims
[Figure 70-60-39].
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Figure 70-60-42
P2969
Install the large shims on the bearing (flanged end)

P2966 [Figure 70-60-44].
Figure 70-60-45
Install the washer [Figure 70-60-42].

Put liquid adhesive (Loctite® #242) on the screw threads.
Install and tighten the screw [Figure 70-60-42].
Short Housing
Figure 70-60-43
P2970
Install the large snap ring in the groove above the shims
[Figure 70-60-45].
P2968
Install a bearing in the flanged end of the housing

[Figure 70-60-43].
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Figure 70-60-46
P2976
1
Install the shaft in the housing, tapered end in the bearing
P2971 at the round flange end of the housing [Figure 70-60-48].
Figure 70-60-49
Install the short key (Item 1) [Figure 70-60-46].

Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [Figure 70-60-46].
Figure 70-60-47
P2977
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-49].
P2975
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-47].
NOTE: This will prevent damage to the shims when

the bearing is installed later.
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Figure 70-60-50
P2978
Install the washer (Item 1) on the shaft. Put liquid

P2974 adhesive (Loctite® #242) on the screw threads and
install the screw [Figure 70-60-52].
Install a bearing on the gear end of the shaft [Figure 70-

60-50].

Figure 70-60-51
P2973
Install the snap ring in the groove above the bearing

[Figure 70-60-51].
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Gearbox, Checking Backlash
Figure 70-60-53
P2981
Install the same size and number of square shims (if

P2987 present during disassembly) between the two housings
[Figure 70-60-54].
NOTE: For procedures requiring the use of #242 Set the long housing on the short housing with a small
Loctite® adhesive, thoroughly clean and dry amount of liquid adhesive (Loctite® #242) between the

affected parts before the application of #242 mounting surfaces.
Loctite®.
NOTE: If square shims are used, put a small amount
The backlash tolerance between the gears should be of the liquid adhesive on both sides of all
0.005 - 0.008 in. (0,127 - 0,203 mm). shims.
To check the gear backlash use the following procedure: Figure 70-60-55
Put the short housing in a vise, square flange facing up

as shown [Figure 70-60-53].
Part Number
Tag
P2983
Install the four mounting bolts through the flange holes

[Figure 70-60-55].
Install the part number tag [Figure 70-60-55].
Install and tighten the nut to 25 - 28 ft.-lb. (34 - 38 N•m)

torque.
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Gearbox, Checking Backlash (Cont'd)
Figure 70-60-56
2
1
1.000”
(25,4 mm)
P-37893
1 Using a magnetic based dial indicator mounted on a

P-37894 bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-58].
Install the long key (Item 1) and the pulley (Item 2) Hold the locking pliers against the long housing and
[Figure 70-60-56]. rotate the pulley back and forth to read the dial gauge

[Figure 70-60-58].
Install a bolt in the set screw hole to maintain a 1.000 in.
(25,4 mm) distance from the shaft center to the bolt head If the backlash is GREATER than 0.008 in. (0,203 mm),
(to be used with a dial indicator) [Figure 70-60-56]. do the following:
Figure 70-60-57 1. Remove a square shim(s) (if present) between the

two housings.
2. Remove a large shim(s) from the tapered end of the

short shaft and add a small shim(s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS than 0.005 in. (0,127 mm) do the

following:
1. Add a square shim(s) between the two housings.

1
2. Remove a small shim(s) between the bearing and the
gear on the screw end of the short shaft and add a
P-37892 large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.
Put the fan nut (Item 1) [Figure 70-60-57] on the shaft
and tighten snugly.
Install a locking pliers on the fan nut and support the

handle against the long housing [Figure 70-60-57].
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Gearbox, Checking Backlash (Cont'd) LONG HOUSING
Figure 70-60-59
P2985
Figure 70-60-61
P3089
SHORT HOUSING
When the backlash is correct, install the seals, cap and

gear oil as follows:

Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (Loctite® #242) on the outside

diameter of the seal(s) [Figure 70-60-59].
P2986
Install the seal(s) flush with the housing surface [Figure

70-60-60] & [Figure 70-60-61].
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25 - 28 ft.-lb. (34 - 38 N•m)

torque.
Add oil to the fan gear box. (See Checking And Adding
Oil on Page 10-140-1.)
A300 Bobcat Loader

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A300 Bobcat Loader

532 of 772
ENGINE COMPONENTS AND TESTS Figure 70-70-2
Engine Compression, Checking
Figure 70-70-1
2
N-19021
1
Remove the high pressure fuel line (Item 1) [Figure 70-
N-19024 70-2] from the fuel pump and the fuel injector.
Installation: Tighten the fuel line nuts to 10 - 12 ft.-lb.

The tools listed will be needed to do the following (13,5 - 16,5 N•m) torque.
procedure:

Disconnect the glow plug harness (Item 2) [Figure 70-
MEL10630 - Engine Compression Tester 70-2] from the glow plug.
MEL1489 - Compression Test Adapter
Remove the glow plug from the cylinder head.
Warm the engine.
Clean the area around the fuel injection pump, injectors

and glow plugs.
Remove the electrical connection (Item 1) [Figure 70-70-

1] from the fuel shut off solenoid.
A300 Bobcat Loader

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ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-5
Engine Compression, Checking (Cont'd)
Figure 70-70-3
N-19023
Connect the compression gauge to the adapter [Figure

N-19012 70-70-5].
Turn the engine with the starter at 200 - 300 RPM. Run
Figure 70-70-4 the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading.

The correct compression to the engine is 320 - 392 PSI
(2206 - 2703 kPa) with no more than 10% difference
1 between the cylinders.
N-19022
Install the compression adapter tool (Item 1) [Figure 70-

70-3] & [Figure 70-70-4] into the glow plug hole and
tighten to 15 - 18 ft.-lb. (20 - 24 N•m) torque.
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -

24 N•m) torque.
A300 Bobcat Loader

534 of 772
Glow Plug, Checking
Figure 70-70-6
P9452
Use a test meter to measure the resistance of each glow

P9451 plug.
Connect the test meter lead to the terminal of the glow

Loaders use four glow plugs, one for each cylinder. The plug as shown in figure [Figure 70-70-7].
glow plugs are located on the rear side of engine in the

cylinder head as shown in figure [Figure 70-70-6]. Touch the other lead from the test meter to the base of
the glow plug as shown in figure [Figure 70-70-7].
Unplug the wire from the glow plug (Item 1) [Figure 70-
70-6]. The reading must be approximately 0.2 ohms.
If the resistance is zero ohms the glow plug has a short

circuit and must be replaced.
If the resistance is infinite, the coil of the glow plug is

broken and the glow plug must be replaced.
A300 Bobcat Loader

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Fuel Shut-Off Solenoid Checking
Figure 70-70-8
N-19025
1
Figure 70-70-10
N-19024
1
Remove the screw (Item 1) [Figure 70-70-8] from the
electrical connection on the fuel shut-off solenoid.

Disconnect the electrical connector from the solenoid.
N-19026
Use a test meter to measure the resistance of the fuel

shut-off solenoid.
Connect the test meter leads to the terminals (Item 1)

[Figure 70-70-9] & [Figure 70-70-10].
The reading must be approximately 02.8 ohms.
If the resistance is zero ohms the solenoid has a short

circuit.
If the resistance is infinite, the coil in the solenoid is

broken.
Replace the solenoid if needed. (See Fuel Shut-Off

Solenoid Removal And Installation on Page 70-70-5.)
A300 Bobcat Loader

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ENGINE COMPONENTS AND TESTS (CONT’D) Fuel Injection Pump Removal
Fuel Shut-Off Solenoid Removal And Installation
Figure 70-70-11
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 Figure 70-70-13
3 3
N-19027
2 2
11]. 1

Installation:Tighten the mounting bolts to 10 - 12 ft.-lb.
(13,5 - 16,3 N•m) torque.
P5282
Remove the fuel shut-off solenoid from the engine.
Figure 70-70-12 The injection pump(s) contain parts which have a very
close tolerance and its operation has a direct effect on
the performance of the engine.
1 Remove the fuel tubeline (Item 1) to the fuel injection

pumps (Item 2) [Figure 70-70-13].
Disconnect the respective high pressure fuel line (Item 3)

[Figure 70-70-13] from the injection pump to be removed
and fuel injector.
N-19028
Check the solenoid spring (Item 1) and linkage (Item 2)

[Figure 70-70-12]. Replace the solenoid as needed.
NOTE: When installing the fuel shut-off solenoid in

the engine the linkage (Item 2) [Figure 70-70-
12] must engage the fuel control rack.
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Fuel Injection Pump Removal (Cont’d)
2 1
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
Figure 70-70-14
P5283
Remove the fuel injection pump (Item 1) [Figure 70-70-

16].
Remove the shim (Item 2) [Figure 70-70-16].
NOTE: The shim(s) are used to time the injection

1 pump, keep the same thickness for each
injection pump.
Figure 70-70-17
P5280
Use a flare nut wrench (Item 1) [Figure 70-70-14] to

loosen the high pressure fuel line nut.
Figure 70-70-15
P5279
1 Use a magnet to remove the injection pump tappet

[Figure 70-70-17].
Inspect the tappet for wear or damage, replace as

P5281 needed.
Remove the two mounting nuts (Item 1) [Figure 70-70-

15] from the injection pump.
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ENGINE COMPONENTS AND TESTS Figure 70-70-20
(CONT’D)ENGINE COMPONENTS AND TESTS
(CONT'D)
Fuel Injection Pump Removal (Cont'd) Tappet

Figure 70-70-18
MC-2175
Measure the distance between the engine block surface

(without shim) and surface of the tappet [Figure 70-70-
20].
P5278
Installation dimension of the injection pump is 2.32 in. (59

mm).
Install the tappet into its respective bore [Figure 70-70-

18].
EXAMPLE:
Fuel Injection Pump Timing
Specifications:
Installation Depth . . . . . . . . . . . . . . . . . 2.32 in. (59 mm)
Figure 70-70-19
Measured Depth a . . . . . . . . . . . . . . 2.25 in. (57,55 mm)
Difference . . . . . . . . . . . . . . . . . . . . . 0.070 in. (1,78 mm)
Determine the number of shim(s) needed to get the

1 correct installation height.
Install the appropriate number of shim(s) on the engine

block surface.
P5284
The fuel injection pump does not need to be timed if the

tappet, shim(s) and the camshaft are not changed.
Install a depth micrometer (Item 1) [Figure 70-70-19].
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Fuel Injection Pump Installation

2
Figure 70-70-21 1
P5288
Use the centering pin (Item 1) to remove the press-in

P5287 plug (Item 2) [Figure 70-70-23] from the injection pump.
(See Deutz Engine Tools Identification Chart on Page 70-
100-1 for correct tool.)
Remove the plug from the engine block. Install control
rack locating pin (Item 1) [Figure 70-70-21]. (See Deutz Figure 70-70-24

Engine Tools Identification Chart on Page 70-100-1 for
correct tool.)
2 1
Figure 70-70-22 3
P5289
Install the centering pin (Item 1) into the injection pump

P5286 and into the control lever (Item 2). Align the marks (Item
3) [Figure 70-70-24] on the pump body and the control
lever. Make sure the control lever is in the center
Move the control rack until the slot (Item 1) [Figure 70- position.
70-22] is in the center of the injection pump bore.
Tighten the locating pin (Item 2) [Figure 70-70-22].
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Fuel Injection Pump Installation (Cont'd)
Figure 70-70-25
P5280
2
1 Install the high pressure fuel line.

P5294
Tighten the fuel line nut to 10 - 12 ft.-lb. (13,5 - 16,5 N•m)
torque [Figure 70-70-27].
Install the injection pump into the engine block. Make
sure the control lever goes into the slot on the fuel control Figure 70-70-28

rack.
Install the two nuts (Item 1) [Figure 70-70-25].
Figure 70-70-26
P5285
2
Install new washers (Item 1) [Figure 70-70-28] on the

1 fuel line fastening bolt.
P5291
Install the fuel line on the injection pumps and tighten to
20 - 23 ft.-lb. (27 - 31 N•m) torque.
Tighten the mounting nuts to 15 ft.-lb. (21 N•m) torque
[Figure 70-70-26].
Remove the fuel control rack locating pin (Item 1) [Figure

70-70-26] and install the plug.
Remove the centering pin (Item 2) [Figure 70-70-26] and

install the press-in plug (Item 2) [Figure 70-70-25].
A300 Bobcat Loader

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Fuel Injector Removal And Installation
Figure 70-70-29
1
P5293
Remove the high pressure fuel line.

P5280
Installation: Tighten the fuel line nut to 10 - 12 ft.-lb.
(13,5 - 16,5 N•m) torque.
Disconnect the respective high pressure fuel line from
fuel injector to be removed and fuel injection pump. Remove the bolt (Item 1) [Figure 70-70-30] and

holddown clamp from the fuel injector.
Use a flare nut wrench (Item 1) [Figure 70-70-29] to
loosen the high pressure fuel line nut. Installation: Tighten the bolt to 15.5 ft.-lb. (21 N•m)
torque.
Figure 70-70-31
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
P5290
Remove the fuel injector (Item 1) and washer (Item 2)

[Figure 70-70-31] from the cylinder head.
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ENGINE COMPONENTS AND TESTS (CONT’D) Fuel Injector Disassembly
Fuel Injector, Checking Figure 70-70-33
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
WARNING
MC-2177

Diesel fuel or hydraulic fluid under pressure can Check nozzles spray pattern [Figure 70-70-33]:
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible. The spray pattern must be uniform from all four holes of
Use a piece of cardboard or wood to find leaks. Do the nozzle.

not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention The nozzles are dirty or defective:
from a physician familiar with this injury.
W-2072-0807
• If the spray pattern is not uniform.
• If fuel drips from the end of the nozzle.
Figure 70-70-32 • If the spray is a solid stream instead of a mist.
Figure 70-70-34
B-8971
The tools listed will be needed to do the following CD-15332

procedure:
OEM1064 - Injection Nozzle Test Remove the nozzle cap nut [Figure 70-70-34].
OEM1065 - Accessory Set
Connect the nozzle to the test pump, in a down position

[Figure 70-70-32].
Operate the test pump until the nozzle valve opens:
Injection Pressure: . . . . . . . . . . . . . . . 3045 PSI (210 bar)

A300 Bobcat Loader
543 of 772
Fuel Injector Disassembly (Cont’d)
Figure 70-70-35
1
2
3
4
5
6
CD-15334
The nozzle needle and body [Figure 70-70-36] are

CD-15333 lapped together and can not be exchanged with other
nozzle parts.
Disassembly the parts as shown in [Figure 70-70-35]. DO NOT touch the nozzle needle with your fingers.

1. Nozzle Cap Nut When the nozzle body is held in the upright position, the
2. Injector Nozzle needle should by its own weight slide slowly and
3. Adapter smoothly on its seat [Figure 70-70-36].
4. Thrust Pin
5. Spring NOTE: If the nozzle needle does not slide smoothly,
6. Shim(s) wash the injector nozzle parts again in clean
diesel fuel. Blow dry with compressed air. Re-
Wash all the parts in clean diesel fuel and blow dry using do the procedure again. Replace the injectors
compressed air. as needed. Wash all new injectors in clean
diesel fuel before installation.
Figure 70-70-37
CD-15335
Check the seat surface of the adapter for wear. Make

sure the centering pins are in place [Figure 70-70-37].
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Fuel Injector Assembly
Figure 70-70-38
CD-15338
Install the thrust pin with the centering collar facing

CD-15336 toward the compression spring [Figure 70-70-40].
Figure 70-70-41
Install the shim(s) [Figure 70-70-38].

The injector opening pressure is adjusted by selecting
the correct amount of shim(s). A thicker shim will
increase the opening pressure at the injector nozzle.
Figure 70-70-39
CD-15339
Install the adapter with the centering pins toward the

thrust pin [Figure 70-70-41].
CD-15337
Install the compression spring [Figure 70-70-39].
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Fuel Injector Assembly (Cont'd)
Figure 70-70-42
CD-15342
Tighten the cap nut to 35 ft.-lb. (47 N•m) torque [Figure

CD-15340 70-70-44].
Check the injector nozzle on the nozzle tester before

Install the injector nozzle, make sure the center bore fits installation. (See Fuel Injector, Checking on Page 70-70-
over the centering pins of the adapter [Figure 70-70-42]. 11.)

NOTE: Be careful that the nozzle needle does not fall
out of the nozzle body.
Figure 70-70-43
CD-15341
Install the nozzle cap nut [Figure 70-70-43].
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Timing Belt Inspection
Figure 70-70-45
P-5292A
P5298
3 Check the timing belt, sprockets and tensioner for wear,

P-5292 cracks or damage [Figure 70-70-46].
Check the timing belt in detail for the following conditions,

NOTE: The timing belt is maintenance free. Timing replace as needed.
belts that are in operation do not need to be

re-tensioned. The timing belt, belt tensioner 1. Oil deposits
and mount bolt must be replaced every 3000 2. Hardened back rubber surfaces
operating hours or every 5 years. A repair kit 3. Cracked
is available. 4. Badly worn teeth
5. Missing tooth
NOTE: If the timing belt has to be removed before 200 6. Side of belt badly worn
hours of engine operation, the timing belt can 7. Side of belt cracked
be re-used and re-tensioned according to the
procedure listed. Timing Belt Removal
To do the following procedure you need the following tool: Remove the bolts (Item 1) [Figure 70-70-45] from the
timing belt inspection cover.
MEL1552 - Torx Bit
Remove the torx bolt (Item 2) [Figure 70-70-45].
timing belt inspection cover. Remove the cover (Item 3) [Figure 70-70-45].
Remove the torx bolt (Item 2) [Figure 70-70-45].
A300 Bobcat Loader

547 of 772
Timing Belt Removal (Cont’d)
Figure 70-70-47
1
1
P5299
1
2
Loosen the belt tensioner mounting bolt (Item 1) [Figure
P5295 70-70-48].
Loosen the belt tensioner.

Remove the bolts (Item 1) from the v-belt pulley (Item 2)
[Figure 70-70-47]. Remove the timing belt.

Remove the V-belt pulley.

timing belt cover.
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Timing Belt Installation
Figure 70-70-49
2
1
P9577 P-9578
The crankshaft plug is located at the front of the engine

P9575 block (Item 1) [Figure 70-70-51] on the exhaust manifold
side.
NOTE: Remove the fuel injectors from the cylinder Remove the plug.
head. (See Fuel Injector Removal And

Installation on Page 70-70-10) This will let the Figure 70-70-52
crankshaft turn easier for timing belt
installation.
The camshaft plug is located at the rear of the engine 1

block (Item 1) [Figure 70-70-49] on the fuel injection
pump side. (See Deutz Engine Tools Identification Chart
on Page 70-100-1 for the correct tool.) 2
Remove the plug.
Rotate the camshaft until the notch in the camshaft can

be seen through the plug hole.
Figure 70-70-50
B-14401
Rotate the crankshaft until the flat spot on the crankshaft

throw (Item 1) [Figure 70-70-52] can be seen through
the plug hole. Turn the crankshaft back a small amount.
Install the timing tool (Item 2) [Figure 70-70-51] &
1
[Figure 70-70-52] and tighten.
Rotate the crankshaft until it hits the timing tool and

stops.
P9573
Install the timing tool (Item 1) [Figure 70-70-50] and

tighten.
A300 Bobcat Loader

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Timing Belt Installation (Cont'd)
Figure 70-70-53
P5632
Using the dimension, align the timing belt to make sure it

P5301 is at an equal distance from the front cover [Figure 70-
70-55].
Loosen the nut at the camshaft gear [Figure 70-70-53]. Figure 70-70-56

Install the new timing belt.
Figure 70-70-54
N-18863
Install the belt tension tool (Item 1) [Figure 70-70-56].

P5630
Turn the idler tensioner pulley in counterclockwise
direction to obtain a scale reading of 3.0 - 3.5. Tighten the
Measure the distance from the edge of the belt to the idler tensioner pulley nut (Item 2) [Figure 70-70-56] to 33
front cover surface [Figure 70-70-54]. ft.-lb. (45 N•m) torque.
A300 Bobcat Loader

550 of 772
Figure 70-70-57
1
N-18864
Mark the crankshaft pulley (Item 1) [Figure 70-70-59].

N-18867
Make four complete crankshaft revolutions in a clockwise
direction of engine rotation. Bring the mark on the
Remove the belt tension tool. crankshaft pulley back to the same position.

Initially tighten camshaft bolt to 22 ft.-lb. (30 N•m) [Figure Figure 70-70-60
70-70-57].
Figure 70-70-58
N-18852
N-18866 Install the belt tension tool (Item 1) [Figure 70-70-60].
NOTE: The belt tension tool may touch the governor

With a torque degree wheel (Item 1) [Figure 70-70-58] linkage cover (Item 2) [Figure 70-70-60], but
tighten the camshaft bolt an additional 210°. will not effect the belt tightening procedure.
Remove the camshaft and crankshaft locating pins. (See

Camshaft Bearing, Removal And Installation on Page 70-
100-23.)
A300 Bobcat Loader

551 of 772
Figure 70-70-61 1
P5295
NOTE: See Valve Timing, (See Valve Timing,

N-18853 Checking on Page 70-70-28) before installing
the timing belt cover.
Check the position of the belt tension tool (Item 1) Install the belt cover (Item 1) [Figure 70-70-63] and
[Figure 70-70-61] on the belt. tighten the bolts.

Figure 70-70-62 Install the v-belt pulley (Item 2) [Figure 70-70-63] and
tighten the bolts to 30 - 36 ft.-lb. (41 - 49 N•m) torque.
Figure 70-70-64
N-18865
Measure the belt tension [Figure 70-70-62], the reading 1

P5292
should be 6.5 - 9.5.
NOTE: If the specified scale reading is not obtained, Install the timing belt inspection cover (Item 1) [Figure
repeat the installation procedure starting with 70-70-64] and tighten the bolts.
[Figure 70-70-49]. (See Timing Belt Installation
on Page 70-70-17)
Remove the belt tension tool.
A300 Bobcat Loader

552 of 772
Timing Belt, Replacement In The Loader
Figure 70-70-65
1
P9563
Loosen the alternator adjustment bolt (Item 1) [Figure

1
70-70-66] and remove the alternator belt.
Remove the crankshaft pulley bolts (Item 2) [Figure 70-

70-66]. Remove the pulley.

Figure 70-70-67
P9566
Use the following procedure to replace the timing belt, 2

tensioner and tensioner bolt. If the belt is broken, 1
additional procedures are required and noted.
• For Broken Belt Replacement Only P9564
• Remove the engine muffler. (See Removal And

Installation on Page 70-30-1.) Remove the throttle linkage bolts (Item 1) [Figure 70-70-
67]. Lower the throttle linkage.
• Remove the valve cover. Remove and inspect the
rocker arms / brackets and push rods. (See Rocker Remove the four belt cover bolts (Item 2) [Figure 70-70-
Arm And Bracket, Checking on Page 70-100-43.) 67]. Remove the front and rear belt covers.
NOTE: The rear door is removed for photo clarity

only.
Disconnect the negative (-) battery cable.
Loosen the screw and unplug the fuel solenoid connector

(Item 1) [Figure 70-70-65].
NOTE: Do not lose the rubber seal gasket on the

solenoid connector.
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Timing Belt, Replacement In The Loader (Cont'd)
Figure 70-70-68
P9570
Rotate the crankshaft in correct rotation as shown in

P9575 figure [Figure 70-70-70] until the notch in the camshaft
can be seen through the access hole.
Remove the camshaft access plug (Item 1) [Figure 70- NOTE: The crankshaft must be turned in correct
70-68]. rotation. Turn clockwise as viewed from the

timing belt end of engine as shown.
Figure 70-70-69
Figure 70-70-71
1
1
P9577
P9573
Remove the crankshaft access plug (Item 1) [Figure 70-

70-69]. Install the camshaft timing tool (Item 1) [Figure 70-70-71]
and tighten. (See Deutz Engine Tools Identification Chart
NOTE: The plug is located on the front of crankcase, on Page 70-100-1.)
below the turbocharger and just above the
right side front engine mount.
A300 Bobcat Loader

554 of 772
Figure 70-70-72
P9578
• Install the crankshaft timing tool (Item 1) [Figure 70-

P9605 70-73] and tighten. (See Deutz Engine Tools
Identification Chart on Page 70-100-1.)
• For Broken Belt Replacement Only • Rotate crankshaft against timing tool.

• Remove the number four cylinder fuel injector. (See Install the crankshaft timing tool (Item 1) [Figure 70-70-
Fuel Injector Removal And Installation on Page 70- 73] and Tighten. (See Deutz Engine Tools Identification
70-10) Chart on Page 70-100-1.)
• Rotate the crankshaft and use a wire (Item 1) [Figure Figure 70-70-74
70-70-72] in the fuel injector hole to indicate piston is
moving upward, to top dead center (T.D.C.).
NOTE: The crankshaft must be turned in correct

rotation. Turn clockwise as viewed from the
timing belt end of engine.
P9565
Remove the tensioner bolt (Item 1) [Figure 70-70-74]

and the tensioner. Remove the timing belt.
NOTE: The timing belt, belt tensioner and mount bolt

must be replaced as a set. A repair kit is
available.
Install the new timing belt, belt tensioner and mount bolt.
Do not tighten the mount bolt.
NOTE: Align the timing belt on gears to obtain equal

distance between the belt and front cover to
insure belt runs straight on gears.
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555 of 772
Figure 70-70-75
P9579
Use a hex wrench to turn the idler tension pulley in

P9571 counterclockwise direction as shown in figure [Figure 70-
70-77]. Obtain a scale reading of 3.0 - 3.5. Tighten the
idler tension pulley mount bolt to 33 ft.-lb. (45 N•m)
Install the camshaft gear tool (Item 1) [Figure 70-70-75]. torque.

100-1.) Figure 70-70-78
Loosen the camshaft gear [Figure 70-70-75].
Figure 70-70-76
P-9569
Remove the belt tension tool, hex wrench and torque

P-9576A P-9574 wrench.
Install the camshaft gear tool.

Install the belt tension tool as shown in [Figure 70-70-
76]. (See Deutz Engine Tools Identification Chart on Tighten camshaft bolt to 22 ft.-lb. (30 N•m) torque as
Page 70-100-1.) shown in [Figure 70-70-78]. Mark the camshaft bolt and
tighten an additional 210°.
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Figure 70-70-79
1
1
P9565
Mark the crankshaft pulley hub (Item 1) [Figure 70-70-

P9573 81].
Figure 70-70-80

1
P9578
Remove the camshaft and crankshaft timing tools (Item

1) [Figure 70-70-79] & [Figure 70-70-80].
A300 Bobcat Loader

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ENGINE COMPONENTS AND TESTS (CONT’D) • For Broken Belt Replacement Only
Timing Belt, Replacement In The Loader (Cont'd) • Install the push rods and rocker arms / brackets.
Replace all damaged parts. (See Rocker Arm And
Figure 70-70-82 Bracket, Checking on Page 70-100-43.)
• Set the valve clearance. (See Valve Clearance

Adjustment on Page 70-70-27)
• Install the valve cover and gasket. Tighten the bolts to

75 in.-lb. (8,5 N•m) torque.
Install the crankshaft and camshaft access plugs.
Install the belt covers and four mounting bolts.
Install the throttle linkage and bolts.
Install the crankshaft pulley and bolts. Tighten the bolts to

P9570 30 - 36 ft.-lb. (41 - 49 N•m) torque.
Install the alternator belt. Adjust the belt tension.

Make four complete crankshaft revolutions in the
direction of engine rotation. Bring the mark on the Plug in the fuel solenoid connector and tighten the screw.

crankshaft pulley back to the same position as before
[Figure 70-70-82]. Reconnect the negative (-) battery cable.
Install the belt tension tool. Check the belt tension
reading. It should be 6.5-9.5.
NOTE: If the specified scale reading is not obtained,

repeat the procedure.
Remove the belt tension tool.
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Valve Clearance Adjustment
Figure 70-70-83
P5633
Loosen the locknut and turn the set screw until the
P5297 clearance is correct [Figure 70-70-85].
Intake - 0.012 in. (0.3 mm)

Make the valve clearance adjustment with engine Exhaust - 0.020 in. (0.5 mm)
stopped and cold.

Tighten the locknut to 13 - 16 ft.-lb. (18 - 22 N•m) torque.
Remove the valve cover (Item 1) [Figure 70-70-83].
When installing the valve cover bolts, tighten to 75 in.-lb.

(8,5 N•m) torque.
Figure 70-70-84
CRANKSHAFT POSITION CRANKSHAFT POSITION
ONE TWO
Turn crankshaft Turn crankshaft further by
until valves one complete revolution
of cylinder No. 1 Overlap (360)°
DO NOT ADJUST ADJUST
MC-2174
Use the following sequence as shown in [Figure 70-70-

84] to set the valve clearance.
Turn the crankshaft until the valves of cylinder No. 1

over-lap [Figure 70-70-84].
Turn the crankshaft by one complete revolution (360°)

and set the other valves.
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Valve Timing, Checking
Figure 70-70-86
P9563
At the crankshaft pulley bolt, install a torque wrench and

P9575 turn the engine in the direction of rotation to 30 ft.-lb. (40
N•m) torque [Figure 70-70-88].
Remove the camshaft access plug (Item 1) [Figure 70- Remove the torque wrench, DO NOT change the
70-86]. crankshaft position.

Figure 70-70-87
P9573
Rotate the crankshaft / camshaft until the notch in the

camshaft can be seen through the plug hole.
Install the timing tool (Item 1) [Figure 70-70-87].
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ENGINE COMPONENTS AND TESTS (CONT’D)
Valve Timing, Checking, (Cont’d)
Figure 70-70-89
2
1
P-9577A P-9578A
P-9578
Remove the crankshaft access plug (Item 1) [Figure 70-

70-89].

NOTE: The access plug is located on the front of the
crankcase, below the turbocharger and just
above the right side front engine mount.
Turn the crankshaft timing tool (Item 2) [Figure 70-70-89]

into the crankcase until it makes slight contact with the
crankshaft.
Mark the position of the timing tool.
The valve timing is correct if the timing tool can be turned

into the crankcase another 3/4 to 2-1/4 turns until it stops.
If the timing tool can not be turned into the crankcase the
required turns, the camshaft (valve timing) setting will
have to be redone.
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ENGINE COMPONENTS AND TESTS (CONT’D) Remove the plug (Item 1) [Figure 70-70-90] and remove
the thermostat and spring assembly (Item 1) [Figure 70-
Thermostat, Oil Pressure Control Valves & Heater 70-91] from the engine block.
Connections
Installation: Install the plug and tighten to 82 ft.-lb. (111
Figure 70-70-90 N•m) torque.
Remove the plug and O-ring (Item 2) [Figure 70-70-90]

and remove the spring and oil pressure control valve
(Item 2) [Figure 70-70-91] from the engine block.
1 Installation: Install the plug and tighten to 82 ft.-lb. (111

N•m) torque.
Remove the adapter fitting (Item 3) [Figure 70-70-90]

plug and O-ring (Item 3) [Figure 70-70-91].
Installation: Install the fitting and/or plug and tighten to

82 ft.-lb. (111 N•m) torque.
2
Remove the plug and O-ring (Item 4) [Figure 70-70-90]
and remove the spring and oil pressure control valve
(Item 4) [Figure 70-70-91] from the engine block.

Installation: Install the plug and tighten to 82 ft.-lb. (111
N•m) torque.
4 3
Remove the adapter fitting (Item 5) [Figure 70-70-90]
plug and O-ring (Item 5) [Figure 70-70-91].
5 Remove the valve and spring (Item 6) [Figure 70-70-91]

from the engine block.
Installation: Install the fitting and/or plug and tighten to

P-18909A
NOTE: Be sure the valve and spring (Item 6) [Figure
70-70-91] is installed as shown.
Figure 70-70-91
5 B-14310
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ENGINE COMPONENTS AND TESTS (CONT’D) Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-30) [Figure
Thermostat, Oil Pressure Control Valves & Heater 70-70-91] for location on the engine block.)
Connections (Cont'd)
Figure 70-70-94
Figure 70-70-92
2 1
1
N-18870
N-18868
NOTE: The adapter fitting (Item 1) [Figure 70-70-94] is

Remove the thermostat spring (Item 1) from the removed when a cab heater is installed on the

thermostat (Item 2) [Figure 70-70-92], inspect all parts loader. The port it comes from on the engine
and replace as needed. block is the oil out let port to the heater.
Installation: (See Thermostat, Oil Pressure Control Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-30.)[Figure Valves & Heater Connections on Page 70-70-30) [Figure
70-70-91] for location on the engine block. 70-70-91] for location on the engine block.)
Figure 70-70-93
3
1
2
N-18869
Remove the spring (Item 1) from the oil pressure control

valve (Item 2). Replace the O-ring (Item 3) [Figure 70-
70-93].
The spring is marked with a yellow mark, for proper

installation. If the yellow mark is missing, the spring coil
diameter is 0.047 in. (1,2 mm).
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Thermostat, Oil Pressure Control Valves & Heater

Connections (Cont'd)
2
Figure 70-70-95
1
1
2
N-18872
Remove the spring (Item 1) from the valve (Item 2)

[Figure 70-70-96].
N-18871
The spring is marked with a blue mark, for proper
installation. If the blue mark is missing, the spring coil
Replace the O-ring (Item 1). Remove the spring (Item 2) diameter is 0.039 in. (1,0 mm).

from the oil pressure control valve (Item 3) [Figure 70-
70-95]. Installation: (See Thermostat, Oil Pressure Control
The spring is marked with a red mark, for proper 70-70-91] for location on the engine block.)
installation. If the red mark is missing, the spring coil
diameter is 0.055 in. (1,4 mm).
Installation: (See Thermostat, Oil Pressure Control

70-70-91] for location on the engine block.)
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ENGINE Figure 70-80-2
Figure 70-80-1
1 2 P-26464
Drain the fluid from the hydraulic reservoir. (See Removal

P-26597 And Installation on Page 20-80-1.)
Disconnect the two hydrostatic pump controllers (Item 1)

NOTE: The engine and hydrostatic pumps will be [Figure 70-80-2] from the loader wiring harness.
removed as an assembly.

Figure 70-80-3
Page 10-20-1.) 2
Place the rear of the loader on jack stands. (See 1


on Page 10-30-1.)
Remove the rear tires. (Both Sides.)
Remove the six access cover mount bolts (Item 1).

Remove the access cover (Item 2) [Figure 70-80-1].
(Both Sides.) P-26700

from the hydraulics pump to the control valve.
Disconnect the hydraulic hose (Item 2) [Figure 70-80-3],

at the steering filter, that comes from the hydraulic pump
to the steering valve.
Cap and plug the hoses and fittings.
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ENGINE (CONT’D) Figure 70-80-6

1
Figure 70-80-4
2
1
P-26733
At the front side of the gear pump, disconnect the return

P-26734 hose from the steering valve (Item 1) [Figure 70-80-6].
Cap and plug the hose and the fitting.

from the hydraulics Hi-flow pump. (If so equipped.) Remove the two hose clamps (Item 2) [Figure 70-80-6]

from the return hoses, and remove the hoses from the
Remove the power Bob-tach block from the back side of pump fitting.
the gear pump. (See Removal And Installation on Page
20-110-1 [early models] or See Removal And Installation Figure 70-80-7
on Page 20-111-1 [later models])
Figure 70-80-5
P-26824
1
P-26640 Disconnect the charge pressure hose (Item 1) [Figure

70-80-7] from the charge pressure sendor.
Remove the lower hose clamp (Item 1) [Figure 70-80-5]

and remove the hydraulic hose from the fitting on the
front side of the gear pump.
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Figure 70-80-8
1
2
1 P-28121
At the left side access cover, remove the fan drive belt
P-28120 (Item 1) [Figure 70-80-9] from the flywheel pulley.
Figure 70-80-10
Mark the hydraulic hoses for the correct installation.

Remove the hose (Item 1) [Figure 70-80-8] that goes to
the case drain filter.
Remove the four high pressure hoses (Item 2) [Figure

70-80-8] from the hydrostatic pump.
1
IMPORTANT
P-28122
damage the system. Remove the engine mount bolt (Item 1) [Figure 70-80-
I-2003-0888 10] at the left front engine mount.
Installation: Tighten the mounting bolt to 61 - 69 ft.-lb.

(83 - 94 N•m) torque.
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ENGINE (CONT’D) Disconnect the wire harness clamp (Item 3) [Figure 70-
80-12].
Figure 70-80-13
Figure 70-80-11
2
1
3
P-34734
P-28123
Remove the mount bolt and ground wire (Item 1) [Figure

Remove the engine mount bolt (Item 1) [Figure 70-80- 70-80-13] from the alternator.
11] at the right front engine mount.

Disconnect the two wires (Item 2) [Figure 70-80-13] from
Installation: Tighten the mounting bolt to 61 - 69 ft.-lb. the alternator.
(83 - 94 N•m) torque.
Disconnect the engine temperature wire (Item 3) [Figure
At the engine compartment, remove the battery. (See 70-80-13].
Disconnect the engine oil pressure wire (Item 4) [Figure
Remove the engine air cleaner. (See Housing Removal 70-80-13].
And Installation on Page 70-40-1.)
Figure 70-80-12 Page 60-30-4.)
3 1
2
P-28124
Disconnect the engine electrical harness (Item 1) [Figure

70-80-12] from the tailgate harness.
Disconnect the fuel shut-off solenoid (Item 2) [Figure 70-

80-12].
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Figure 70-80-14
1
1 1
P-34737
2 Remove the fuel line (Item 1) [Figure 70-80-16] from the

P-34735 fuel screen assembly.
Cap the hose and plug the fitting.

Disconnect the four glow plug connectors (Item 1)
[Figure 70-80-14]. Remove the glow plug harness from Figure 70-80-17

behind the injector lines.
Remove the harness clamp (Item 2) [Figure 70-80-14].
Figure 70-80-15
1
2
3 P-28134
Disconnect and plug the fuel return line (Item 1) [Figure

70-80-17].
P-34736
Disconnect the loader wiring harness connector (Item 1)

[Figure 70-80-15] from the speed sensor.
Remove the bolt and ground cable (Item 2) [Figure 70-

80-15] from the loader frame.
Remove the three wires (Item 3) [Figure 70-80-15] from

the starter.
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Figure 70-80-18
1 P-34738
Remove the left rear engine mounting bolt (Item 1)

P-28132 [Figure 70-80-20].
Installation: Tighten the nut and bolt to 61 - 69 ft.-lb. (83

Disconnect and cap the engine oil to cooler hoses (Item - 94 N•m) torque.
1) [Figure 70-80-18].

Figure 70-80-21
Figure 70-80-19
1
2
1
N-19990
P-28131
Remove the right rear engine mounting bolt (Item 1)

At the right side of the engine, remove the throttle bracket [Figure 70-80-21].
mount nuts (Item 1) [Figure 70-80-19].
Installation: Tighten the nut and bolt to 61 - 69 ft.-lb. (83
Disconnect the throttle linkage connector (Item 2) - 94 N•m) torque.
[Figure 70-80-19].
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ENGINE (CONT’D)
Figure 70-80-22
1
2 2
P7917
Use the dimensions from (Next Page 70-80-8) to make

the engine removal and installation brackets.

Install the bracket (Item 1) [Figure 70-80-22] on the
engine.
Tighten the bolts (Item 2) [Figure 70-80-22] until the lift

bracket is held firmly against the valve cover.
NOTE: Bolts required are two 12x80 mm x 1.75

thread.
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ENGINE (CONT’D)
Figure 70-80-23
13.0
(330)
2.5
(64)
1-1/2” I.S. Dia.

2-1/2” O.S. Dia.
2.5 (64)
4.0
(102) 1-1/2” Square Tubing 1/4” (4)
2.0
(51) Thick Gusset
1.0 (25) 16.0

0.5 1.0 (25)

(406)
(12,7)
0.375
0.3125 Dia. (2) (9,5)
Use Two 3/8” x 1-1/4” Bolts

for Drilled and Tapped Holes
4.0
(102)
4.25
(108) 2.0 (51)
9.0
0.5 0.6875 (229)
(12,7) (17,5) 45°
1.0
(25)
1.75
(44,5)
1.375
(35,0) 0.66 (16,8)
4.5
(114)
8,525
(218)
1.125 1.125
(28,6) 1.75 (28,6)
(44,5)
(2) 2 x 2 x 1/4 0.775

Gusset (19,7)
3/8 Dia. Hole (4)

17.750 9/16 Gusset
Dia. Hole (2)
2-1/2 x 2-1/2 x 22
1/4” Thick
MC-1799B
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ENGINE (CONT’D)
Figure 70-80-24

P7915
Connect a chain hoist to the ring (Item 1) [Figure 70-80-

24] on the lift bracket.
Remove the engine / hydrostatic pump assembly from

the loader [Figure 70-80-24]
NOTE: Residue remaining in the engine oil cooler

may contaminate the engine oil and damage
the engine. In the event of severe engine oil
contamination, oil cooler replacement is
recommended. Drain and flush the cab heater
and plumbing thoroughly.
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Mount Replacement HEAVY DUTY Engine

ENGINE Mounting
MOUNT Bracket
Figure 70-80-25
Washer
1 2
Loader Engine
3 Frame
Mount
5 Spacer
Snubbing
Washer TS-1520
6
Install the new engine mount as shown in the cut away

7
MC-1771 side view [Figure 70-80-26].
Tighten the mounting bolts to 61 - 69 ft.-lb. (83 - 94 N•m)

Use the following procedure to install new engine torque.
mounts:

Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts (two front and two rear).
Use the parts shown to install the new engine mounts

[Figure 70-80-25].
Item 1 - Square Nut - Used on left side engine mounts

Item 2 - Hex Nut - Used on right side engine mounts
Item 3 - Mount Washer
Item 4 - Engine Mount
Item 5 - Tube Spacer
Item 6 - Snubbing Washer
Item 7 - Mounting Bolt
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FLYWHEEL AND HOUSING The ring gear (Item 1) [Figure 70-90-2] on the flywheel is
an interference fit. Heat the ring gear enough to expand it
Flywheel Removal And Installation and hit it with a hammer to remove it evenly.
Figure 70-90-1 Clean the outer surface of the flywheel to give it a smooth
fit.
Clean the new ring gear and heat it to a maximum

temperature of 428° F (220° C).
Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
1
P5558
Remove the drive belt. (See DRIVE BELT on Page 30-

50-1.)

flywheel.
Installation: Tighten the flywheel bolts as follows:

Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 N•m)
1st. Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd. Step Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Ring Gear Removal And Installation
Figure 70-90-2
P5564
Remove the flywheel from the engine crankshaft [Figure

70-90-2].
NOTE: The lead chamfer on ring gear tooth must face

the starter.
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FLYWHEEL AND HOUSING (CONT’D)
Flywheel Housing Removal And Installation
Figure 70-90-3
1
1
P5562
Remove the drive belt. (See DRIVE BELT on Page 30-

50-1.)

Remove the hydrostatic pump. (See Removal And
Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation on Page 30-50-2.)
Remove the starter. (See Removal And Installation on

Page 60-40-1.)
Remove the flywheel housing mounting bolts (Item 1)

[Figure 70-90-3].
Remove the flywheel housing from the engine.
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RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
Figure 70-100-1
B-16718
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RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-3
Disassembly
Figure 70-100-2
CD-15481
Remove the rocker arms and brackets [Figure 70-100-

CD-15486 3].
Figure 70-100-4
Remove the starter. (See Removal And Installation on
Page 60-40-1.)

Page 60-30-4.)
Drain the oil from the engine oil pan.
Remove the turbocharger. (See Turbo Charger Removal

and Installation on Page 70-100-59.)
Remove the exhaust manifold.
Remove the intake manifold.

CD-15480
Remove the fuel injection pumps. (See Fuel Injection
Pump Removal on Page 70-70-5.)
Remove the push rods [Figure 70-100-4].
Remove the fuel injectors. (See Fuel Injector Removal
Remove the oil filter.
Remove the fuel filter & fuel lift pump [Figure 70-100-2].
Remove the valve cover.
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Figure 70-100-5
P5292
Remove the belt pulley (Item 1) [Figure 70-100-7].

CD-15513
Remove the front cover and timing belt. (See Front Cover
Disassembly on Page 70-100-44 and (See Timing Belt
Remove the cylinder head bolts [Figure 70-100-5]. Removal on Page 70-70-15.)

Remove the cylinder head. Remove the crankshaft gear.
Figure 70-100-6 Figure 70-100-8
CD-15515 CD-15471
Remove the oil pressure control valve [Figure 70-100-6]. Remove the oil pump [Figure 70-100-8].
Remove the plugs or fittings from the engine block. Remove the oil pump relief valve (Item 1) [Figure 70-
100-8].
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Figure 70-100-9
CD-15520
Remove the connecting rod bolts [Figure 70-100-11].

CD-15518
Remove all the piston / connecting rod assembly from the
engine block.
Remove the oil pan [Figure 70-100-9].
To check the piston / connecting rod assembly. (See

Figure 70-100-10 Piston Installation On The Connecting Rod on Page 70-
100-38.)
Figure 70-100-12
CD-15519
Remove the oil suction pipe [Figure 70-100-10].

CD-15521
Remove the front cover [Figure 70-100-12].
To disassemble and assemble the front cover. (See Front

Cover Disassembly on Page 70-100-44.)
Remove the flywheel. (See Flywheel Removal And

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Figure 70-100-13
CD-15541
Remove the camshaft [Figure 70-100-15].

CD-15524
Figure 70-100-16
Remove the rear cover [Figure 70-100-13].

To install a new rear seal and inspect the cover. (See
Rear Cover Seal Removal And Installation on Page 70-
100-30.)
Figure 70-100-14
CD-15526
Mark the location of each main bearing cap so it will be

1
returned to original position.
Remove the main bearing caps bolts [Figure 70-100-16].
CD-15525 Remove the main bearing caps.
Remove the crankshaft.

Install the timing tool (Item 1) [Figure 70-100-14] for the
camshaft. To check the crankshaft specifications. (See Crankshaft,
Checking on Page 70-100-31.)
Remove the thrust washer from the camshaft [Figure 70-
100-14]. Remove the upper half of the main bearings.
Remove the timing tool.
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Figure 70-100-17
CD-15531
Install the oil pressure control valve and compression

CD-15527 spring [Figure 70-100-19].
Install the plug.

Remove the tappets from the engine block [Figure 70-
100-17]. Figure 70-100-20

Assembly
Figure 70-100-18
CD-15532
Install new seals on the fittings and/or plugs.

CD-15528
Install all the fittings and/or plugs and tighten to 82 ft.-lb.
(111 N•m) torque [Figure 70-100-20].
Install the thermostat and compression spring [Figure
70-100-18].
Install the plug and tighten to 82 ft.-lb. (111 N•m) torque.
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Assembly (Cont'd)
Figure 70-100-21
CD-15539
Install a new seal on the plug and install in the block.

CD-15537 Tighten the plug to 21 ft.-lb. (28 N•m) torque [Figure 70-
100-23].
Install the plug and tighten to 37 ft.-lb. (50 N•m) torque Figure 70-100-24
[Figure 70-100-21].

Figure 70-100-22
CD-15540
CD-15538 Install the tappets [Figure 70-100-24].
Install the oil pressure switch and tighten to 115 in.-lb. (13
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Assembly (Cont'd)
Figure 70-100-25
CD-15542
Install the thrust washer with the lubricating groove

CD-15435 toward the crankcase [Figure 70-100-27].
Figure 70-100-28
Before installing the new piston cooling oil nozzle, check
that the bores in the block are clean and free of oil. Press

in the piston cooling nozzle as far as it will go [Figure 70-
100-25].
Figure 70-100-26
1
CD-15543
Install the camshaft timing tool (Item 1) [Figure 70-100-

28].
CD-15541 Tighten the camshaft thrust washer bolt to 15 ft.-lb. (21

Install the camshaft [Figure 70-100-26]. Remove the timing tool.
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Assembly (Cont'd)
Figure 70-100-29
CD-15546
Install the thrust bearings halves on the main bearing cap

CD-15544 [Figure 70-100-31].
Measure the width of the thrust washers / main bearing

Install the upper main bearing halves [Figure 70-100- cap [Figure 70-100-31].
29].

Figure 70-100-30
CD-15545
Install the other main bearing half into the main bearing
caps [Figure 70-100-30].
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Assembly (Cont'd)
Figure 70-100-32
CD-15547
CD-15549
Install the main bearing locating sleeves [Figure 70-100-

CD-15548 33].
Figure 70-100-34
Measure the bearing journal width at the crankshaft
(inset) [Figure 70-100-32].

Specifications:
Journal Width Std.................................1.378 - 1.379 in.
(35,0 - 35,04 mm)
Limit for O/S..................................1.395 in. (35,44 mm)
Determine the end play for the crankshaft [Figure 70-

100-32].
Specifications:
Std. End Play....................................... 0.004 - 0.010 in.
(0,1 - 0,273 mm) CD-15550
Wear Limit.......................................0.016 in. (0,4 mm)
Use new thrust washer as needed to get the correct end Install the crankshaft into the engine block [Figure 70-
play. 100-34].
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Assembly (Cont'd)
Figure 70-100-35
CD-15553
Install the main bearing caps / main bearing assembly

CD-15551 [Figure 70-100-37].
Make sure they are returned to their original location.

Lubricate the thrust washer with grease and install them
on the main bearing cap [Figure 70-100-35]. Figure 70-100-38

Figure 70-100-36
CD-15554
CD-15552
Tighten the main bearing cap bolts as follows [Figure 70-
100-38]:
Install the main bearing / thrust washer assembly [Figure
70-100-36]. Initial Torque......................................37 ft.-lb. (50 N•m)
1st Step Angle.......................................................60°
NOTE: The main bearing cap No. 1, at the flywheel
end, the chamfer must be towards the 2nd Step Angle.........................................................45°
flywheel end.
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Assembly (Cont'd)
Figure 70-100-39
CD-15557
Measure the distance between the top edge of the crank

CD-15555 pin (TDC) and cylinder head sealing surface at all
cylinders [Figure 70-100-41].
Put sealing compound on the rear cover [Figure 70-100- Figure 70-100-42
39].

Figure 70-100-40
A B C
CD-15558
CD-15556 Compare actual dimension with the dimension listed

[Figure 70-100-42]:
Install the rear cover complete with a new rear seal Specifications:
[Figure 70-100-40].
Piston Class A.....................................7.732 - 7.736 in.
NOTE: Make sure the rear cover oil pan surface (196,39 - 196,49 mm)
aligns with the engine block surface.
NOTE: If the crankshaft is undersize, 0.005 in. (0,125
Tighten the bolts to 15 ft.-lb. (21 N•m) torque [Figure 70- mm) must be added to the dimension listed.
100-40].
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Assembly (Cont'd)
Figure 70-100-43
CD-15561
Install a piston ring compressor on the piston rings.

CD-15559
Install the piston / connecting rod assembly into the
engine block [Figure 70-100-45].
Install the connecting rod bearing halves into the
connecting rod [Figure 70-100-43]. NOTE: The flywheel symbol on the piston must be

toward the flywheel.
Figure 70-100-44
Figure 70-100-46
CD-15560
CD-15562
Before installing piston / connecting rod assembly, make

sure the piston ring gaps are staggered as shown in Install the connecting rod cap on the connecting rod,
[Figure 70-100-44]. make sure the numbers are aligned [Figure 70-100-46].
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Assembly (Cont'd)
Figure 70-100-47
CD-15565
Put sealing compound on the front cover sealing surface

CD-15563 [Figure 70-100-49].
NOTE: Make sure the camshaft / centrifugal governor

Tighten the connecting rod bolts as follows [Figure 70- connecting is clean and free of oil.
100-47]:

Figure 70-100-50
Initial Torque......................................22 ft.-lb. (30 N•m)
1st Step Angle.......................................................60°
2nd Step Angle........................................................ 60°
Figure 70-100-48
CD-15566
Install the front cover with the new shaft seals on the
CD-15564
NOTE: Make sure the oil pan sealing surface on the
front cover aligns with the sealing surface on
Check that the connecting rods can be easily moved the block [Figure 70-100-50].
back and forth on the crank pin [Figure 70-100-48].
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Assembly (Cont'd)
Figure 70-100-51
CD-15468
Install the camshaft gear [Figure 70-100-53].

CD-15567
Make sure all mating surfaces are clean and free of oil.
Tighten the front cover bolts to 15 ft.-lb. (21 N•m) torque Install the camshaft bolt [Figure 70-100-53].
[Figure 70-100-51].

Figure 70-100-54
Figure 70-100-52
CD-15469
CD-15568
Tighten the camshaft bolt finger tight only [Figure 70-

Install the crankshaft gear on the crankshaft [Figure 70- 100-54]. Camshaft gear must still turn freely.
100-52]. Make sure the mating surfaces are clean and
free of oil.
Install the bolt and tighten to 243 - 295 ft.-lb. (330 - 400
N•m) torque.
A300 Bobcat Loader

591 of 772
Assembly (Cont'd)
Figure 70-100-55
CD-15472
Tighten the oil pump bolts to 16 ft.-lb. (22 N•m) torque

CD-15470 [Figure 70-100-57].
Install the engine timing belt. (See Timing Belt Installation

Install a new gasket on the oil pump [Figure 70-100-55]. on Page 70-70-17.)

Figure 70-100-56 Figure 70-100-58
CD-15471 CD-15473
Install the oil pump on the engine block [Figure 70-100- Put spacers on sealing surface of the engine block and
56]. set dial indicator gauge to 0 [Figure 70-100-58]. (See
Deutz Engine Tools Identification Chart on Page 70-100-
1.)
A300 Bobcat Loader

592 of 772
Assembly (Cont'd)
Figure 70-100-59
CD-15475
Compare the measurements with the specifications to

CD-15474 determine the correct cylinder head gasket [Figure 70-
100-61].
Position the dial gauge on the piston [Figure 70-100-59]. Specifications:

Figure 70-100-60 Piston Projection Marking of Cylinder
Head Gasket
0.023 - 0.027 in. (0,59 - 0,69 mm)....................1 Notch
0.027 - 0.030 in. (0,69 - 0,76 mm).................2 Notches
1 0.030 - 0.033 in. (0,76 - 0,83 mm).................3 Notches
1 Figure 70-100-62
Piston pin axis B-14695
Measure at the gauge points (Item 1) [Figure 70-100-

60].
To determine maximum piston projection measure all the

pistons. CD-15476
Make sure the dowel pins are installed in the engine

block [Figure 70-100-62].
A300 Bobcat Loader

593 of 772
Assembly (Cont'd) 8 6 4 5 9
Figure 70-100-63 10 3 1 2 7
CD-15479
Tighten the cylinder head bolts to the correct torque in

CD-15477 the correct sequence [Figure 70-100-65].

Install the cylinder head gasket [Figure 70-100-63].
1st Stage Torque................................59 ft.-lb. (80 N•m)
Gasket is marked TOP.
2nd Stage Torque..........................118 ft.-lb. (160 N•m)

Make sure the sealing surfaces of the cylinder head 3rd Stage Torque....................................................90°
gasket is free of oil.
Figure 70-100-66
Install the cylinder head.
Figure 70-100-64
CD-15480
Install the push rods [Figure 70-100-66].

CD-15478
Measure the cylinder head bolts.
Std. Length.................... 5.90 ± 0.03 in. (150 ± 0,8 mm)
Put a light coat of oil on the head bolts [Figure 70-100-

64].
Install the head bolts.
A300 Bobcat Loader

594 of 772
Assembly (Cont'd)
Figure 70-100-67
CD-15483
Install the valve cover gasket [Figure 70-100-69]. Install

CD-15481 the valve cover. Tighten the bolts to 75 in.-lb. (8,5 N•m)
torque.
Install the rocker arms / bracket assembly [Figure 70- Install new intake manifold gasket.
100-67].

Install the intake manifold and tighten the bolts to 15 ft.-
Figure 70-100-68 lb. (20 N•m) torque.
Install new exhaust manifold gaskets.
Install the exhaust manifold and tighten the bolts to 30 ft.-

lb. (40 N•m) torque.
Figure 70-100-70
CD-15482
Tighten the rocker arm bracket bolts to 15 ft.-lb. (21 N•m)

torque [Figure 70-100-68].
Set the valve clearance. (See Valve Seats, Checking on

Page 70-100-41.)
CD-15484
Install a new seal on the fuel lift pump [Figure 70-100-

70].
A300 Bobcat Loader

595 of 772
Assembly (Cont'd)
Figure 70-100-71
CD-15487
Tighten the lift pump bolts to 15 ft.-lb. (21 N•m) torque

CD-15485 [Figure 70-100-73].
Install a new oil filter.

Turn the camshaft so the fuel lift pump lobe is at B.D.C.
(bottom dead center) [Figure 70-100-71]. Install the fuel injectors. (See Fuel Injector Removal And

Figure 70-100-72
Install the fuel injector pumps. (See Fuel Injection Pump
Figure 70-100-74
CD-15486
Install the fuel lift pump [Figure 70-100-72].

CD-15488
Put sealing compound on the sealing surface of the oil

suction pipe [Figure 70-100-74].
A300 Bobcat Loader

596 of 772
Assembly (Cont'd)
Figure 70-100-75
B-14696
Initially install the corner bolts first and tighten to 5 in.-lb.

CD-15489 (0,5 N•m) torque.
Install the oil pan bolts and tighten to 15 ft.-lb. (21 N•m)
Install the oil suction pipe and tighten the bolts to 16 ft.-lb. torque as shown in [Figure 70-100-77].
(22 N•m) torque [Figure 70-100-75].

Install the oil pan plug and tighten to 40 ft.-lb. (55 N•m)
Figure 70-100-76 torque.
Install the flywheel. (See Flywheel Removal And

Install the turbocharger. (See Turbo Charger Removal

and Installation on Page 70-100-59.)
Install the starter. (See Removal And Installation on Page

60-40-1.)
Install the alternator. (See Removal And Installation on

Page 60-30-4.)
CD-15490
Put sealing compound on the sealing surface of the oil

pan [Figure 70-100-76].
Install the oil pan
A300 Bobcat Loader

597 of 772
Cylinder, Checking
Figure 70-100-78 b 1
2
a 1 2
B-14697
Check the cylinders with engine block longitudinal (a)

CD-15319 and transverse (b) axis and in three planes [Figure 70-
100-80].
Clean the engine block and inspect for damage. Specifications:

Install the main bearing caps [Figure 70-100-78]. Cylinder Bore......................................3.58 + 0.0008 in.
(91 + 0,02 mm)
Tighten the main bearing cap bolts as follows:
Wear Limit........................................3.59 in. (91,1 mm)
Camshaft Bearing, Checking
1st Stage Angle......................................................60°
2nd Stage Angle......................................................45° Figure 70-100-81
Figure 70-100-79
b
a
1 2
B-14698
CD-15421
Check the camshaft bearing bushings at points (1) and
(2) in the planes of (a) and (b) [Figure 70-100-81].
Using a dial indicator gauge check the cylinders [Figure
70-100-79].
A300 Bobcat Loader

598 of 772
Camshaft Bearing, Checking (Cont’d)
(228.1±0.3 mm)
(117.1±0.3 mm)
Figure 70-100-82
4.61±1.1012 in.
0.019±0.012 in.
8398±0.012 in.
(0.5±0.3 mm)
0.098±0.12 in.
(25±.3mm)
0
0
A B
B-14699
Use the dimensions in [Figure 70-100-84] to install the

CD-15350 camshaft bushings.
Figure 70-100-85
Check the camshaft bushings using a gauge [Figure 70-
100-82].

Inner Diameter.....................................2.126 + 0.002 in.
(54 + 0,054 mm)
Wear Limit....................................2.129 in. (54,08 mm)
Camshaft Bearing, Removal And Installation
Figure 70-100-83
CD-15383
When installing the new camshaft bushings make sure

the oil lube hole aligns with the oil hole in the engine
CD-15361
Remove all the camshaft bearing bushings using a

camshaft bushing removal tool as needed [Figure 70-
100-83].
A300 Bobcat Loader

599 of 772
Camshaft Bearing Removal And Installation (Cont'd)
Figure 70-100-86
CD-15411
Remove the control rod and spring [Figure 70-100-88].

CD-15404
Figure 70-100-89
Install the new camshaft bushings using a camshaft

bushing installation tool [Figure 70-100-86].

Control Rod Guide Bushing Removal
Figure 70-100-87
CD-15412
Remove the cover [Figure 70-100-89].
CD-15409
Remove the parallel pin [Figure 70-100-87].
A300 Bobcat Loader

600 of 772
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-90
CD-15415
Install the spacer tool in position. Pull the pipe from the
CD-15413 lower press fit [Figure 70-100-92].
NOTE: Do Not pull pipe completely out.

Drill a 7/32 in. (5,5 mm) hole on one side of the pipe
[Figure 70-100-90]. Remove the spacer tool.

NOTE: Carefully clean the engine block after drilling. Figure 70-100-93
Figure 70-100-91
CD-15416
CD-15414
Press pin in until it does not project beyond the pipe
[Figure 70-100-93]. Pull the pipe out completely.
Install the puller into the bore until the pin engages
[Figure 70-100-91].
A300 Bobcat Loader

601 of 772
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-94
CD-15419
Install the guide on the arbor assembly with the chamfer

CD-15417 pointing toward the crankcase [Figure 70-100-96].
Figure 70-100-97
Using the tool, drive the guide bushing out [Figure 70-
100-94].

Control Rod Guide Bushing Installation
Figure 70-100-95
CD-15420
Fasten the arbor assembly and bushing on the engine

CD-15418
Install the new bushing into the center of the arbor

A300 Bobcat Loader

602 of 772
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-98
CD-15424
Remove the guide bushing at the flywheel end of the

CD-15422 engine block [Figure 70-100-100].
Figure 70-100-101
Drive the bushing into the engine block as far as it will go
[Figure 70-100-98].

Figure 70-100-99
CD-15425
Assemble the arbor without the spacer [Figure 70-100-

CD-15423 101].
Remove the arbor assembly [Figure 70-100-99].
A300 Bobcat Loader

603 of 772
Figure 70-100-102
CD-15428
Drive in the guide bushing as far as it will go, at the

CD-15426 flywheel end [Figure 70-100-104].
Figure 70-100-105
Install the guide bushing on the arbor assembly with the
chamfer pointing toward the crankcase [Figure 70-100-

102].
Figure 70-100-103
CD-15429
Remove the arbor assembly [Figure 70-100-105].
CD-15427
Fasten the arbor assembly and guide bushing to the

A300 Bobcat Loader

604 of 772
Figure 70-100-106
CD-15432
Install the new cover flush with the engine block [Figure
CD-15430 70-100-108].
Figure 70-100-109
Install the new pipe in the block as far as it will go with the
arbor assembly [Figure 70-100-106].

Figure 70-100-107
CD-15433
Install the control rod with starter spring into the guide
CD-15431 bushings [Figure 70-100-109].
Put sealing compound on the new cover [Figure 70-100-

107].
A300 Bobcat Loader

605 of 772
Figure 70-100-110
CD-15439
Clean the seal seating surface [Figure 70-100-112].

CD-15434 Inspect the cover for damage, replace as needed.
Figure 70-100-113
Compress the starter spring. Install the parallel pin into
the recess for the control rod travel limitation [Figure 70-

100-110].
(20.4±0.2 mm)
0.803±0.008 in.
Check to make sure it is flush with the surface.
Rear Cover Seal Removal And Installation
Figure 70-100-111
B-14700
When installing the new shaft seal, use the dimension

shown in [Figure 70-100-113].
CD-15438
Remove the rear cover shaft seal [Figure 70-100-111].
A300 Bobcat Loader

606 of 772
RECONDITIONING THE ENGINE (CONT’D) Crankshaft, Checking
Rear Cover Seal Removal And Installation (Cont’d) Figure 70-100-115
Figure 70-100-114
CD-15443
CD-15441
Put the crankshaft on v-blocks.
Use the seal driver tool and install to the correct depth Check the main bearing journals:
[Figure 70-100-114]. (See Deutz Engine Tools

Identification Chart on Page 70-100-1.) Specifications:
Journal Diameter 2.7538 - 2.7546 in.

(69,97 - 69,99 mm)
Each Undersize 0.010 in. (0,25 mm)
Undersize Limit 2.7348 - 2.7356 in.
(69.48 - 69,50 mm)
Check the thrust bearing width [Figure 70-100-115].
Specifications:
Journal Width.....................................1.378 +0.0016 in.

(35 + 0,04 mm)
Wear Limit.........................................3.59 in. (91,1 mm)
Journal Width
Each Oversize..............................1.395 in. (35,44 mm)
A300 Bobcat Loader

607 of 772
Crankshaft, Checking (Cont’d)
Figure 70-100-116
CD-15446
Check the surface of the crankshaft seal area [Figure

CD-15444 70-100-118].
Recondition the crankshaft as needed.

Check the connecting rod journals [Figure 70-100-116].

Specifications:
Pin Diameter...................................2.1588 - 2.1596 in.)

(54,97 - 54,99 mm)
Undersize Limit...............................2.1448 - 2.1456 in.)
(54,47 - 54,49 mm)
Wear Limit......................................0.0004 in. (0,1 mm)
Figure 70-100-117
CD-15445
Use a dial indicator and check crankshaft for out of

roundness [Figure 70-100-117].
Specifications:
Out of Roundness Max...................0.002 in. (0,05 mm)
A300 Bobcat Loader

608 of 772
Connecting Rod, Checking
Figure 70-100-119
b
a
1 2
CD-15448
Replace small end busing as needed [Figure 70-100-

B-14701 121].
Bore for Small End Bushing..............1.299 + 0.0008 in.

When checking the connecting rod large and small end,
(33 + 0,02 mm)
measure at the points (1) and (2) and in planes (a) and
O.D. of Small End Bushing................1.3017 - 1.303 in.

(b) [Figure 70-100-119].
(33,07 - 33,11 mm)
Figure 70-100-120
Figure 70-100-122
CD-15447
CD-15449
Check the small end bushing [Figure 70-100-120].

Press in the small end bushing, make sure the lubrication
Specifications: holes are in alignment [Figure 70-100-122].
I.D. of Small End Bushing..................1.181 in. (30 mm)

Wear Limit Bushing Clearance.......0.003 in. (0,08 mm)
A300 Bobcat Loader

609 of 772
Connecting Rod, Checking (Cont'd)
Figure 70-100-123
CD-15452
Tighten the connecting rod cap nuts as follows [Figure

CD-15450 70-100-125].

After pressing in the small end bushing, bore the bushing
1st Step Angle.......................................................60°
to the following dimensions [Figure 70-100-123].
2nd Step Angle.........................................................60°

Specifications:
I.D. of Small End Bushing.................1.181 in. (30 mm)
Figure 70-100-124
2908 2908
CD-15451
Install the correct cap on the correct rod [Figure 70-100-

124].
A300 Bobcat Loader

610 of 772
RECONDITIONING THE ENGINE (CONT’D) Piston, Checking
Connecting Rod, Checking (Cont'd) Figure 70-100-127
Figure 70-100-126
B-8194
CD-15454
Remove the piston rings from the piston [Figure 70-100-
127].
Measure the big end bore [Figure 70-100-126]. If the
measurement is the same as the specific valve, the Remove the piston from the connecting rod.

necessary preload on the bearing halves will be
obtained. (See Connecting Rod, Checking on Page 70-100-33.) to
check connecting rod specifications.
Specifications:
Figure 70-100-128
Big End I.D........................................2.303 + 0.0008 in.
(58,5 + 0,02 mm)
Remove connecting rod cap. Install new bearing halves.

Tighten the connecting rod cap nuts and tighten as listed
above.
Measure the bearing halves:
Big End Bearing I.D...........................2.1655 - 2.167 in.

(55,004 - 55,04 mm)
Each Undersize.............................0.010 in. (0,25 mm)
Limit For Undersize............................2.148 - 2.1472 in.
(54,504 - 54,54 mm) B-8231
Radial Clearance
Wear Limit.................................. 0.005 in. (0,12 mm)
Clean and inspect piston and piston ring grooves [Figure
70-100-128].
Check the connecting rod, without bearing halves, on a
connecting rod tester.
Specifications:
Parallel Check-Tolerance...............0.004 in. (0,10 mm)

Over a Distance of............................3.94 in. (100 mm)
Squareness Check-Tolerance.........0.002 in. (0,05 mm)
A300 Bobcat Loader

611 of 772
RECONDITIONING THE ENGINE (CONT’D) Specifications:
Piston, Checking (Cont’d) Wear Limit

1st Ring..........................................0.008 in. (0,2 mm)
Figure 70-100-129
2nd Ring.......................................0.006 in. (0,16 mm)
3rd Ring.......................................0.005 in. (0,12 mm)
Piston Pin, Checking
Figure 70-100-131
B-8229
Measure the ring gap with a feeler gauge in the cylinder

[Figure 70-100-129].

Specifications: B-8230
Wear Limit
Check piston pin for wear [Figure 70-100-131].
1st Ring Gap.................0.012 - 0.020 in. (0,3 - 0,5 mm)
2nd Ring Gap................0.031 - 0.039 in. (0,8 - 1,0 mm) Specifications:
3rd Ring Gap.............0.018 - 0.028 in. (0,45 - 0,7 mm)
Pin O.D...............1.118-0.0002 in. (30,0-0,005 mm)
Figure 70-100-130
B-8228
Using new rings, measure the ring grooves using a feeler

gauge [Figure 70-100-130].
A300 Bobcat Loader

612 of 772
Piston Rings Installation
Figure 70-100-132 1
3
TS-1928A
lst Ring - Is a double tapered ring, (Item 1) [Figure 70-

B-8194 100-133] & [Figure 70-100-134]. It is installed on the
piston with the mark TOP facing the combustion
chamber.
When installing the piston rings position them as listed
below [Figure 70-100-132]. 2nd Ring - Is a rectangular ring, (Item 2) [Figure 70-100-

133] on earlier model loaders, or an inside tapered ring
Figure 70-100-133 (Item 2) [Figure 70-100-134] which is installed on the
piston with the mark TOP facing the combustion chamber
[Figure 70-100-134], on later model loaders.
1
3rd Ring - Is a bevelled edge slotted oil control ring (Item
2
3) [Figure 70-100-133] & [Figure 70-100-134].
The gap of each ring must be offset by 180° to the other

ring.
NOTE: Check the piston rings that are installed on

your loaders engine before ordering new ring
sets from Bobcat Parts, to insure proper fit.
3
TS-1927
A300 Bobcat Loader

613 of 772
Piston Installation On The Connecting Rod
Figure 70-100-135
CD-15458
Install the piston on the connecting rod [Figure 70-100-

CD-15456 137].
Install the snap ring into the piston [Figure 70-100-135].

Figure 70-100-136
CD-15457
NOTE: The snap ring gap must be towards the piston

crown (Item 1) [Figure 70-100-136].
A300 Bobcat Loader

614 of 772
Piston Installation On The Connecting Rod (Cont'd)

1
Figure 70-100-138
3
P13908
The flywheel symbol (Item 1) [Figure 70-100-138] &

N-19068 [Figure 70-100-140] on the piston must point toward the
flywheel (Item 3) [Figure 70-100-140], when properly
installed on the connecting rod.
Figure 70-100-139
The numbers on the connecting rod and cap (Item 1)

[Figure 70-100-139] & (Item 2) [Figure 70-100-140]
point toward the camshaft side of the engine when being
install in the engine block.
Figure 70-100-141
2908 2908
CD-15451
CD-15459
Install the other side snap ring [Figure 70-100-141].
A300 Bobcat Loader

615 of 772
RECONDITIONING THE ENGINE (CONT’D) Valves, Checking
Cylinder Head Disassembly Figure 70-100-143
Figure 70-100-142
B-8205
CD-15461
Measure the valve stem clearance [Figure 70-100-143].
NOTE: Do not grind the cylinder head surface, if its Specifications:

damaged, replace the cylinder head.

Wear Limit
Using a valve spring tool, remove the spring locks, valve
Intake Valve...................................0.005 in. (0,12 mm)
spring cap, valve spring and valve [Figure 70-100-142].
Exhaust Valve...............................0.006 in. (0,15 mm)
100-1.)
Figure 70-100-144
Repeat the procedure for all the valves.
Remove the valve seals.
Clean the cylinder head and inspect for damage.
B-8204
Measure the valve stem diameter [Figure 70-100-144].
Std. Intake Valve...............................0.314 - 0.0006 in.

(7,98 - 0,015 mm)
Std. Exhaust Valve.............................0.313 - 0.0006 in.
(7,96 - 0,015 mm)
A300 Bobcat Loader

616 of 772
Valves, Checking (Cont’d)
Figure 70-100-145
Angle
CD-15463
Diameter Thickness
Measure the valve seat width [Figure 70-100-146].
B-8202
Specifications:
Measure the valve rim thickness [Figure 70-100-145]. Width (Intake)............0.062 ± 0.016 in. (1,58 ± 0,4 mm)
(Exhaust)...........0.067 ± 0.016 in. (1,7 ± 0,4 mm)

Specifications:
Valve Seats, Checking
Intake Valve.....................................0.055 in. (1,4 mm)
Exhaust Valve...................................0.05 in. (1,2 mm) Figure 70-100-147
Measure the valve head diameter [Figure 70-100-145].
Specifications:
Intake Valve...............1.594 ± 0.004 in. (40,5 ± 0,1 mm)

Exhaust Valve..........1.374 ± 0.004 in. (34,9 ± 0,01 mm)
Valve seat angle [Figure 70-100-145].
Specifications:
Intake Valve...........................................................30° CD-15464
Exhaust Valve.......................................................45°
Measure the valve clearance between the valve head
and cylinder head sealing surface [Figure 70-100-147].
Valve penetration into cylinder head:

Specifications:
Wear Limit.............0.0512 ± 0.0051 in. (1,3 ± 0,13 mm)
Recondition the valve seats and valve guides if worn.
A300 Bobcat Loader

617 of 772
Valve Spring, Checking (Cont’d)
Figure 70-100-148
Inclination
Free Length
CD-15323
Square Install the valve seal on the protective sleeve and push
B-8208 the seal down [Figure 70-100-150].
Remove the protective sleeve.

Measure valve spring free length [Figure 70-100-148]
Figure 70-100-151

Specifications:
Valve Spring Diameter....................0.132 in. (3,35 mm)

Free Length................................1.74 in. (44,3 mm)
Valve Spring Diameter..................0.134 in. (3,40 mm)
Free Length................................1.547 in. (39,3 mm)
Inclination......................................0.126 in. (3,2 mm)
Cylinder Head Assembly
Figure 70-100-149
CD-15324
Use the tool and press the valve stem as far as it will go
[Figure 70-100-151]. (See Deutz Engine Tools
Identification Chart on Page 70-100-1.)
CD-15322
Install the valve into the cylinder head [Figure 70-100-

149].
Install the protective sleeve or masking tape on the valve

stem grooves [Figure 70-100-149].
A300 Bobcat Loader

618 of 772
RECONDITIONING THE ENGINE (CONT’D) Rocker Arm And Bracket, Checking
Cylinder Head Assembly (Cont'd) Figure 70-100-154
Figure 70-100-152
CD-15327
CD-15325
Disassembly the rocker arms from the bracket [Figure
70-100-154].
Install the valve spring and cap [Figure 70-100-152].
Figure 70-100-155

Figure 70-100-153
CD-15328
CD-15461
Check for wear at the following locations and replace as

Use the valve spring tool, install the valve spring tool needed [Figure 70-100-155]:
[Figure 70-100-153].
Journals
Repeat the above procedure to install all the valves. Adjusting Bolt
Rocker Arm Contact Face
Bore
A300 Bobcat Loader

619 of 772
RECONDITIONING THE ENGINE (CONT’D) Front Cover Disassembly
Rocker Arm And Bracket, Checking (Cont’d) Figure 70-100-158
Figure 70-100-156
CD-15343
CD-15330
NOTE: Dynamometer testing is recommended if the
governor assembly is re-built.
Check the oil passages that they are open and clean
[Figure 70-100-156]. Remove the engine shut-down solenoid [Figure 70-100-

158].
Figure 70-100-157
Figure 70-100-159
CD-15331
CD-15344
Install the rocker arms on the bracket.

Disconnect the governor spring [Figure 70-100-159].
Install the snap ring [Figure 70-100-157].
A300 Bobcat Loader

620 of 772
Front Cover Disassembly (Cont’d)
Figure 70-100-160
CD-15347
Remove the centrifugal governor [Figure 70-100-162].

CD-15345
Figure 70-100-163
Mark the governor lever shaft (Item 1) [Figure 70-100-

160] for proper installation.

Remove the governor lever shaft.
Figure 70-100-161
CD-15348
Remove the camshaft seal [Figure 70-100-163].
Figure 70-100-164
CD-15346
Remove the shims below the governor lever shaft

[Figure 70-100-161].
CD-15349
Remove the crankshaft seal [Figure 70-100-164].
A300 Bobcat Loader

621 of 772
Front Cover Disassembly (Cont’d)
Figure 70-100-165
CD-15353
Remove the shutdown lever with spacer bushings

CD-15351 [Figure 70-100-167].
Figure 70-100-168
Disconnect the spring [Figure 70-100-165].

Figure 70-100-166
CD-15354
CD-15352 Remove the shaft, spacer bushing and spring [Figure

70-100-168].
Remove the dowel pin [Figure 70-100-166].
A300 Bobcat Loader

622 of 772
Front Cover Disassembly (Cont'd)
Figure 70-100-169
CD-15357
Remove the dowel pin [Figure 70-100-171].

CD-15355
Figure 70-100-172
Remove the O-ring [Figure 70-100-169].

Figure 70-100-170
CD-15358
Remove the pin from the lever [Figure 70-100-172].

CD-15356
Do not damage the cover sealing surface.
Remove the cover [Figure 70-100-170].
A300 Bobcat Loader

623 of 772
Front Cover Disassembly (Cont'd)
Figure 70-100-173
CD-15373
Before removing the torque control assembly, measure

CD-15359 the height from the cover [Figure 70-100-175] and make
a record of this for assembly.
Remove the speed control lever and spacer bushing Figure 70-100-176
[Figure 70-100-173].

Figure 70-100-174
CD-15363
CD-15360 Remove the nut and clamp [Figure 70-100-176].
Remove the torque control assembly.

Remove the O-ring [Figure 70-100-174].
A300 Bobcat Loader

624 of 772
RECONDITIONING THE ENGINE (CONT’D) Front Cover Assembly
Front Cover Disassembly (Cont'd) Figure 70-100-178
Figure 70-100-177
CD-15365
CD-15364
Inspect the front cover for damage [Figure 70-100-178].
Remove the breather vent [Figure 70-100-177]. Replace the front cover as needed.

NOTE: On later model Deutz engines the breather is Figure 70-100-179
located in the valve cover. The breather vent
shown in photo [Figure 70-100-177] is used in
both engines.
B-14703
Inspect the individual parts of the torque control

Replace the parts as needed.
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Front Cover Assembly (Cont'd)
Figure 70-100-180
2
1 3
6
CD-15373
1-1.5 Turns
5 4
Install the torque control assembly to the dimensions
B-14704 taken (See Front Cover Disassembly on Page 70-100-
44.) [Figure 70-100-182] or use the procedure below:
If the torque control was disassemble, do the following Figure 70-100-183

procedure to assemble:

Turn (Item 1) as far as it will go into (Item 2). Unscrew
(Item 1) [Figure 70-100-180] 1 to 1.5 turns.
Tighten the lock nut (Item 3) [Figure 70-100-180] to 12

ft.-lb. (16 N•m) torque.
Turn (Item 4) as far as it will go into (Item 5) [Figure 70-

100-180]. Turn back one full turn.
Tighten the lock nut (Item 6) [Figure 70-100-180] to 53

in.-lb. (6 N•m) torque.
Figure 70-100-181 CD-15374
Measure the thread reach [Figure 70-100-183].
Specifications:
Thread Reach......................................0.252 ± 0.019 in.

(6,4 ± 0,5 mm)
NOTE: Dynamometer testing may be necessary

depending on engine performance.
Install the clamp and nut [Figure 70-100-183].
CD-15371
Install the torque control into the front cover [Figure 70-
100-181].
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Figure 70-100-184
CD-15377
Do Not put oil on the crankshaft seal.

CD-15375
Press the crankshaft seal into the front cover [Figure 70-
100-186].
Tighten the clamp nut to 88 in.-lb. (10 N•m) torque
[Figure 70-100-184]. Figure 70-100-187

Figure 70-100-185 0.236 ± 0.039 in.
(6 ± 1 mm)
B-14705
CD-15376
Adjust the distance of the shut-down stop screw to 0.236
± 0.039 in. (6 + 1 mm) [Figure 70-100-187].
Put a light coat of oil on the camshaft seal.
Tighten the lock nut to 40 in.-lb. (4,5 N•m) torque.
Press the camshaft seal into the front cover [Figure 70-
100-185]. (See Deutz Engine Tools Identification Chart
on Page 70-100-1.)
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Figure 70-100-188
0.79±0.39 in.
(20±1 mm)
B-14707
Install the shut down shaft [Figure 70-100-190].

-
B-14706
Figure 70-100-191
Adjust the minimum speed screw to 0.79 + 0.039 in. (20

± 1.0 mm) [Figure 70-100-188].

Tighten the lock nut to 40 in.-lb. (4.5 N•m) torque.
Figure 70-100-189
CD-15382
Put grease on the O-ring and install on the shaft [Figure

70-100-191].
CD-15380
Install the spacer bushing and spring on the shut down

shaft [Figure 70-100-189].
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Figure 70-100-192
CD-15386
Put grease on the O-ring and install in the front cover

CD-15384 [Figure 70-100-194].
Figure 70-100-195
Install the spacer bushing [Figure 70-100-192].

Figure 70-100-193
CD-15387
CD-15385 Install the spacer bushing on the speed control lever

[Figure 70-100-195].
Install the shut down lever and dowel pin [Figure 70-100- Install the speed control lever into the front cover [Figure
193]. 70-100-195].
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Figure 70-100-196
CD-15390
Drive the pin into the lever [Figure 70-100-198].

B-14708
The groove in the speed control shaft must be in line with
the dowel pin bore.
When installing the speed control lever, make sure it is
installed in the correct direction [Figure 70-100-196]. Figure 70-100-199

Figure 70-100-197
CD-15391
CD-15389
Inspect the centrifugal governor for wear [Figure 70-100-
199]. Replace as needed.
Install the dowel pin into the speed control lever [Figure
70-100-197].
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Figure 70-100-200
CD-15394
Install centrifugal governor assembly into the front cover

CD-15392 [Figure 70-100-202].
Be careful not to damage the shaft seal.

Inspect the governor plate for wear [Figure 70-100-200].
Figure 70-100-203

Replace as needed.
Figure 70-100-201
CD-15395
CD-15393 Inspect roller lever, shaft and idling lever wear [Figure
70-100-203].
Assemble the governor plate with the centrifugal Replace the parts as needed.
governor [Figure 70-100-201].
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Figure 70-100-204
CD-15398
Measure the ball bearing (Item 1) [Figure 70-100-206],

CD-15396 by lightly pressing the roller lever.
Set the dial gauge to zero.

Install shims of at least 0.011 in. (0,3 mm) thickness at
points (Items 1 & 2) [Figure 70-100-204]. Figure 70-100-207

Figure 70-100-205
1
N-18859
CD-15399
CD-15397
Place dial indicator on ball bearing (Item 1) [Figure 70-
100-207].
Install the governor lever shaft without the idling lever
[Figure 70-100-205]. Tighten the bolts to 81 in.-lb. (9,2 Make record of the two readings.
N•m) torque.
The required tolerance is 0.0019 in. (0,05 mm).
NOTE: The longer space (Item 1) [Figure 70-100-205]
on the governor lever shaft goes toward the It is possible to install extra shims at (Items 1 & 2)
cover when being installed. [Figure 70-100-204] to get the required measurement.
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Figure 70-100-208
CD-15402
Connect the governor spring [Figure 70-100-210].

CD-15400
Figure 70-100-211
Assemble the roller lever with the idling lever and shaft
[Figure 70-100-208].

Figure 70-100-209
1
N-18859
CD-15403
Install the cover with new gasket. Tighten the bolts to 40

in-lb. (4,5 N•m) torque [Figure 70-100-211].
CD-15401
Install the complete governor lever shaft assembly into

the front cover.
Tighten the bolts to 81 in.-lb. (9,2 N•m) torque [Figure

70-100-209].
NOTE: The longer space (Item 1) [Figure 70-100-209]

on the governor lever shaft goes down toward
the cover when installed.
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Figure 70-100-212
CD-15407
Install new O-ring on the breather vent [Figure 70-100-

CD-15405 214].
Figure 70-100-215
Install a greased O-ring on the shutdown solenoid
[Figure 70-100-212].

Figure 70-100-213
CD-15408
Install the breather vent into the front cover. Tighten the
CD-15406 bolts to 75 in.-lb. (8,5 N•m) torque [Figure 70-100-215].
Install the shutdown solenoid into the front cover [Figure

70-100-213].
Tighten the bolts to 79 in.-lb. (9 N•m) torque.
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Turbo Charger Removal and Installation
Figure 70-100-216
1
3
4
1
P7779
Disconnect the air cleaner hose (Item 1) [Figure 70-100-

P7780 217], inspect the air intake system.
Remove the oil tubeline (Item 2) [Figure 70-100-217]

Remove the exhaust pipe (Item 1) [Figure 70-100-216]. and clean the inside of the line with solvent or air, to
remove contaminated oil.
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RECONDITIONING THE ENGINE (CONT’D) NOTE: In the event of severe engine oil
contamination, drain and flush the engine oil
Turbo Charger Removal and Installation (Cont’d) cooler, cab heater and plumbing.
Figure 70-100-218 Drain the engine oil from the crankcase and replace the
engine oil and filter. (See Replacing Oil And Filter on
Page 10-110-1.)
Start the engine and run at idle until oil pressure is

assured.
Work the unit until operating temperature of engine is

maintained for approximately 15 minutes.
Idle and cool the down engine approximately 3 to 4

1 minutes, and stop the engine.
Drain the engine oil from the crankcase again, replace

the engine oil and filter. (See Replacing Oil And Filter on
Page 10-110-1.)
Re-start engine, check for leaks and performance.

P7343
Remove the oil tubeline (Item 1) [Figure 70-100-218],

clean the inside of the line with solvent or air to remove
contaminated oil.
Remove the exhaust manifold nuts (Item 3) [Figure 70-

100-217].
Installation: Tighten the nuts to 22 ft.-lb. (30 N•m) torque.
Remove the hose clamps (Item 4) [Figure 70-100-217].
Remove the turbocharger from the intake manifold hose.
Install the replacement turbo.
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Crankshaft Gear Mounting Bolt Torque Procedure
Figure 70-100-219
P13135
Mark the crankshaft gear mounting bolt (Item 1) [Figure

P5292 70-100-221].
Figure 70-100-222
The tool listed will be needed to do the following
procedure:

MEL1522 - Torque Multiplier Support Device
MEL1526 - Torque Multiplier 1
If the v-belt pulley is installed, remove the four bolts and

remove the pulley (Item 1) [Figure 70-100-219].
Figure 70-100-220
P13136
NOTE: If the torque multiplier tool (Item 1) [Figure 70-

100-222] has a degree wheel, the crankshaft
2
bolt does not have to be marked.
Install the torque multiplier tool (Item 1) [Figure 70-100-

222], with the socket, into the tool.
P13135A
Install the tool (Item 1) [Figure 70-100-220] on the

crankshaft hub using the v-belt pulley bolts.
Install the crankshaft gear mounting bolt (Item 2) [Figure

70-100-220] and tighten to 95 ft.-lb. (130 N•m) torque.
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RECONDITIONING THE ENGINE (CONT’D)
Crankshaft Gear Mounting Bolt Torque Procedure

(Cont’d)
Figure 70-100-223
P13137
Figure 70-100-224

1
P13135
Tighten the gear bolt 210° (+ or - 10°) [Figure 70-100-

223] & [Figure 70-100-224].
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HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SAFETY &
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-6
Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-2
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-5 DRIVE
Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-13 SYSTEM
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-14
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Receiver/Drier Sight Glass Inspection . . . . . . . . . . . . . . . . 80-50-4
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

ELECTRICAL
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 SYSTEM &
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2 ANALYSIS
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 ENGINE

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 SERVICE
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
HVAC
EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-3
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1

Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-2
Component Replacement And Refrigeration Leaks. . . . . . 80-60-3
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1

Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2
Continued on Next Page
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HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1

Wire Connector Removal And Installation . . . . . . . . . . . . 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1

PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-40-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1

Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-3
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1

Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
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AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) See Chart on Page 80-10-3. where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. 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 heated low pressure gas is again drawn into the compressor.
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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 R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas

B-16691
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COMPONENTS Figure 80-20-3
Identification
2
Figure 80-20-1
N-22134
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P-26890 20-3] 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 80-20-1] 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 80-20-4
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.
1
Figure 80-20-2
1
N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-20-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-20-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 535 PSI.
N-22266
Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
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COMPONENTS (CONT’D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
3
1
2 1
N-22087
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-

N-22121 20-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-20-7]
(Item 1) [Figure 80-20-5] is located behind the loader controls the temperature of the evaporator coil.

cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
heat & A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
N-22150
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the Heater / Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-20-8] is used to push air through the heater and
evaporator coils and into the cab.
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COMPONENTS (CONT’D) Figure 80-20-10
Identification (Cont'd)
Figure 80-20-9
1 1
4
N-22149
2
3
Heater Valve: The heater (Item 1) [Figure 80-20-10] is

N-22261 used to control the amount of engine coolant that flows to
the heater coil.
Control Panel: The panel (Item 1) [Figure 80-20-9] has Figure 80-20-11
three separate components.

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-20-9]. When the fan switch is in the off 1
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-20-9]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

20-9] 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.
N-22134
Pressure Switch: The pressure switch (Item 1) [Figure

80-20-11] will disengage the compressor clutch at high
pressure readings over 384 PSI (2647 kPa) on the high
side, or if it senses very low pressure of 28 PSI (193 kPa)
or less on the high side, which indicates loss of
refrigerant.
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SAFETY Figure 80-30-2
Safety Equipment
Figure 80-30-1
P16399
R-134a inside a canister or in an A/C system is a liquid

P16398 under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
“INSTANTLY”. If it spills on your skin or in your eyes you
In servicing A/C and heater systems you will be exposed should flood the area with cool water and SEEK
to high pressures, temperatures and several chemical MEDICAL ATTENTION FAST! It is a good idea to wear

hazards. Moving belts and pulleys are normal shop gloves [Figure 80-30-2] to prevent frost bite if you should
hazards get refrigerant on your hands
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
30-1] 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.
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REGULAR MAINTENANCE Figure 80-40-3
Filter Elements Removal And Installation
Figure 80-40-1
P-28820
1
Remove the filter (Item 1) [Figure 80-40-3] from the

P-28818 cover.
The fresh air filter must be cleaned sometimes as often

Remove the two mount bolts (Item 1) [Figure 80-40-1] as twice a day, depending on the operating environment.
from the fresh air filter cover at the rear of the loader cab. The filter can be cleaned by removing and shaking it. A

small amount of air pressure can be used to clean the
Figure 80-40-2 filter. However the fresh air filter should be changed at
least 2-4 times per year in normal conditions. In
extremely dusty conditions the fresh air filter may need to
be changed weekly
1
Figure 80-40-4
2
P-28819
1
Remove the filter cover and filter (Item 1) [Figure 80-40-
2] from the loader.
P-28821P-
28821
Remove the two retaining knobs (Item 1) [Figure 80-40-

4] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-40-4]

from the loader cab.
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REGULAR MAINTENANCE (CONT’D) Compressor Drive Belt Inspection
Filter Elements Removal And Installation (Cont'd) Figure 80-40-7
Figure 80-40-5
N-23037
P-28822
It is good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Remove the recirculating air filter (Item 1) [Figure 80-40-
5] from the rear of the cab. Open the rear door.

Figure 80-40-6 Check the tension on the compressor belt (Item 1)
[Figure 80-40-7].
N-22274
The recirculating air filter [Figure 80-40-6] is made of

open cell foam and should be cleaned with water. A mild
detergent may also be used. It does not require cleaning
as frequently as the fresh air intake filter.
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REGULAR MAINTENANCE (CONT’D) Figure 80-40-10
Cleaning The Condenser

1
Figure 80-40-8
N-23036
2
Rotate the condenser (Item 1) [Figure 80-40-10] up
N-22976 against the right side lift arm.
Slide the hydraulic cooler (Item 2) [Figure 80-40-10]

Open the rear door. toward the rear of the loader.

Raise the rear grill on the loader. Figure 80-40-11
Check the condenser (Item 1) [Figure 80-40-8] for mud

or dirt.
Remove the two retainer clips (Item 2) [Figure 80-40-8] 1
Figure 80-40-9
N-22272
1 With water, or air, the radiator (Item 1) the oil cooler (Item
2) and the condenser (Item 3) [Figure 80-40-11]. can be
cleaned.
N-23035
Lift the condenser, and slide it toward the rear of the

loader until the mounting tabs (Item 1) [Figure 80-40-9]
clear the frame of the loader.
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BASIC TROUBLESHOOTING Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Inspection on Page 80-50-5.)
Poor A/C Performance
Check the A/C condenser for dirt or mud and clean if
Figure 80-50-1 necessary. (See Cleaning The Condenser on Page 80-
40-3.)
Check the A/C evaporator coil for dirt or mud and clean if
necessary. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-2.)
Inspect the sight glass located on the receiver / drier for

air bubbles. (See Receiver/Drier Sight Glass Inspection
on Page 80-50-4.)
1
Check the engine coolant to see if it is bypassing the
heater valve. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-2.)
N-22273
Figure 80-50-2

N-22411
Start the loader, lock the park brake, and engage the A/C
system with the blower fan on High. Run the loader at full
throttle for approximately 15 minutes, with the loader cab
door closed.
Check the temperature at the louvers (Item 1) [Figure

80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 36 - 53° F

(2,2 - 11,6° C) depending on the amount of humidity in
the air.
If louver temperature is too high. (See SYSTEM

TROUBLESHOOTING CHART on Page 80-70-1.)
Check the heater/AC fan for proper operation, or noise,

and replace if necessary.
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BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-5
Cleaning The A/C Evaporator Coil & Heater Coil
Figure 80-50-3
1 1
N-22129
Disconnect the blower fan wiring connector (Item 1)

N-22122 [Figure 80-50-5] from the loader wiring harness.
Figure 80-50-6

Page 10-20-1.)

on Page 10-30-1.)
At the rear of the cab, disconnect the thermostat wiring

connector (Item 1) [Figure 80-50-3]. 1
Figure 80-50-4
2 N-22119

6].
N-22130

the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-4] from

the loader.
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(Cont'd)
Figure 80-50-7
1 1
N-22124

from the Evaporator / Heater Unit rear cover.
N-22120
Figure 80-50-10

7].
Figure 80-50-8
1
2
N-22125
1
Remove the three mount bolts (Item 1) and the one

center mount bolt (Item 2) [Figure 80-50-10] from the
N-22123 Evaporator / Heater Unit rear cover.
Remove the rear cover from the unit.

Remove the Evaporator / Heater Unit from the rear of the
cab and place it on the fenders of the loader supported
by 2X4's [Figure 80-50-8].

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(Cont'd)
Figure 80-50-11
2
1
1
2
N-23039
N-22127 Page 10-20-1.)
Push the A/C switch to the ON position. Turn the fan

With air or water clean the heater coil (Item 1) [Figure switch to the High Speed position, with the loader ignition

80-50-11] and evaporator coil (Item 2) [Figure 80-50-11]. switch OFF.
Receiver / Drier Sight Glass Inspection Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 80-50-12
1 REMOTE START on Page 10-60-1.)

the right side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-13]

from the loader.
Figure 80-50-14
N-22134
1
Inspect the sight glass (Item 1) [Figure 80-50-12],

located on the receiver / drier, weekly or if the A/C system
does not perform properly.
N-22249
Remove the protective tape (Item 1) [Figure 80-50-14]

from the sight glass.
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BASIC TROUBLESHOOTING (CONT’D) Compressor Drive Belt Inspection
Receiver / Drier Sight Glass Inspection (Cont’d) Figure 80-50-16
Figure 80-50-15
1
1
N-23037
N-22250
It is good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Using the remote start tool, start the loader and run at
high idle. Open the rear door.

Watch the sight glass (Item 1) [Figure 80-50-15] for Check the tension on the compressor belt (Item 1)
passing bubbles. [Figure 80-50-16].
Bubbles indicate that the system is low on refrigerant and The belt tension should be set by measuring the belt
is due for recharging. (See SYSTEM CHARGING AND deflection, which should be 0.16 in. (4mm) with a
RECLAMATION on Page 80-100-1.) deflection load of 3.5 - 4 lb. (1,6 - 1,8 kg) force.
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BASIC TROUBLESHOOTING (CONT’D) NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
Checking The Electrical System for both the Heater and the A/C systems.
Figure 80-50-17 Figure 80-50-19
2
1
1
N-22284 P-26891
Check to see if the compressor clutch is engaging. Raise the lift arms and install an approved lift arm support

With an operator in the loader seat and the cab door Page 10-20-1.)
open, turn the loader key switch to RUN (Standard Panel)
OR press the RUN / ENTER Button (Deluxe Panel), Raise the operator cab. (See Raising The Operator Cab
without starting the loader. on Page 10-30-1.)
Push the A/C switch (Item 1) to the ON position. Turn the Disconnect the loader harness (Item 1) [Figure 80-50-
blower fan switch (Item 2) [Figure 80-50-17] to the first 19] from the compressor clutch wire.
ON position.
Figure 80-50-20
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-50-18
1
1
2 P-26892
With a multimeter, check the resistance to the

N-22287 compressor clutch at harness connector (Item 1) [Figure
80-50-20].
If the compressor clutch does not engage, check the If there is no resistance value, replace the compressor
loader fuse (Item 1) [Figure 80-50-18] located on the clutch. (See Compressor Clutch Disassembly on Page
control panel in the loader cab. 80-110-2.)
Replace the fuse if burned out.
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Checking The Electrical System (Cont'd)
Figure 80-50-21
P-26894
1
Using a multimeter check the loader wiring harness (Item
P-26892 1) [Figure 80-50-23] for voltage.
The voltage should be around 12 volts.

With a multimeter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-50-21]. If there is no voltage at the wiring harness, check the

harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-50-24
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
1
Figure 80-50-22
P-26894
1
If there is voltage at the harness, check the resistance at

the pressure switch (Item 1)[Figure 80-50-24].
If there is no resistance value, check for low refrigerant

P-26893 level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-50-22].
Reconnect the loader harness to the pressure switch.
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Figure 80-50-25
1 1
N-22259
If there is voltage at the wiring harness, check the

N-22258 thermostat (Item 1) [Figure 80-50-27] for resistance.
The resistance value of the thermostat should be 10

Disconnect the thermostat wiring connector (Item1) Ohms at 68° F (20° C).
[Figure 80-50-25] from the loader wiring harness.

If there is no resistance value, replace the thermostat.
Figure 80-50-26 (See Removal And Installation on Page 80-170-1.)
If there is a resistance value, check the blower fan.
Figure 80-50-28
N-22259
1
Check the loader harness (Item 1) [Figure 80-50-26] for
voltage. The voltage should be 12 volts.
N-22130
If there is no voltage at the wiring harness, check the

harness for broken wires. Remove the mount bolt (Item 1) [Figure 80-50-28] from

from the loader.
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Figure 80-50-29
1
1
N-22260
If there is voltage at the wiring harness, check the

N-22129 resistance to the blower fan at the blower fan wiring
Disconnect the blower fan wiring connector (Item 1) If there is no resistance value replace the heater/AC fan.
[Figure 80-50-29] from the loader wiring harness. (See Removal And Installation on Page 80-210-1.)

Figure 80-50-30 If there is a resistance value check the climate controls at
the control panel inside the loader cab.
Figure 80-50-32
N-22260
1
Check the loader harness (Item 1) [Figure 80-50-30] for

N-22261
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the Remove the three mount bolts (Item 1) [Figure 80-50-32]
harness for broken wires. from the cab control panel.
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H
Figure 80-50-33 C
B
M
N-22288
If there is voltage at the wiring harness, check the blower

N-22262 switch [Figure 80-50-35] for resistance.
With the switch in the OFF position, there should be zero

Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-50-33].

With the switch in the 1 position, there should be
Figure 80-50-34 resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-35].

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
1 [Figure 80-50-35].

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-50-35].
If any of the above resistance tests fail, replace the

N-22265 blower switch.
If the above resistance tests are good, check the A/C

Disconnect the loader wiring harness (Item 1) [Figure switch.
80-50-34] from the blower switch.
Check the loader harness for voltage. The voltage should

be 12 volts.
If there is no voltage at the wiring harness, check the

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BASIC TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Checking The Electrical System (Cont'd) If a resistance value is found, check the potentiometer.
Figure 80-50-36 Figure 80-50-38
N-22264 N-22262
At the loader cab, disconnect the loader harness (Item 1) The potentiometer will effect the A/C system and also
[Figure 80-50-36] from the A/C switch. effect the operation of the heater.

Check the harness for voltage. The voltage should be 12 If heater valve does not open, or close, or the A/C does
volts. not work, check the potentiometer.
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-50-38] from the potentiometer.
Figure 80-50-37 Figure 80-50-39
1
2
1
N-22289 N-22263
If there is voltage at the wiring harness, check the A/C Check the loader harness (Item 1) [Figure 80-50-39] for
switch [Figure 80-50-37] for resistance. voltage. The voltage should be 12 volts.
With the switch in the OFF position there should be no If there is no voltage at the wiring harness, check the
resistance between any of the three terminals on the A/C harness for broken wires.
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-50-37].
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Figure 80-50-40
C
A 1
N-22175
B To check the resistance of the white wire, turn the

N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-50-42].
If there is voltage at the wiring harness, check the Figure 80-50-43

potentiometer [Figure 80-50-40] for resistance.

The resistance should be 10 K Ohm's between wire pin A
and wire pin C frame [Figure 80-50-40].
If no resistance is found replace the potentiometer.
Figure 80-50-41
A C
B N-22290
The resistance between the wire terminal A and wire

terminal B frame [Figure 80-50-43] should be around 49
1
K Ohm's.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-50-43] should be
around 39 K Ohm's.
The white wire B, (Item 1) [Figure 80-50-41], on the

potentiometer, is a resister wire.
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BASIC TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Checking The Electrical System (Cont'd) Figure 80-50-46
Figure 80-50-44
3
2 1
1
N-22284
N-22175
To check the resistance of the white wire, turn the Page 10-20-1.)
potentiometer control (Item 1) [Figure 80-50-44] to the

full Heater position. Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position. Turn
Figure 80-50-45 the temperature control (Item 3) [Figure 80-50-46] to the
High A/C position, with the loader ignition switch OFF.
Figure 80-50-47
A C
N-22290
B
Check the resistance between the wire terminal A and N-22131

wire terminal B frame [Figure 80-50-45] should be
around 39 K Ohm's.
on Page 10-30-1.)
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-50-45] should be Connect the remote start tool to the loader. (See
around 49 K Ohm's. REMOTE START on Page 10-60-1.)
If the resistance is not found replace the potentiometer. Start the loader and run at high idle, for ten minutes.
Check the heater hose (Item 1) [Figure 80-50-47] for

temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replace.
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Heater Valve Not Opening Or Closing
Figure 80-50-48 1
3
2 N-22131
1

N-22284 on Page 10-30-1.)

Raise the lift arms and install an approved lift arm support REMOTE START on Page 10-60-1.)

Page 10-20-1.) Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
Push the A/C switch (Item 1) to the OFF position. Turn shaft (Item 1) [Figure 80-50-49], as the key of the remote
the fan switch (Item 2) to position 1. Turn the temperature start is turned to the ON position without starting the
control (Item 3) [Figure 80-50-48] to the High A/C loader. The heater valve should rotate. Place a mark on
position, with the loader ignition switch OFF. the loader shaft.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-50-48]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-50-49], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Checking The Electrical System on Page
80-50-6.)
Replace the heater valve. (See Removal And Installation

on Page 80-220-1.)
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GENERAL AIR CONDITIONING SERVICE
GUIDELINES
Compressor Oil
Figure 80-60-1
N-22243
The compressor (Item 1) [Figure 80-60-1] is factory filled

with 150-170 cc's of PAG 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:
1. When ever the evaporator, condenser or receiver-

drier is replaced.
2. Whenever the refrigerant has leaked from the system.
3. Whenever the refrigerant is suddenly released from

the cooling cycle.
4. Whenever any oil-related problems occur in the

cooling cycle.
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 oil should be used, and never mix

R-12 and R-134a Oils.
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GENERAL AIR CONDITIONING SERVICE Open the cab door and windows.
GUIDELINES (CONT'D)
Run the blower at maximum speed.
Compressor Oil Check
Run the compressor for at least 20 minutes at 800 - 1200
Figure 80-60-2 RPM.
Remove the compressor from the loader. (See Removal

Remove the oil drain plug (Item 1) [Figure 80-60-2] and

drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4 - 10.8 ft.-lb.

1
(13 - 15 N•m) torque.
Figure 80-60-4
N-22245
Figure 80-60-3

1
N-22246
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil
through the discharge-side connector by
P-16534A rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
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
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)
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GENERAL AIR CONDITIONING SERVICE Component Replacement And Refrigeration Leaks
GUIDELINES (CONT'D)
Figure 80-60-6
Compressor Oil Check (Cont'd)
Figure 80-60-5
1
1
P-24229
N-22245 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 80-60-6] must be changed.
Measure the drained oil in a measuring cylinder.

Never leave hose fittings, compressor fittings or
Check the oil for contamination, dirt, metal shavings, or components uncapped while working on the A/C system.
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Add new compressor oil through the suction side

Installation: Add 150 -170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the larger port on the
compressor.
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SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate

Possible Cause Inspection Solution
1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient
1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).

4. Plugged cab filters Check cab filter condition. Clean or replace filters.
Insufficient cooling although air flow and compressor operation are normal
1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
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 oil. 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.
components. thermostat, Relay, etc.
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SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86° - 96° F (30° -
38° C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210 - 265 PSI
Low pressure side pressure: 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 The low pressure side pressure normally becomes too
Too high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective The high and low pressure side gauge pressures Replace compressor.
compressor. equalize when the magnetic clutch is engaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge

charge. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Adjust thermostat’s
malfunction. temperature setting or probe
placement or replace
thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
performance. Operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
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Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low and bubbles may be Repair any leaks and
present in sight glass on receive drier. recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.
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Troubleshooting Tree
B-21491
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Troubleshooting Tree (Cont’d)
B-21491A
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B-21492
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B-21493
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TEMPERATURE / PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F PSIG TEMP F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30

44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
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 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 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.
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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:
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SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
WARNING
Figure 80-100-1
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
1 contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.
Figure 80-100-3
N-23024
NOTE: Before reclaiming a refrigeration system, 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 80-100-1]
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 N-23026
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
Connect the Refrigerant Identifier to the low pressure
that are reclaimed and charged from your
hose [Figure 80-100-3].
MEL1581 Recovery / Recycling / Recharging
Machine.
Connect the Refrigerant Identifier to its power source.
Figure 80-100-2
Follow the steps displayed on the refrigerant identifier
screen.
Allow two minutes for the refrigerant identifier to display

1 the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.

N-22293
Remove the protective cap (Item 1) [Figure 80-100-2]

from the low pressure hose.
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SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-5
Reclamation Procedure (Cont'd)
2
1
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances. N-22380
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition Connect the reclaimer to the loader A/C charge ports.
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment, Connect the Red hose (Item 1) [Figure 80-100-5] to the
knowledge, and experience to service refrigeration high pressure port and open the valve.
equipment.
W-2373-0500 Connect the Blue hose (Item 2) [Figure 80-100-5] to the

low pressure port and open the valve.
NOTE: Only A/C trained technicians should perform
Figure 80-100-6
the reclaiming and recharging procedure.
Figure 80-100-4
N-22292
N-22291 Turn the reclaimer unit [Figure 80-100-6] to the ON

position and follow the on screen instructions.
Use an approved recovery / charging unit [Figure 80-
100-4] to evacuate the system.
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SYSTEM CHARGING AND RECLAMATION (CONT’D) Charging Procedure With A Manifold Gauge Set
Reclamation Procedure (Cont'd)
Figure 80-100-7
WARNING
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-100-8
N-22381
NOTE: The reclaimer unit, has a complete step by

step set of instructions [Figure 80-100-7] to

follow for reclimation and recharging of the A/
C system. A trained technician should follow
these instructions as they may very slightly
depending on the model and brand of 1
reclaimer used.
N-22382

on Page 10-30-1.)
Check to see that the hand valves (Item 1) [Figure 80-

100-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-100-1.)
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Charging Procedure With A Manifold Gauge Set

(Cont’d)
Figure 80-100-9
N-23043
2 Start the vacuum pump and open Iso-valve (Item 1)

1
[Figure 80-100-11] on the vacuum pump.
N-22382
Run the vacuum pump for at least 5-10 minutes to insure
that a vacuum has been pulled on the system.
Connect the gauges to the loader A/C charge ports.

Close the Iso-valve (Item 1) [Figure 80-100-11] (which
Connect the Red hose (Item 1) [Figure 80-100-9] to the isolates the vacuum pump from the A/C system) and turn
high pressure port and open the valve. OFF the vacuum pump.
Connect the Blue hose (Item 2) [Figure 80-100-9] to the

low pressure port and open the valve.
Figure 80-100-10
P-26942
Connect the Yellow hose (Item 1) [Figure 80-100-10] to

the vacuum pump.
A300 Bobcat Loader

688 of 772
Charging Procedure
Figure 80-100-12
1 1
N-22385
A thermistor vacuum gauge (Item 1) [Figure 80-100-13]

N-22382 may be necessary to use to determine the critical
vacuum level during evacuation. It is a solid state
instrument that constantly monitors and visually indicates
Note vacuum pressure indicated on the low pressure the vacuum level.
(Blue) gauge (Item 1) [Figure 80-100-12]. Let stand for

5-10 min. and recheck the pressure for changes. The thermistor vacuum gauge is used with the vacuum
pump [Figure 80-100-13].
If the pressure drops, this may be an indication of a leak
in the A/C system. Start the vacuum pump and open Iso-valve on the
vacuum pump.
Determine the problem with the A/C system and repair it.
Be sure that both hand valves, and both charge port
valves are open.
Run the vacuum pump for at least 45 minutes to insure

that all the moisture is boiled out of the system.
Stop the vacuum pump and close the Iso-valve on the

vacuum pump.
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermister vacuum

gauge.
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Charging Procedure (Cont'd)
Figure 80-100-14
1 2 1
N-22284
2
P-26943 REMOTE START on Page 10-60-1.)
Press the A/C (Item 1) [Figure 80-100-16] switch to ON

Place a refrigerant container with R134a (Item 1) on a position.
charging scale (Item 2) [Figure 80-100-14] and zero out

the scale. Turn fan switch (Item 2) [Figure 80-100-16] to HIGH
position.
Connect the yellow hose (Item 3) [Figure 80-100-14]
from the manifold gauge set to the valve on the Raise the operator cab. (See Raising The Operator Cab
refrigerant tank. on Page 10-30-1.)
Figure 80-100-15 Start loader engine, with the remote start switch, and run
at medium speed.
Watch the scale and run system until the predetermined

2 amount of refrigerant is added to the A/C system.
The A/C system holds 2.00 lb. (0,91 kg) of refrigerant.
Turn OFF the valve on the refrigerant container, and

hand valves on the manifold gauge set.
Turn OFF the engine, and remove the A/C charging

1 equipment from the loader.

N-23044 Cab on Page 10-30-2.)
Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-100-15] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.
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COMPRESSOR Figure 80-110-2

Figure 80-110-1
2
1
N-22377
Remove the compressor mount bolt (Item 1) [Figure 80-

N-22379A 110-2].
Remove the compressor from the loader.
WARNING

gas.
W-2371-0500

on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.)
Remove the compressor adjustment bolt (Item 1) [Figure

80-110-1].
Installation: Tighten the compressor adjustment bolt to

Remove the compressor belt.
Mark the compressor hoses for proper installation.
Remove the compressor hoses (Item 2) [Figure 80-110-

1] from the compressor.
Installation: Tighten the compressor hoses to 22 ft.-lb.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
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COMPRESSOR (CONT’D) Figure 80-110-5
Compressor Clutch Disassembly
Figure 80-110-3
1.32”
1.32”
1.32”
2
1 1
N-22275
The armature plate puller, (Item 1) can be constructed by

N-22244 drilling three 10 mm holes in a flat circular plate, located
1.32 in. apart [Figure 80-110-5].
Remove the center armature bolt (Item 1) [Figure 80- Attach the puller to the armature plate using three 8 mm
110-3]. bolts (Item 2) [Figure 80-110-5].

Installation: Tighten the armature bolt to 8 - 10 ft.-lb. (12 Figure 80-110-6
- 14 N•m) torque.
Figure 80-110-4
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-4] on the armature plate as shown in [Figure 80-
110-6].
To remove the armature plate (Item 1) [Figure 80-110-4]
from the clutch face, you must make an armature plate
puller.
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Compressor Clutch Disassembly (Cont'd)
Figure 80-110-7
N-22280
1
Remove the shims (Item 1) [Figure 80-110-8] from either
N-22279 the armature shaft or armature plate.
Installation: Insure that the clutch has the correct

Attach a slide hammer puller (Item 1) [Figure 80-110-7] clearance by adding the shims (Item 1) [Figure 80-110-
to the armature puller disk. 8].

Remove the armature plate from the compressor clutch. The specified clearance for the clutch is 0.01-0.02 in.
(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0.1mm)

0.0118 in. (0.3 mm)
0.0197 in. (0.5mm)
Figure 80-110-9
N-22283
Remove the snap ring (Item 1) [Figure 80-110-9] from

the pulley assembly.
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Figure 80-110-10
N-22371
The pulley assembly and bearing [Figure 80-110-12]

N-22369 must be replace as a complete unit.
Figure 80-110-13
Install the pulley puller tool MEL1595 on the compressor
pulley [Figure 80-110-10].

Figure 80-110-11
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-13] from

N-22370 the wire holder.
Remove the pulley from the compressor [Figure 80-110-

11].
A300 Bobcat Loader

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Figure 80-110-14
N-22375
The compressor [Figure 80-110-16] must be replaced as

N-22374 a complete unit.
Remove the coil lead wire (Item 1) [Figure 80-110-14]

from the wire holder on the compressor.

Figure 80-110-15
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80-

110-15] from the compressor.
Installation: Tighten the mount bolts to 2.9 - 4.3 ft.-lb. (4

- 6 N•m) torque.
Remove the coil from the compressor.
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A300 Bobcat Loader

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CONDENSER Figure 80-120-2
Figure 80-120-1
N-22977
1
Mark the two A/C hoses (Item 1) [Figure 80-120-2] for
N-22976 proper installation.
Disconnect the two hoses from the condenser.

Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80- Cap and plug the hoses and the condenser fittings with

100-1.) the proper A/C caps and plugs.
Open the rear door of the loader. Figure 80-120-3
Open the rear grill on the loader.
Remove the two retaining clips (Item 1) [Figure 80-120-

1] from the condenser mount bracket.
WARNING
gas. N-22978
W-2371-0500
Lift the rear of the condenser, and pull toward the rear of
the loader [Figure 80-120-3].
Remove the condenser from the loader.
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CONDENSER (CONT’D)
Figure 80-120-4
N-22977A
Installation: When installing the condenser, be sure the

condenser tabs (Item 1) [Figure 80-120-4] are positioned

in the slots in the loader frame.
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RECEIVER / DRIER

WARNING
Figure 80-130-1
gas.
W-2371-0500
1
Note the flow direction on the drier (Item 1) [Figure 80-

130-2] for proper installation.
Remove the two A/C hoses (Item 2) [Figure 80-130-2]

from the receiver / drier.
Cap and plug the hoses and the receiver / drier fittings
N-22134
Loosen the hose clamps (Item 3) [Figure 80-130-2] that

Raise the loader lift arms and install an approved lift arm holds the receiver / drier to the mount.
Remove the receiver / drier from the loader.

Raise the operator cab. (See Raising The Operator Cab NOTE: When replacing a receiver / drier in an A/C
on Page 10-30-1.) system 1 fl. oz. (30 cc) of PAG oil must be
added to the system when recharging.
SYSTEM CHARGING AND RECLAMATION on Page 80- Figure 80-130-3
100-1.)
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper

installation.
Both fittings on the drier are the same size, so the hoses 1
can be hooked up incorrectly.
Figure 80-130-2
2 1
N-22135

3 from the receiver / drier mount bracket.
Remove the bracket from the top of the hydraulic filter

bracket.
N-22134
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PRESSURE RELIEF VALVE
Figure 80-140-1
N-22205
The pressure relief valve (Item 1) [Figure 80-140-1] is

located on the drier assembly.

Figure 80-140-2
N-22206
The pressure relief valve [Figure 80-140-2] is designed

to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa).
This will cause the A/C system to shut down, saving the
compressor.
The Pressure Relief Valve is a secondary protection

device in the A./C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
NOTE: If a Pressure Relief Valve is found open, check

the A/C system for problems. Replace the
complete receiver / drier unit.
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A300 Bobcat Loader

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PRESSURE SWITCH

WARNING
Figure 80-160-1
gas.
W-2371-0500
Remove the pressure switch (Item 1) [Figure 80-150-

1 2]from the A/C high pressure hose.
Remove the pressure switch from the loader.
Shreader Valve Removal And Installation
N-22256
Figure 80-150-3


on Page 10-30-1.)
Disconnect the loader wire harness (Item 1) [Figure 80- 1

160-1] from the pressure switch wire harness.
Figure 80-150-2
N-22166
The shreader valve (Item 1) [Figure 80-150-3] is located

in the A/C high pressure hose and is located under the
pressure switch.
1

N-22134
on Page 10-30-1.)

NOTE: The pressure switch can be change without SYSTEM CHARGING AND RECLAMATION on Page 80-
evacuating the A/C system. 100-1.)
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.
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A300 Bobcat Loader

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EVAPORATOR / HEATER UNIT Figure 80-160-3
Figure 80-160-1
1
1
N-22129
Disconnect the blower fan wiring connector (Item 1)

N-22122 [Figure 80-160-3] from the loader wiring harness.
Figure 80-160-4

Page 10-20-1.)

on Page 10-30-1.)

1
At the rear of the cab, disconnect the thermostat wiring
Figure 80-160-2
N-22119

2 4].
N-22130


from the loader.
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705 of 772
EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-160-6
Figure 80-160-5
N-22126
N-22120
WARNING
5]. In the event of a leak, wear safety goggles. Escaping

gas.
W-2371-0500
Remove the Evaporator / Heater Unit from the rear of the

cab and place it on the fenders of the loader supported
by 2X4's [Figure 80-160-6].

from the expansion valve.
Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8

N•m) torque.
Cap and plug the hoses and the expansion valve fittings
A300 Bobcat Loader

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EVAPORATOR / HEATER UNIT (CONT’D) Disassembly And Assembly
Figure 80-160-7
1
1
1
N-22065
N-22128
Remove the eight mount bolts (Item 1) [Figure 80-160-8]
Remove the heater hoses (Item 1) [Figure 80-160-7]
from the heater coil. Remove the rear cover from the unit.

Installation: Tighten the heater hoses to 22 ft.-lb. (29,8
N•m) torque.
Remove the evaporator / heater unit from the loader
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A300 Bobcat Loader

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THERMOSTAT Figure 80-170-3
Figure 80-170- 1
1
N-22072
Remove the thermostat from the unit [Figure 80-170-3].

N-22069
Figure 80-170-4
NOTE: The thermostat can be changed without A

evacuating the A/C system, or removing the

evaporator / heater unit from the loader. B
Remove the rear cover from the evaporator / heater unit.

(See Disassembly And Assembly on Page 80-160-3.) C
Remove the two thermostat mount bolts (Item 1) [Figure

80-170- 1], and remove the wiring harness and grommet
from the evaporator / heater housing. 1
Figure 80-170-2
N-22072A
The wire connector (Item 1) [Figure 80-170-4] can be

change. The wiring position and color in the connector is:
A Blue
1 B White
C Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2]

from the A/C evaporator coil.
A300 Bobcat Loader

80-170-1 service Manual
709 of 772
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EXPANSION VALVE Figure 80-180-2
NOTE: The expansion valve can be changed without

removing the evaporator / heater unit from the
loader.
Figure 80-180-1
1
1 N-22073A
Remove the two evaporator fittings (Item 1) [Figure 80-

180-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-

lb. (29,8 N•m) torque.
N-22150

Remove the two mount bolts (Item 2) [Figure 80-180-2].
Remove the expansion valve from the loader.
WARNING Figure 80-180-3

gas. 1
W-2371-0500
Page 10-20-1.)

on Page 10-30-1.)
N-22074A
Cap and plug the evaporator tubelines (Item 1) [Figure
80-180-3] and the expansion valve fittings with the
proper A/C caps and plugs.
from the expansion valve.
Installation: Tighten the two A/C hose fittings to 22 ft.-lb.

Cap and plug the hoses and the expansion valve fittings
A300 Bobcat Loader

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EXPANSION VALVE (CONT’D)
Figure 80-180-4
N-22074A

from the expansion valve mount.

Remove the expansion valve mount from the unit.
Figure 80-180-5
N-22085
The expansion valve [Figure 80-180-5] is replaced as a

complete unit.
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EVAPORATOR Figure 80-190-3
Figure 80-190-1
N-22075
Remove the two mount bolts (Item 1) from the mount

1 plate (Item 2) [Figure 80-190-3].
N-22073
Remove the mount plate from the unit.

device.(See Installing The Lift Arm Support Device on Figure 80-190-4

Page 10-20-1.)

on Page 10-30-1.)

Remove the evaporator / heater unit from the back of the

cab. (See Removal And Installation on Page 80-160-1.)
Remove the expansion valve (Item 1) [Figure 80-190-1]

from the unit. (See Removal And Installation on Page 80- 1
180-1.)
N-22076
Figure 80-190-2

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)

[Figure 80-190-2] from the unit.
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EVAPORATOR (CONT’D)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,


Clean with low water or air pressure.
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HEATER COIL Figure 80-200-2
Removal And Installation With A/C

1
Figure 80-200-1
1
1
N-22086

N-22128 (See Disassembly And Assembly on Page 80-160-3.)

Raise the lift arms and install an approved lift arm support from the heater coil at the expansion valve end of the
device. (See Installing The Lift Arm Support Device on unit.

Page 10-20-1.)
Figure 80-200-3
on Page 10-30-1.)
Remove the evaporator / heater unit from the back of the

Mark the heater hoses (Item 1) [Figure 80-200-1] for

proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps 1
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.- N-22087


3] that connect the evaporator coil, to the heater coil.
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HEATER COIL (CONT’D) Removal And Installation Without A/C
Removal And Installation With A/C (Cont'd) Figure 80-200-6
Figure 80-200-4
1
1 1
N-22128
N-22089
Remove the three mount bolts (Item 1) [Figure 80-200-4] Page 10-20-1.)
and remove the mount plate from the end of the unit.

Remove the two mount bolts (Item 2) [Figure 80-200-4] on Page 10-30-1.)
that support the heater coil tubelines to the unit.
Remove the heater unit from the back of the cab. (See
Remove the heater coil from the unit. Removal And Installation on Page 80-160-1.)
Figure 80-200-5 Mark the heater hoses (Item 1) [Figure 80-200-6] for
proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
Installation: Tighten the two heater hose fittings to 22 ft.-

N-22090
The heater coil [Figure 80-200-5] can be cleaned with

low air or water pressure.
If the heater coil needs replacement it must be replaced

as complete unit.
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HEATER COIL (CONT’D)
Removal and Installation Without A/C (Cont’d)
Figure 80-200-7
1 1
N-22093

(See Disassembly And Assembly on Page 80-160-3.)

and remove the mount plate from the end of the unit.

that support the heater coil tubelines to the unit.
Figure 80-200-8
N-22094

from the heater coil.
Remove the heater coil from the unit.
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A300 Bobcat Loader

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HEATER / AC FAN Figure 80-210-2
Figure 80-210-1
1
N-22097
NOTE: On some early evaporator / heater units the

N-22096 metal was not cut out, so the blower wiring
harness (Item 1) [Figure 80-210-2] could be
removed without removing the wiring
Raise the lift arms and install an approved lift arm support connector.

Page 10-20-1.) Figure 80-210-3

on Page 10-30-1.)
Remove the evaporator / heater unit from the back of the 1

NOTE: The heater / AC fan assembly can be removed

from the evaporator / heater unit without
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity.

side of the evaporator / heater unit.
N-22098
If the metal is not cut out on the housing, mark the area
(Item 1) [Figure 80-210-3] and remove it with a metal
shears.
A300 Bobcat Loader

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HEATER / AC FAN (CONT’D) Disassembly And Assembly
Figure 80-210-4
2
1
1 1
2 N-22102
N-22099
Remove the eight mount bolts (Item 1) [Figure 80-210-6]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-210-4] from the unit Remove the blower wheel cover from the fan housings.

Figure 80-210-5 Remove the four mount bolts (Item 2) [Figure 80-210-6]
from the fan motor mount.
1
Remove the fan motor mount.
Remove the fan motor assembly from the housing.
Figure 80-210-7
N-22100

from the blower fan housing. 1 2
Remove the blower fan housing from the evaporator /

heater unit.
N-22107
Check the blower housing (Item 1) and fan motor mount

(Item 2) [Figure 80-210-7] for wear and replace as
needed.
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HEATER / AC FAN (CONT’D) Figure 80-210-10
Figure 80-210-8
N-22110
2 Figure 80-210-11
N-22108
Remove the outside rings (Item 1) and fan wheel covers

(Item 2) [Figure 80-210-8] from the fan motor and blower

wheels.
Figure 80-210-9
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-210-10] & [Figure 80-210-11] from the blower wheel.
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-9].
A300 Bobcat Loader

721 of 772
HEATER / AC FAN (CONT’D) Wire Connector Removal And Installation
Disassembly And Assembly (Cont'd) Figure 80-210-14
Figure 80-210-12
N-22103
N-22111
Figure 80-210-15
Remove the inside blower wheel clamp (Item 1) [Figure

80-210-12] from the blower wheel.

Figure 80-210-13
1
1
2
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-14] &

[Figure 80-210-15] from the center of the blower fan
N-22116 motor wiring connector.
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-210-13] from the blower fan motor shaft.
Repeat the procedure for the other blower wheel.
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HEATER / AC FAN (CONT’D) Figure 80-210-17
Wire Connector Removal And Installation (Cont'd)
Figure 80-210-16
1 N-22106
The wiring code for the blower fan connector [Figure 80-
N-22105 210-17] is:
With a pointed screw driver lightly press in on the tabs Number on Connector Wire Color
(Item 1) [Figure 80-210-16] and remove the individual 1 Orange

wires from the connector.
2 Red
3 Yellow
4 Black
5 Open
6 Open
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A300 Bobcat Loader

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HEATER VALVE Figure 80-220-3
Figure 80-220-1
N-22133
Figure 80-220-4
N-22131

the electrical relay mount.

1
Move the electrical relay to the side for clearance.
Figure 80-220-2
1
N-22139
NOTE: Early model loaders were equipped with a

heater valve that had a wiring harness, and
connector (Item 1) [Figure 80-220-3]. Later
model loaders are equipped with heater
2 valves that allowed the loader wiring harness
(Item 1) [Figure 80-220-4] to be connected
N-22132 directly to the rear of the valve.

Remove the two hydraulic hoses (Item 1) [Figure 80- from the heater valve mount bracket.
220-2] from the heater valve.
Remove the heater valve and mount bracket from the
Cap the hoses and the heater valve with hydraulic caps loader.
Disconnect the loader wiring harness (Item 2) [Figure

80-220-2] from the heater valve.
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HEATER VALVE (CONT’D) Figure 80-220-7
Figure 80-220-5
1
1
N-22157

N-22155 220-7] from the heater valve mount plate.
Figure 80-220-8
from the heater valve actuator.

Figure 80-220-6
2 1
N-22158
Remove the mount plate (Item 1) [Figure 80-220-8] from

N-22156 the heater valve bracket.
Remove the actuator (Item 1) and the three mounting

spacers (Item 2) [Figure 80-220-6] from the heater valve
mount plate.
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HEATER VALVE (CONT’D)
Figure 80-220-9
N-22159

9] from the heater valve.

Figure 80-220-10
N-22160
Remove the heater valve mount bracket (Item 1) [Figure

80-220-10] from the heater valve.
Replace the parts as needed.
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A300 Bobcat Loader

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SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head And Block . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 DRIVE
Valve And Valve Guide And Seat Insert. . . . . . . . . . . . SPEC-20-1 SYSTEM
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-50-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-50-2

ELECTRICAL
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2 SYSTEM &
ANALYSIS
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-60-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
ENGINE
LOADER SPECIFICATIONS (A300) . . . . . . . . . . . . . . . . . SPEC-10-1 SERVICE
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 SPECIFICATIONS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 SPECIFICATIONS
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-40-1
Torque For Kabota Metric Engine Bolts . . . . . . . . . . . . SPEC-40-3
A300 Bobcat Loader

SPEC-01 Service Manual
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A300 Bobcat Loader

SPEC-02 Service Manual
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LOADER SPECIFICATIONS (A300)
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

B-16394
B-16395
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.
A300 Bobcat Loader

SPEC-10-1 Service Manual
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LOADER SPECIFICATIONS (A300) (CONT’D)
Performance
Rated Operating Capacity (SAE J732) 3000 lb. (1361 kg)
Tipping Load (SAE Rating) 6000 lb. (2722 kg)
Operating Weight (SAE) 8350 lb. (3788 kg)
SAE Breakout Force-Lift 6600 lbf. (2994 kg)
-Tilt 7150 lbf. (3243 kg)
Axle Torque 6200 ft.-lb. (8406 N•m)
Travel Speed (Inching) 4.0 MPH (6,4 km/hr.)
(Two-Speed Loader Low / High Range) 7.0 MPH (11,3 km/hr.) / 12.4 MPH (19,9 km/hr.)
Controls
Vehicle Steering (AWS) Speed and direction are controlled with LH joystick lever. Pattern is a “C” type.
Vehicle Steering (SSL) Speed and direction are controlled with LH joystick lever. Pattern is an “S” type.
Loader Hydraulics - Lift and Tilt Controlled by Right Hand (RH) joystick
Front Auxiliary (Std.) Controlled by electrical switches on RH joystick
Rear Auxiliary (Opt.) Controlled by electrical switch on LH joystick
Auxiliary Pressure Release Pressure is relieved through the coupler block, push in and hold for five seconds

Engine Key-type starter switch and shutdown
Engine Speed Control Hand Lever and Foot Accelerator pedal
Starting Aid Glow Plugs - automatically activated by Standard or Deluxe Instrument Panel
Service Brake Two independent hydrostatic systems controlled by LH joystick lever
Secondary Brake One of the hydrostatic transmissions
Parking Brake Finger-operated rocker switch on center control panel with spring applied,
pressure release multi disk brake
Engine
Make / Model Deutz/BF4M1011F Turbo-Charged

Fuel / Cooling Diesel / Oil
Horsepower (SAE J1349 Net) 73 HP (54 kW)
Maximum Governed RPM 2350 RPM
Torque @ 1800 RPM (SAE Net) 176 ft.-lb. (239 N•m)
Number of Cylinders 4
Displacement 178 cu. in. (2,92 L)
Bore / Stroke 3.59 / 4.41 (91 / 112)
Fuel Consumption 3.7 Gal./hr. (14,0 L/hr.)
Lubrication Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with safety element
Ignition Diesel-Compression
Low Idle 1125 - 1175 RPM
High Idle 2537 - 2693 RPM
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Hydraulic System
Pump Type Engine driven, Gear type
Pump Capacity - Standard 20.0 GPM (75,7 L/min.)
System Relief at Quick Couplers 3000 PSI (206 bar)
Hydraulic Filter Full flow replaceable, 3-micron synthetic media element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 2.50 (63,5)
Tilt Cylinder (2) 3.50 (88,9)
Steering Cylinder (4) 2.00 (50,8)
Rod Diameter: Lift Cylinder (2) 1.75 (44,5)
Tilt Cylinder (2) 1.63 (41,4)
Stroke: Lift Cylinder (2) 32.48 (825,0)
Tilt Cylinder (2) 18.17 (461,5)
Control Valve 3-Spool, open center type with float detent on lift and electrically controlled
auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type Bobcat Fluid (P/N 6563328) If fluid is not available, use 10W-30/10W-40 Class
SE motor oil for temperatures above 0° F (-18° C) or 5W-30 Class SE motor oil

for temperatures below 0° F (-18° C)
Hydraulic Function Time:
Wheel Cycle Time (Left / Right Turn) 1.4 Seconds
Raise Lift Arms 4.1 Seconds
Lower Lift Arms 3.9 Seconds
Bucket Dump 2.6 Seconds
Bucket Rollback 2.0 Seconds
Electrical
Alternator Belt driven; 90 amps

Battery 12 volts; 1000 cold cranking amps @ 0° F (-18° C); 180 minute reserve capacity
Starter 12 volts; gear type; 3.62 HP (2,7 kW)
Instrumentation Gauges: Hourmeter, Fuel, Engine Coolant Temperature.
Warning lights: Fuel Level, Glow Plugs, System Voltage, Seat Belt, Engine
Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydraulic Oil Temperature, Engine Air Filter & Hydraulic Filter.
Other: Audible Alarm, BICS Function, Lights, Opt. / Accessory Switches.
Optional Deluxe Instrumentation:
*Same gauges and warning lights as standard instrumentation.
*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil, Temperature.
*Additional Features Incl.: Keyless Start, Clock, Job Clock, Help Screens,
Diagnostic Capability, Automatic Shutdown Function.
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Drive System
Main Drive Fully hydrostatic, 4-wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive Pre-stressed #100 HSOC endless roller chain (no master link) and sprockets in
sealed chaincase with oil lubrication (Chains do not require periodic
adjustments) Two chains per side with no idler sprocket
Engine to Wheel Reduction 29:9:1
Axle Size 2.76 (70,1), Heat treated
Wheel Bolts (8) 9/16’” Wheel bolts fixed to axle hubs
Capacities
Fuel 22.8 Gal. (86,3 L)

Engine Lubrication & Cooling System 16 qt. (15,1L)
W/ Filter
Hydraulic Reservoir 4.7 Gal. (17,8 L)
Hydraulic/Hydrostatic System 10.7 Gal. (40,5 L)
Chaincase Reservoir 11 Gal. (41,6 L)

Engine Oil Change W/ Filter 10 qt. (9,4 L)
Tires
Standard 12-16.5 Bobcat Heavy Duty

Hippo 33 x 15.5 - 16.5
Bulky Hulk 33 x 15.5 - 16.5
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
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ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Displacement 177.7 cu. in. (2912 cu. cm.)

Bore 3.58 (91)
Stroke 4.41 (112)
Crankshaft Rotation (Facing Flywheel) Counterclockwise
Ignition 4 Stroke Diesel - Compression
Combustion System Direct Injection
Compression Ratio 17-1
Compression 320 - 392 PSI (2206 - 2703 kPa) (22 - 27 bar)
Firing Order 1-3-4-2
Fuel System
Fuel Injection Pump Pressure (Five Revolutions) Min. 4350 PSI (29993 kPa) (300 bar)
Injection Pump Testing Tightness 2175 PSI-145 PSI permissible drop/min. (14997 kPa-1000 kPa)
(150 bar-10 bar)
Injection Nozzle Opening Pressure 3625 PSI + 116 (24994 kPa + 800 kPa) (210 bar + 8 bar)

Valve And Valve Guide And Seat Insert
Valve Clearance (Intake) Oil Temp. Below 176° F (80° C) 0.012 (0,3)
Valve Clearance (Exhaust) Oil Temp. Below 176° F (80° C) 0.020 (0,5)
Valve Guide I.D. 0.315 ± 0.0010 (8,0 ± 0,025)
Valve Seat Insert O.D. (Intake) 1.680 ± 0.0002 (42,67 ± 0,005)
Valve Seat Insert O.D. (Exhaust) 1.460 ± 0.0002 (37,075 ± 0,006)
Valve Seat Insert Bore (Intake) 1.677 ± 0.001 (42,6 ± 0,03)
Valve Seat Insert Bore (Exhaust) 1.457 ± 0.001 (37,0 ± 0,03)
Valve Stem Diameter (Intake) 0.314 - 0.0006 (7,98 - 0,015)
Valve Stem Diameter (Exhaust) 0.313 - 0.0006 (7,96 - 0,015)
Valve Stem Clearance (Intake) 0.0008 - 0.0023 (0,02 - 0,06)
Wear Limit 0.005 (0,12)
Valve Stem Clearance (Exhaust) 0.0016- 0.003 (0,04 - 0,08)
Wear Limit 0.006 (0,15)
Valve Head O.D. (Intake) 1.594 ± 0.004 (40,5 ± 0,1)
Valve Head O.D. (Exhaust) 1.374 ± 0.004 (34,9 ± 0,1)
Valve Seat Width - (Intake) 0.062 ± 0.016 (1,58 ± 0,4)
(Exhaust) 0.067 ± 0.016 (1,7 ± 0,4)
Seat Angle - (Intake) 30°
(Exhaust) 45°
Marg Thickness (Intake) N/A
Wear Limit 0.0551 (1,4)
Marg Thickness (Exhaust) N/A
Wear Limit 0.047 (1,2)
Valve Recess 0.0512 ± 0.0051 (1,3 ± 0,13)
Wear Limit 0.0512 (1,3)
Valve Spring Free Length 0.132 (3,35) Diameter 1.531 (38,9)
0.134 (3,40) Diameter 1.547 (39,3)
Valve Spring Inclination 0.126 (3,2)
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ENGINE SPECIFICATIONS (CONT’D)
Piston And Rings

Piston Diameter 3.578 (90,9)
I.D. for Piston Pin 1.0236 + 0.0004 - 0.0016 (26,0 + 0,01 - 0,04)
Piston Pin Diameter 1.118 - 0.0002 (30,0 - 0,005)
Piston Ring Groove - 1st 0.0787 + 0.004 (2,0 + 0,10 - 0,08)
2nd 0.0787 + 0.004 - 0.003 (2,0 + 0,10 - 0,08)
3rd 0.118 + 0.002 - 0.0008 (3,0 + 0,04 - 0,02)
Piston Ring Clearance - 1st 0.004 - 0.005 (0,09 - 0,12)
Wear Limit 0.0078 (0,2)
2nd 0.003 - 0.004 (0,07 - 0,10)
Wear Limit 0.006 (0,16)
3rd 0.015 - 0.003 (0,04 - 0,07)
Wear Limit 0.005 (0,12)
Piston Ring Gap - 1st 0.0118 - 0.019 (0,3 - 0,5)
2nd 0.0315 - 0.039 (0,8 - 1,0)
3rd 0.018 - 0.028 (0,45 - 0,7)
Wear Limit - 1st 0.0315 - (0,8)
2nd 0.071 (1,8)
3rd 0.035 (0,9)
Bore for Piston Pin Bushing N/A

Piston Pin Bushing O.D. N/A
Piston Pin Bushing I.D. (Pressed In) N/A
Piston Pin Clearance 0.0009 - 0.0016 (0,025 - 0,04)
Wear Limit 0.0031 (0,08)
Connecting Rod
Small End Bushing I.D. (Pressed In) 1.181 + 0.0014 +0.00010 (30,0 + 0,035 + 0,025)
Wear Limit 0.003 (0,08)
Bore for Small End Bushing 1.299 + 0.0008 (33,0 + 0,02)
O.D. for Small End Bushing 1.299 + 0.0043 + 0.0028 (33,0 + 0,11 + 0,07)
Parallel Check Permissible 0.0039 over a distance of 3.937 (0,10 Over
100,0)
Alignment 0.002 (0,05)
Connecting Rod Width 1.063 - 0.0023 (27,0 - 0,06)
Connecting Rod End Play 0.0078 - 0.022 (0,2 - 0,56)
Wear Limit 0.0315 (0,8)
Center Distance from Small to Large Bore 6.811 ± 0.012 (173,0 ± 0,03)
Bore for Large End Bearing 2.303 + 0.0008 (58,5 + 0,02)
Large End Bearing Shells I.D. 2.166 - 2.167 (55,004 - 55,04)
Limit for Undersize 2.146 - 2.147 (54,504 - 54,54)
Large End Bearing Radial Clearance 0.0009 - 0.003 (0,024 - 0,078)
Wear Limit 0.005 (0,12 mm)
Large End Bearing Width 1.008 - 0.012 (25,6 - 0,3)
Cylinder Head And Block
Cylinder Head Studs - Length 5.906 ± 0.031 (150,0 ± 0,8)

Cylinder Bore 3.583 + 0.0008 (91,0 + 0,02)
Wear Limit 3.587 (91,1)
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ENGINE SPECIFICATIONS (CONT’D)
Crankshaft And Main Bearings

Crankshaft Pin Width 1.220 (31,0)
Crankshaft Pin Diameter 2.165 - 0.0004 - 0.0012 (55,0 - 0,01 - 0,03)
Oval Wear Limit 0.0004 (0,01)
Crankshaft Journal Width 1.378 + 0.0016 (35,0 + 0,04)
Crankshaft Journal Diameter 2.756 - 0.0004 - 0.0012 (70,0 - 0,01 - 0,03)
Oval Wear Limit 0.0003 (0,008)
Eccentricity Max. Permitted 0.002 (0,05)
Thrust Bearing Journal Width 1.378 + 0.002 (35,0 + 0,04)
Main Bearing Shell I.D. 2.757 - 2.758 (70,02 - 70,055)
Radial Clearance 0.0011 - 0.0033 (0,03 - 0,084)
Wear Limit 0.0047 (0,12)
Bearing Bore in Crankcase 2.953 + 0.0007 (75,0 + 0.019)
Thrust Bearing Stop Rings O.D. 1.374 - 0.005 (34,9 - 0,133)
Oversize 0.0157 (0,4)
Limit for Oversize 1.406 - 0.0052 (35,7 - 0,133)
Crankshaft End Play 0.0039-0.0106 (0,1- 0,27)
Wear Limit 0.016 (0,4)
Camshaft And Bearings

Camshaft End Play 0.0118- 0.0236 (0,3 - 0,6)
Wear Limit 0.0315 (0,8)
Camshaft Bearing I.D. 2.126 + 0.0021 (54,0 + 0,054)
Wear Limit 2.129 (54,08)
Radial Clearance 0.0019 - 0.0048 (0,05 - 0,124)
Cam Lift (Intake) 0.260 (6,6)
Cam Lift (Exhaust) 0.268 (6,8)
Oil Pump
Oil Pump Pressure Setting 101.5 PSI (700 kPa) (7 bar)

Min. Eng. Oil Pressure, Oil Temp. 230° F (110° C) at:
900 RPM 20.3 PSI (140 kPa) (1.4 bar)
1800 RPM 31.9 PSI (220 kPa) (2.2 bar)
2800 RPM 43.5 PSI (300 kPa) (3.0 bar)
Thermostat Rating 203° F (95° C)
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A300 Bobcat Loader

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LOADER TORQUE
Specifications
ITEM ft.-lb. N•m
Air Intake Manifold Bolts (M8 Torx) 15 20
Adapter Housing Bolts (M12) 21 - 24 28 - 33
Camshaft Bolts (M14 x 1.5 x 110) 22 30
Plus 210 degrees
Camshaft Thrust Washer Bolt (M8) 15 20
Connecting Rod Cap Nuts 22 30
Plus 60 degrees, 60 degrees = 120 degrees
Crankcase Screw Plugs (M18) 37 50
(M24) 82 111
(M30) 12 - 15 16 - 20
Crankshaft Gear Mount Bolt 243 - 295 330 - 400
Cylinder Head Bolts - Step 1 22 30
Step 2 59 80
Step 3 118 160
Plus 90 degrees
Exhaust Manifold Bolts (M10) 30 40
Exhaust Turbocharger Nuts (M8) 22 30
Flywheel Bolts 22 30

Front Cover Bolts 15 20
Front Mount Foot Bolts (M14 x 55) 38 52
Fuel Lift Pump Bolts (M8 Torx) 15 20
Glow Plug 15 - 18 20 - 24
Injector Cap Nut 35 47
Injector Pump Mounting Nuts 15 21
Main Bearing Bolts 37 50
Oil Pan Bolts (M8) 15 20
Oil Pan Drain Plug 40 54
Oil Pump Bolts (M8 Torx) 16 22
Oil Pressure Control Valve Screw Plug 82 111
Oil Return Line Cap Nut 13 - 14 18 - 19
Oil Suction Pipe 16 22
Oil Temperature Switch 21 28
Rocker Arm Bracket Bolts (M8 Torx) 15 20
Rear Cover Bolts 15 20
Rear Mounting Foot Bolts (M12) 23 31
Starter Carrier Bolts (M12) 15 - 18 20 - 24
Starter Fastening Bolts 25 - 28 34 - 38
Thermostat Housing Screw Plug (M38) 82 111
Timing Belt Tensioner Pulley Nut 33 45
V-Belt Pulley Bolts (M10) 30 - 36 41 - 49
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LOADER TORQUE (CONT’D)
Specifications (Cont’d)
ITEM ft.-lb. N•m

Air Intake 3-Hole Flange Bolts (M8 Torx) 54 - 65 6,1 - 7,3
Breather Vent Bolts 75 8,5
Crankcase Screw Plugs (M20) 85 - 104 9,6 - 11,7
(M10) 28 - 36 3,1 - 4,0
(M6) 13 - 16 1,4 - 1,8
(M16) 62 - 78 7,0 - 8,8
Cylinder Head Cover 75 8,5
Fuel Filter Bracket Bolt (M8) 54 6,1
Full Load Stop Screw Nut 40 4,5
Governor Lever Shaft Bolts 81 9,2
Injector Fastening Bolt (M8 Torx) 49 - 59 5,5 - 6,6
Injector Line 36 - 45 4,1 - 5,1
Minimum Speed Screw 40 4,5
Oil Filter Bracket Bolts (M6) 24 - 30 2,7 - 3,4
Oil Intake Housing Bolts (M8 Torx) 54 - 65 6,1 - 7,3
Oil Pressure Switch 115 13
Piston Cooling Oil Nozzles 11 1,2
Rocker Arm Set Screw Nut 49 - 59 5,5 - 6,6

Shut Down Stop Screw 40 4,5
Shut Down Solenoid Bolts 79 9
Thermostat Housing Bolts (M6 Torx) 20 - 24 2,2 - 2,7
Thermostat Housing Bolts (M8 Torx) 24 - 32 2,7 - 3,6
Turbocharger Backing Plate Screws 88 10
Turbocharger Compressor Housing Bolts 62 7
Turbocharger Compressor Wheel Nut 44 5
Valve Plunger Housing Bolts (M8 Torx) 24 - 32 2,7 - 3,6
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LOADER TORQUE (CONT’D)
Specifications (Cont’d)
ITEM ft.-lb. N•m

Air Cleaner Mounting Bolts 25 - 28 34 - 38
Alternator Pulley Nut 50 68
Axle Hub Mounting Bolt 350 475
Axle Sprocket Bolt 475 - 525 645 - 710
BICS™ Control Valve Mounting Bolts 15 - 16 20 - 22
Bob-Tach Lever Pivot Bolt 25 - 28 34 - 38
Control Valve Mounting Bolts & Nuts 15 - 16 20 - 22
Engine Mounting Bolts 65 - 70 88 - 95
Exhaust Pipe to Exhaust Manifold 20 - 35 27 - 47
Filter Housing Mounting Bolts 25 34
Front Panel Bolts 16 - 20 22 - 27
Hydraulic Pump Bolts 45 - 50 61 - 68
Hydraulic Pump Mounting Bolts 25 - 27 34 - 37
Hydraulic Reservoir Strap Bolts 16 - 20 22 - 27
Hydrostatic Motor Mounting Bolts 210 - 230 285 - 310
Hydrostatic Pump Mounting Bolts 65 - 70 88 - 95
Hydrostatic Pump Pulley Bolt 175 - 200 237 - 271
Lift Arm Bypass Control Valve Mounting Bolts 15 - 16 20 - 22

Main Frame to Chaincase Bolts 300 - 330 410 - 450
Main Relief Valve 35 - 40 47 - 54
Motor Carrier Bolts 220 - 245 300 - 330
Operator Cab Fastening Nuts 40 - 50 54 - 68
Operator Cab Pivot Bolts & Nuts 25 - 35 34 - 47
Pivot Pins Lock Bolt & Nut 18 - 20 24 - 27
Seat Belt Fastening Bolts 40 - 45 54 - 61
Seat Mounting Bolts 9 - 11 12,2 - 15
Seat Bar Pivot Bolts 25 - 28 34 - 38
Wheel Nuts 105 - 115 142 - 156
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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 SIZE SAE GRADE 5 SAE GRADE 8
in.-lb. 0.250 80 - 90 110 - 120
(N•m) (9 - 10) (13 - 14)
0.3125 180 - 200 215 - 240
(21 - 23) (24 - 27)
x 0.375 25 - 28 35 - 40
x (34 - 38) (48 - 54)
x 0.4375 40 - 45 60 - 65
x (54 - 61) (82 - 88)
x
x 0.500 65 - 70 90 - 100
x (88 - 95) (125 - 135)
x 0.5625 90 - 100 125 - 140
x (125 - 135) (170 - 190)
x 0.625 125 - 140 175 - 190
x (170 - 190) (240 - 190)
x
0.750 220 - 245 300 - 330

ft.-lb.
(N•m) (300 - 330) (410 - 450)
0.875 330 - 360 475 - 525
(450 - 490) (645 - 710)
1.000 475 - 525 725 - 800
(645 - 710) (985 - 1085)
1.125 650 - 720 1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 - 4750) (7450 - 8300)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)
A300 Bobcat Loader

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TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts
Thread Size Material

(Dia.) 8.8 10.9 12.9
M4 2.0 - 2.5 ft.-lb. 2.8 - 3.1 ft.-lb. 3.5 - 3.9 ft.-lb.
(2,5 - 3,5 N•m) (3,8 - 4,2 N•m) (4,7 - 5,3 N•m)
M5 4.0 - 5.0 ft.-lb. 5.6 - 6.2 ft.-lb. 6.2 - 7.0 ft.-lb.
(5,5 - 6,5 N•m) (8,4 - 7,6 N•m) (8,5 - 9,5 N•m)
M6 7.0 - 7.5 ft.-lb. 9.1 - 10.1 ft.-lb. 10.4 - 11.6 ft.-lb.
(9,5 - 10,5 N•m) (12,2 - 13,7 N•m) (14,2 - 15,8 N•m)
M7 11.0 - 12.5 ft.-lb. 16.2 - 14.7 ft.-lb. 17.5 - 19.5 ft.-lb.
(15 - 17 N•m) (20 - 22 N•m) (23,7 - 26,3 N•m)
M8 18 - 19 ft.-lb. 21.7 - 24.0 ft.-lb. 25.5 - 28.5 ft.-lb.
(24 - 26 N•m) (29,4 - 32,6 N•m) (35 - 39 N•m)
M10 32 - 35 ft.-lb. 42.0 - 46.5 ft.-lb. 52.5 - 58.5 ft.-lb.
(43 - 47 N•m) (57 - 63 N•m) (71 - 79 N•m)
M12 55 - 60 ft.-lb. 78 - 85 ft.-lb. 91 - 110 ft.-lb.
(75 - 85 N•m) (105 - 115 N•m) (91 - 110 N•m)
M14 100 - 90 ft.-lb. 118 - 133 ft.-lb. 140 - 155 ft.-lb.

(125 - 140 N•m) (118 - 133 N•m) (140 - 155 N•m)
M16 140 - 155 ft.-lb. 188 - 210 ft.-lb. 225 - 245 ft.-lb.
(190 - 210 N•m) (255 - 285 N•m) (300 - 330 N•m)
M18 190 - 215 ft.-lb. 255 - 285 ft.-lb. 210 - 340 ft.-lb.
(260 - 290 N•m) (345 - 385 N•m) (420 - 460 N•m)
M20 275 - 300 ft.-lb. 360 - 405 ft.-lb. 440 - 490 ft.-lb.
(370 - 410 N•m) (490 - 550 N•m) (590 - 650 N•m)
M22 370 - 400 ft.-lb. 554 - 560 ft.-lb. 590 - 650 ft.-lb.
(500 - 550 N•m) (740 - 760 N•m) (800 - 880 N•m)
M24 470 - 520 ft.-lb. 625 - 700 ft.-lb. 730 - 830 ft.-lb.
(640 - 700 N•m) (850 - 950 N•m) (1000 - 1120 N•m)
M27 680 - 760 ft.-lb. 900 - 1000 ft.-lb. 1100 - 1200 ft.-lb.
(930 - 1030 N•m) (1230 - 1370 N•m) (1470 - 1630 N•m)
M30 930 - 1030 ft.-lb. 1250 - 1400 ft.-lb. 1500 - 1600 ft.-lb.
(1260 - 1400 N•m) (1700 - 1900 N•m) (2000 - 2200 N•m)
M33 1270 - 1400 ft.-lb. 2300 - 2500 ft.-lb. 2000 - 2300 ft.-lb.
(1720 - 1900 N•m) (2300 - 2500 N•m) (2700 - 3100 N•m)
M36 1620 - 1800 ft.-lb. 2200 - 2400 ft.-lb. 2600 - 2900 ft.-lb.
(200 - 2450 N•m) (2900 - 3200 N•m) (3500 - 3900 N•m)
A300 Bobcat Loader

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TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For Kubota Metric Engine Bolts
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M14 x 1.5 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)
A300 Bobcat Loader

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A300 Bobcat Loader

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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x ft.-lb.
IMPORTANT Diameter
1/4”
Thread Size
9/16” - 18
(N•m)
13 (18)
When repairing hydrostatic and hydraulic systems, 3/8” 11/16” - 16 22 (30)
clean the work area before disassembly and keep all 1/2” 13/16” - 16 40 (54)
5/8” 1” - 14 60 (81)
damage the system. 3/4” 1-3/16” - 12 84 (114)
I-2003-0888 7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-50-1
1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)

B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-50-1].
A300 Bobcat Loader

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HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the flare fitting:
(CONT’D)
Tighten the nut until it makes contact with the seat. Make
Straight Thread O-ring Fitting a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-4]
Figure SPEC-50-3
Use the chart [Figure SPEC-50-5 on Page 3] to find the
correct tightness needed (Item 2) [Figure SPEC-50-4]. If
the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-50-
3].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
Flare Fitting
Figure SPEC-50-4
TS-1619
A300 Bobcat Loader

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(CONT’D)
Hex Flat Tightening Method
Flare Fitting (Cont’d)
Figure SPEC-50-5
1
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
2
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
TS-1619
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
Tighten the nut until it contacts with the seat. Make a
7/8” 1-3/16” - 12 98 (133) mark across the flats of both the male and female parts of
1” 1-5/16” - 12 118 (160) the connection (Item 1) [Figure SPEC-50-7].
1-1/4” 1-5/8” - 12 154 (209)
Use the chart [Figure SPEC-50-8 on Page 4] to find the
1-1/2” 1-7/8” - 12 163 (221) correct tightness needed (Item 2) [Figure SPEC-50-7]. If

2” 2-1/2” - 12 252 (342) the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
O-ring Flare Fitting
Figure SPEC-50-6
Primary O-ring Flare

Seal
Secondary
Seal
P13009
The flare is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-6].
If necessary, the O-ring-flare fitting can be used without

an O-ring.
Use the following procedure to tighten the O-ring flare

fitting.
A300 Bobcat Loader

749 of 772
(CONT’D)
O-ring Flare Fitting (Cont’d)

Copper Bonnet Orifice
Figure SPEC-50-8
O-ring Flare Fitting Tightening Torque

x x *
Tubeline x TORQUE
Outside x ft.-lb.
1
Diameter Thread Size (N•m)
1/4” 7/1” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30) P13572
1/2” 3/4” - 16 40 (54)

5/8” 7/8” - 14 60 (81) NOTE: O-ring flare fittings are not recommended in
all applications. Use the standard flare fittings
3/4” 1-1/16” - 12 84 (114)
in these applications.
7/8” 1-3/16 - 12 98 (133)
1” 1-5/16” - 12 118 (160) Do not use a O-ring flare fitting when a copper bonnet
orifice is used. When tightened the connection at the
1-1/4” 1-5/8” - 12 154 (209)

bonnet may distort the flare face and prevent it from
1-1/2” 1-7/8” - 12 163 (221) sealing.
2” 2-1/2” - 12 252 (342)
Use a standard flare fitting (Item 1) [Figure SPEC-50-9]
* If a torque wrench is used to tighten a new fitting to a as shown.
used hose / tubeline.
When a O-ring flare fitting is used as a straight thread
* If a toque wrench is used to tighten a used fitting to a port adapter the O-ring flare face is not used to seal. The
new hose / tubeline. O-ring may come off the fitting and enter the system.
* If a torque wrench is used to tighten a new fitting to a Figure SPEC-50-10

new hose / tubeline.
** If using the hex flat tightening method to tighten a new

fitting to a new hose / tubeline.
2
** If using the hex flat tightening method to tighten a new
fitting to a used hose / tubeline.
*** If using the hex flat tightening method to tighten a

used fitting to a new hose / tubeline.
1
P13573
NOTE: Always remove the O-ring (Item 1) [Figure

SPEC-50-10] from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-50-10] is added to the

flat boss of the fitting to seal the connection in this
application.
A300 Bobcat Loader

750 of 772
HYDRAULIC CONNECTION SPECIFICATIONS Port seal and nut, washer and O-ring (O-ring Boss)
(CONT'D) fittings use the same tightening torque valve chart.
Port Seal Fitting If a torque wrench cannot be used, use the following
method.
Figure SPEC-50-11
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Nut Seals NOTE: If a torque wrench cannot be used, use the

To Fitting hex flat tightening method as an approximate
guideline.
Nut Seals NOTE: Port seal fittings are not recommended in all
To Port applications. Use O-ring boss fittings in these
applications.

Secondary O-ring Seal P-13008
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-11].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Figure SPEC-50-12
Port Seal and O-ring Boss

Tightening Torque
x TORQUE
x ft.-lb.
Thread Size (N•m)
7/16” - 20 13 18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
1-5/8” - 12 163 (221)
Use the following procedure to tighten the port seal

fitting:
A300 Bobcat Loader

751 of 772
A300 Bobcat Loader

752 of 772
HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18° C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic transmission fluid (P/N 6563328). If not flow easily and it makes action on the hydraulic
this fluid is not available, use 10W-30 or 10W-40 SAE function slower. Loss of fluid flow to the hydrostatic
Motor Oil (5W-30 for 0° F [-18° C] and Below). transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
AVOID INJURY OR DEATH five minutes at less than half throttle. This warm-up
Diesel fuel or hydraulic fluid under pressure can period is necessary for foot pedal operation and safe
penetrate skin or eyes, causing serious injury or stopping. Do not operate controls during warm-up
death. Fluid leaks under pressure may not be visible. period.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid When temperatures are below -20°F (-30°C), the
enters skin or eyes, get immediate medical attention hydrostatic oil must be heated or kept warm. The
from a physician familiar with this injury. hydrostatic system will not get enough oil at low

W-2072-0807
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
A300 Bobcat Loader

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A300 Bobcat Loader

754 of 772
CONVERSIONS
Decimal And Millimeter Equivalents
A300 Bobcat Loader

755 of 772
A300 Bobcat Loader

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ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
SALES MANAGER
REVISION
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Revision No:A300-1
Date:24 May 2002
Product:Bobcat Loader
Model:A300
Manual No:6901756 (3-02)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN CHANGE DESCRIPTION
Cover Cover Revised Serial Numbers
Alphabetical Index Added
ALL ALL
HYDRAULIC/HYDROSTATIC HYDRAULIC/HYDROSTATIC
SCHEMATIC SCHEMATIC
Printed March 2002 Printed May 2002
Section 30 Add Section

ALL ALL
WIRING SCHEMATIC WIRING SCHEMATIC
Printed March 2002 Printed May 2002
SPEC-01 thru SPEC-02 SPEC-01 thru SPEC-02 Revised Pages

SPEC 50-01 thru SPEC 50-04 SPEC 50-01 thru SPEC 50-06 Revised text and photos
Printed in U.S.A.
757 of 772
758 of 772
ROUTE TO
ATTENTION
PARTS MANAGER
REVISION SALES MANAGER
Revision No:A300-2 Manual No:6901756 (3-02)
Date:30 October 2003
Model:A300
TAKE OUT
Take out existing PUT INas listed below:
pages and put in the new pages CHANGE DESCRIPTION

10-10-1 thru 10-10-2 10-10-1 thru 10-10-2 Revised text
10-151-1 thru 10-151-2 10-151-1 thru 10-151-2 Revised photo
20-01 thru 20-04 20-01 thru 20-04 Revised text

20-60-1 thru 20-60-8 20-60-1 thru 20-60-14 Revised and Added information
20-130-1 thru 20-130-2 20-130-1 thru 20-130-2 Added information
40-01 thru 40-02 40-01 thru 40-02 Revised text
50-20-1 thru 50-20-6 50-20-1 thru 50-20-8 Added 3rd Gas Spring information

60-50-1 thru 60-50-14 60-50-1 thru 60-50-14 Revised text and photos
Printed in U.S.A.
759 of 772
760 of 772
ROUTE TO
ATTENTION
PARTS MANAGER
Date:8 December 2003
Model:A300
TAKE OUT
Take out existing PUT INas listed below:
pages and put in the new pages CHANGE DESCRIPTION

60-90-1 thru 60-90-120 60-90-1 thru 60-90-6 Revised text and removed Troubleshooting Trees
Printed in U.S.A.
761 of 772
762 of 772
ROUTE TO
ATTENTION
PARTS MANAGER
Date:4 May 2004
Model:A300
TAKEpages
Take out existing OUT and put in the new pagesPUT IN below:
as listed CHANGE DESCRIPTION

ALL HYDRAULIC/HYDROSTATIC ALL HYDRAULIC/HYDROSTATIC Revised all Hydraulic/Hydrostatic Schematics

SCHEMATICS SCHEMATICS
(Printed MAY 2002) (Printed MAY 2004)

20-101-1 thru 20-101-8 Added text
20-111-1 thru 20-111-8 Added text
20-130-1 thru 20-130-2 Remove this sub section
ALL WIRING SCHEMATICS ALL WIRING SCHEMATICS Revised all Wiring Schematics
(Printed MAY 2002) (Printed MAY 2004)
SPEC-10-1 thru SPEC-10-4 SPEC-10-1 thru SPEC-10-4 Revised text
Printed in U.S.A.
763 of 772
764 of 772
ROUTE TO
ATTENTION
PARTS MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: A300-5

Date: 23 March 2006
Product: Bobcat Loader
Model: A300
Manual No: 6901756 (3-02)
A300 Service Manual (P/N 6901756) Dated (3-06) contains updated service information which replaces the
previous A300 Service Manual (P/N 6901756) Dated (3-02).
Printed in U.S.A.
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ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: A300-6

Date: 21 March 2008
Model: A300
Manual No: 6901756 (3-08)
The following Sections are a revision to the above Service Manual.
COVER

ALPHABETICAL INDEX
80-01
80-10
80-20
80-30
80-40
80-50
80-60
80-70
80-80
80-90
80-100
80-110
80-120
80-130
80-140
80-150
80-160
80-170
80-180
80-190
80-200
80-210
80-220
Printed in U.S.A.
767 of 772
768 of 772
2
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: A300-7

Date: 23 July 2010
Model: A300
Manual No: 6901756 (7-10)
COVER
MAINTENANCE SAFETY

FOREWORD
70-80
Printed in U.S.A.
769 of 772
770 of 772
2
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
Revision No: A300-8

Date: 15 June 2012
Model: A300
Manual No: 6901756 (7-10)

COVER
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A300 6901756 enUS SM

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Service

Dealer Copy -- Not for Resale

BOBCAT SKID-STEER LOADER

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

CORRECT CORRECT CORRECT

B-10731a B-16261 B-16264

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

B-16271 B-16270 B-6589

AWS CONTROLLER .............................................. 60-01 HEATER COIL .........................................................80-01

Dealer Copy -- Not for Resale

DIAGNOSTICS SERVICE CODES ......................60-01 OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

SPARK ARRESTOR MUFFLER .............................10-01

TEMPERATURE / PRESSURE ...............................80-01

WHEEL POSITION SENSORS .............................. 60-01

Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

BOBCAT LOADER INDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

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

Dealer Copy -- Not for Resale

A300 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

Dealer Copy -- Not for Resale

22. Check for any field

A300 Bobcat Loader

A300 Bobcat Loader

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

A300 Bobcat Loader

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

A300 Bobcat Loader

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

A300 Bobcat Loader

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale

Always use the serial number of the loader when Figure 2

Loader Serial Number

Dealer Copy -- Not for Resale

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

2. The five digit Production Sequence Number identifies