T650 Aljg #5,8,10

Service Manual
Dealer Copy -- Not for Resale
Compact Track Loader
S/N ALJG11001 & Above

S/N T1ML11001 & Above
S/N B2KZ11001 & Above
6990755enUS (09-18) (G) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
T4-B S3B
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1711 NA1715

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

NA1714 NA1710 NA1712
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1722 NA1725 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW40-0609
1-1
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1-2
CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
5 of 1288 1-3 T650 Service Manual


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

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

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15


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

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

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

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

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

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

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

the work lights.
FW SSL-0617 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and

wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

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

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

operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine

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

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

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

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

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

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

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

Dial 811 (USA Only)

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

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

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

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

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

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

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

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

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

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1016 SM

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

requesting service information or when ordering parts.
Earlier or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number 1
Figure 1
1 P109660
The engine serial number (Item 1) [Figure 3] is located

on the side of the engine next to the oil fill cap.

P109923B
The loader serial number plate (Item 1) [Figure 1] is

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

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

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

the order which the loader is produced.

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

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.

The delivery report must be reviewed and signed by the
owner or operator and the dealer.

LOADER IDENTIFICATION
2 20
1
11
3
19
4
12
18
5 13
10
14
6 9
7 8 15 17
16
NA1669
NA1670

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


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

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

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

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

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

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

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

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

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

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

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

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Hydraulic / Hydrostatic Filter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic / Hydrostatic Filter (Earlier Models) . . . . . . . . 10-120-5
Removing And Replacing Hydraulic / Hydrostatic Filter (Later Models) . . . . . . . . . 10-120-6
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-9

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

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

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Track Roller And Idler Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-4
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1


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

B-7023A notched area of the frame [Figure 10-10-2].
Figure 10-10-3
WARNING

Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807 P-85424
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the struts [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tracks. Make sure the tracks clear the floor or
any obstacles.
NOTE: The lift arms are raised for photo clarity.

WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
23 of 1288 10-10-1 T650 Service Manual


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

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
Figure 10-20-1

1
P109924
The lift arm support device (Item 1) [Figure 10-20-1] is

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

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

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

LIFT ARM SUPPORT DEVICE (CONT’D) Start the engine and raise the lift arms all the way up.
Installing Figure 10-20-3
DANGER
P-90328
AVOID DEATH P-90567F

• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure Have a second person install the lift arm support device
can cause lift arms to drop. over the rod of one of the lift cylinders [Figure 10-20-3].
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm The lift arm support device must be tight against the
support. Replace if damaged.

cylinder rod.
D-1009-0409
Figure 10-20-4
Remove attachment from the loader. (See Removal And
Installation on Page 50-40-1.) OR (See Removal And
Installation on Page 50-41-1.)
Figure 10-20-2
P100005A
P100005
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
P107247A P100009
of the lift arm support device must go past the end of the
cylinder (Inset) [Figure 10-20-4].
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-2].
Remove the lift arm support device (Item 1) [Figure 10-

20-2] from the storage position.
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5
Removing
DANGER
P-90567F
P-90328
AVOID DEATH Have a second person remove the lift arm support device
• Disconnecting or loosening any hydraulic [Figure 10-20-5] after the lift arms are all the way up.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Lower the lift arms all the way and stop the engine.
unless supported by an approved lift arm Figure 10-20-6

D-1009-0409
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is removed and the lift arms are lowered
all the way.
NOTE: The lift arm support device should remain

resting on the cylinder barrel when the lift
arms are raised. Service or replace the lift arm
support device if the lift arm support raises
with the cylinder rod.
Start the engine and raise the lift arms all the way up. P109924
P100009
Return the lift arm support device to the storage position

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


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

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

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

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

and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines

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

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

could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3

P107247
Install jackstands under the rear of the loader frame

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

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

sides) at the front corners of the operator cab.

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

operator cab. WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
Hardware Removed Hardware Installed

P100953 P-90565A
Pull down on the bottom of the operator cab until it stops

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

when equipped with options and accessories P100236A P100235A
such as cab door, heater, air conditioning,

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

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

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

OPERATOR CAB (CONT’D)
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
NA3275
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

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

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

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

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

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

NA1026
Available for special applications to restrict material from

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

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

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

and objects from entering the cab. Kit includes 19,1 mm

(0.75 in) thick laminated polycarbonate front door,
1
polycarbonate side windows, and polycarbonate rear
window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

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

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

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

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can P107245A P107253B
break and cause personal injury.

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

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

loading or unloading the loader on a trailer.
Figure 10-40-1

P-90559C
Alternate Rear Tie-Down Alternate Front Tie-Down
P107246A P-85599C
1
P-90558C Use the following procedure to fasten the Bobcat loader

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

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


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

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

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


REMOTE START TOOL KIT - MEL1563 The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
Remote Start Tool - MEL1563 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
Tools that will be needed to complete the following steps the switch again will turn the flow OFF. The switch is used
are: when testing pressures and flow rate.
MEL1563 - Remote Start Tool Kit NOTE: With the engine running; pushing and holding
MEL1566 - Service Tool Harness Communicator the pressure release switch (Item 3) [Figure
(Computer Interface) 10-60-2] will cause the engine to stop.
Figure 10-60-1 Figure 10-60-3
2
1

P16114 P16114
The Remote Start Tool (Item 1) [Figure 10-60-1] is Remove the service tool harness (Item 1) from the cover
required when the service technician is testing the (Item 2) [Figure 10-60-3].
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics. Figure 10-60-4
Figure 10-60-2
2
3
1
P-85729
P16117
Loaders without an attachment harness, remove the cap
(Item 1) [Figure 10-60-4] from the loader harness
The traction lock switch (Item 1) [Figure 10-60-2] is used connector.
to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate Connect the service tool harness control to the loader
traction lock OVERRIDE, in this position the wheels are harness connector.
able to turn.

REMOTE START TOOL - MEL1563 (CONT’D) Service Tool Harness Communicator - MEL1566
Remote Start Tool - MEL1563 (Cont'd) Figure 10-60-6
Figure 10-60-5 2
1
1
P16119
P114629
The Service Tool Harness Communicator (Item 1) is
required to connect Remote Start Tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-6].
must disconnect the attachment harness from the loader

harness (Item 2) [Figure 10-60-5].
Connect the service tool harness to the ACD connector

and the loader harness connector.
NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.

REMOTE START TOOL - MEL1563 (CONT’D) Figure 10-60-8
Remote Start Procedure
The tool listed will be needed to do the following

1
procedure:
MEL1563: Remote Start Tool Kit
Figure 10-60-7
1
P-85729
Figure 10-60-9

P16115
1
The Remote Start Tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.

P114629
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Remove the cap (Item 1) [Figure 10-60-8].
Raise the operator cab (if required by the procedure).
OR
Open the rear door of the loader.
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped).

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

WARNING
Figure 10-60-10
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
1 the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area.
W-2457-1110
P114631
Figure 10-60-12
Figure 10-60-11

2
1
1
P16116
P114632
The Remote Start Tool (Item 1) [Figure 10-60-12] has

Connect the Remote Start Tool to the engine harness three rocker switches.
connector (Item 1) [Figure 10-60-10].
OR
Connect the Remote Start Tool to the engine harness

connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT - MEL1563 (CONT’D) Figure 10-60-14
Figure 10-60-13
2
3 1
P-85311
Push the couplers on the front auxiliary block toward the

P16118 block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-14].
The traction lock switch (Item 1) [Figure 10-60-13] is

used to turn traction lock ON or OFF. Push the switch to

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

10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when testing pressures and flow rate.
NOTE: With the engine running; pushing and holding

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


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

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

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

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

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

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

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

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader electrical system. The button will illuminate to
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678 The traction lock button (Item 5) [Figure 10-61-2] is used

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

7217666 (CONT'D)
Loader Service Tool Harness - 6689747
Figure 10-61-3 1
P114629
2
Loaders with an attachment control harness (7 pin or 14

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

The Loader Service Tool Harness (Item 1) is used to the loader connector cap (Item 1) [Figure 10-61-4] or

connect the Remote Start Tool (Service Tool) (Item 2) reconnect the attachment control harness to the loader
[Figure 10-61-3] to the electrical system on the loader. harness (Item 1) [Figure 10-61-5].
Figure 10-61-4
P-85729
Loaders without an attachment control harness, remove

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
3 2
2
P-76450
P114632 The Computer Service Tool Harness (Item 1) is required

to connect Remote Start Tool (Service Tool) to the
Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)

connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

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

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

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

REMOTE START TOOL (SERVICE TOOL) KIT - Raise the operator cab (if required by the procedure).
7217666 (CONT'D)
Remote Start Procedure
Figure 10-61-9
WARNING
1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
P-85729
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area. Loaders without an attachment control harness, remove
W-2457-1110 the loader harness cap (Item 1) [Figure 10-61-9] and

connect the Loader Service Tool Harness from the
The tool listed will be needed to do the following Remote Start Tool (Service Tool).
procedure: NOTE: When using a Remote Start Tool (Service tool)
harness on loaders not equipped with an
7217666: Remote Start Tool (Service Tool) Kit attachment control device, the Remote Start
Tool (Service Tool) harness attachment
Figure 10-61-8 control device connector must be capped.
Figure 10-61-10
1
2
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure P114629
10-61-8] is required when the operator cab is in the

raised position for service and the service technician
Loaders with an attachment control harness (7 pin or 14
needs to turn on the loader or start the engine. Example:
pin), (Item 1) must be disconnected from the loader
adjusting the steering linkage.
harness (Item 2) [Figure 10-61-10].
Lift and block the loader. When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-9] or
Raise the lift arms (if required by the procedure) and reconnect the attachment control harness to the loader
install an approved lift arm support device. harness.

7217666 (CONT'D)
2
Figure 10-61-11
5 3
6 4
3
2
P-76439
The Remote Start Tool (Service Tool) (Item 1) [Figure

10-61-12] has five buttons.
P114632
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.

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

7217666 (CONT'D)
Figure 10-61-13
1 2
P-85311
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure

10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

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

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


SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures.
WARNING
The service schedule is a guide for correct maintenance
of the Bobcat loader. 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
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Every 10 Hours (Before Starting The Loader)
• Engine Oil – Check level and add as needed.

• Engine Air Filters and Air System – Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System – Clean debris from hydraulic fluid cooler and radiator assembly, fuel cooler, air conditioning
condenser (if equipped), and rear grille. Check coolant level COLD and add premixed coolant as needed.
• Fuel Filter – Check the display panel. Remove the trapped water when required.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges – Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks – Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) – Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm – Check for proper function.
• 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.
• Safety Signs and Safety Treads – Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid – Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) – Clean or replace filters as needed.
SS CTL MF EXMF T4-B-0118

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

• Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours or Every 12 Months
• Engine / Hydrostatic Drive Belt – Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) – Check condition. Replace as needed.

• Bobcat Interlock Control System (BICS™) – Check the function of the lift arm bypass control.
• Fuel Filter – Replace filter element.

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

• Hydraulic Reservoir – Replace the fluid.
• Engine Valves – Adjust the engine valve clearance.
• Coolant – Replace the coolant.
SS CTL MF EXMF T4-B-0118

AIR CLEANER SERVICE Figure 10-80-2
Replacing Filter Elements
Figure 10-80-1
2
2
3
1
1
P109624A
NA3352
Open four latches (Item 1) and move the cover (Item 2)

Replace the air filters only when necessary. The service [Figure 10-80-2] out of the way. (One latch is not visible
indicator (Item 1) will FLASH. Press the Information in the photo.)
button (Item 3) until the display screen shows the service
codes. Service code [AIRF] (Replace Engine Air Filter) Figure 10-80-3
or [M0117] (Air Filter Plugged) will show in the display

screen (Item 2) [Figure 10-80-1] when air filter
replacement is necessary.
NOTE: Prolonged operation with an active [AIRF] or

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

code will cause the engine to derate (torque
and rpm reduction).
Replace the inner filter every second time the outer filter 1
is replaced or as indicated.
P109625
Outer Filter
Stop the engine, open the rear door, and remove the rear Remove the outer filter (Item 1) [Figure 10-80-3] and
grille. (See Removing on Page 50-60-1.) discard.
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new outer filter. Push in until the filter contacts the
base of the housing.
Install the cover and secure four latches [Figure 10-80-

2].
Install the rear grille and close the rear door.

ENGINE AIR CLEANER (CONT’D) Figure 10-80-5
Replacing Filter Elements (Cont’d)
Inner Filter
Replace the inner filter only under the following 2

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

filter is replaced.
• After the outer filter has been replaced, start the 1

engine and operate at full rpm. If service code [AIRF]
(Replace Engine Air Filter) or [M0117] (Air Filter
Plugged) is still displayed in the data display, replace
P109624A
the inner filter.
Stop the engine, open the rear door, and remove the rear Install the cover (Item 2) and secure four latches (Item 1)
grille. (See Removing on Page 50-60-1.) [Figure 10-80-5]. (One latch is not visible in the photo.)
Remove the cover [Figure 10-80-2] and the outer filter Install the rear grille and close the rear door.
[Figure 10-80-3].

Figure 10-80-4
P109626
Remove the inner filter (Item 1) [Figure 10-80-4].
NOTE: Make sure the filter housing is free of dirt and

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

ENGINE COOLING SYSTEM Cleaning
Check the cooling system every day to prevent See the SERVICE SCHEDULE for the correct service
overheating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Maintenance Platform Stop the engine, open the rear door, and remove the rear
grille. (See Removing on Page 50-60-1.)
Figure 10-90-1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P107266 Figure 10-90-2

Use the maintenance platform [Figure 10-90-1] to
facilitate access when cleaning the engine cooling
system.
1
P109632
Use low air pressure or water pressure to clean the top of

the fuel cooler (Item 1) [Figure 10-90-2].

ENGINE COOLING SYSTEM (CONT’D) Return the support bar to storage position and lower the
air conditioning condenser.
Cleaning (Cont’d)
Figure 10-90-5
Loaders With Air Conditioning
Figure 10-90-3
1 2
1
2
P121162
P109573A
Ensure the air conditioning condenser is installed into the
two slotted brackets [Figure 10-90-5]. (Right side
shown.)

Use low air pressure or water pressure to clean the top of
the air conditioning condenser (Item 1) [Figure 10-90-3]. Ensure the clips (Item 1) are properly installed over the
two slotted brackets (Item 2) [Figure 10-90-5]. (Right
Unhook the two rubber straps (Item 2) [Figure 10-90-3]. side shown.)
NOTE: The air conditioning condenser fits into two Fasten the two rubber straps [Figure 10-90-3].
slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the NOTE: The air conditioning condenser can be lifted
air conditioning condenser remains out of the two slotted brackets by removing
connected to the brackets when raising and the clips. This allows greater access to clean
lowering. the hydraulic fluid cooler and radiator
assembly.
Figure 10-90-4
NOTE: Be careful when removing and installing the
air conditioning condenser so that the air
conditioning condenser does not fall on the
hydraulic fluid cooler and radiator assembly
1 and damage the fins.
Skip ahead to All Loaders. (See All Loaders on Page 10-

2 90-3.)
3
P109572A
Pivot the air conditioning condenser (Item 1) up and

rotate the support bar (Item 2) into position. Use low air
pressure or water pressure to clean the top of the
hydraulic fluid cooler and radiator assembly (Item 3)
[Figure 10-90-4].

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Figure 10-90-7
Loaders Without Air Conditioning
Figure 10-90-6
1
2
1
P109633
The area between the fuel cooler and the hydraulic fluid
P109641
cooler and radiator assembly will require occasional
cleaning. Remove the bolt (Item 2) and lift the fuel cooler
up while sliding out of the bracket (Item 1) [Figure 10-90-

Use low air pressure or water pressure to clean the top of 7].
the hydraulic fluid cooler and radiator assembly (Item 1)
[Figure 10-90-6]. NOTE: Be careful when removing and installing the
fuel cooler so that the fuel cooler does not fall
on the hydraulic fluid cooler and radiator
assembly and damage the fins.
Install the fuel cooler into the bracket. Install and tighten
the bolt (Item 2) [Figure 10-90-7].
Check the cooling system for leaks.

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

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

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-90-8].

P109634B Install the coolant fill cap (Item 1) [Figure 10-90-8].
NOTE: The coolant fill cap must be tightened until the

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

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

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

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

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

1
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P109814
is hot. You can be seriously burned.
W-2607-0804
Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
NOTE: This procedure requires the use of a spare [Figure 10-90-10] or similar tool.
0.75 in coolant hose approximately 600 mm
(24 in) long. Install the coolant fill cap (Item 1) [Figure 10-90-9].

1 3
2
P109634B P109813
Remove the coolant fill cap (Item 1) [Figure 10-90-9]. Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-11].
Quickly install the spare 0.75 in coolant hose onto the

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

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

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

protect the internal engine components; reduces the
P109634B
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

Remove the coolant fill cap (Item 1) [Figure 10-90-12] to concentrated coolant can cause serious premature
drain the coolant faster. engine damage.

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

cap clicks.
Install the rear grille (See Installing on Page 50-60-2.)

and close the rear door.
2
1
Operate the engine until coolant reaches normal
operating temperature. Stop the engine.
Check the coolant level when cool. Add coolant as

P109635 needed. (See Checking Level on Page 10-90-4.)
Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-13].
Remove the tool used to pinch off the coolant hose.
Recycle or dispose of used coolant in an environmentally

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

on Page SPEC-10-5.)

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

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

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Stop the engine and open the rear door. NA1684
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1 1].
NOTE: The fuel fill cap must be tightened until the cap
clicks.
Close the rear door.
P121905
WARNING
Remove the fill cap (Item 1) [Figure 10-100-1].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Replacing Element
Fuel Filter See the SERVICE SCHEDULE for the correct service
For the service interval for removing water from, or
replacing the fuel filter (See SERVICE SCHEDULE on Stop the engine and open the rear door.
Page 10-70-1.)
Figure 10-100-4
Removing Water
3
Stop the engine and open the rear door.
1
Figure 10-100-3
P121907
1

Disconnect the electrical connector (Item 2) [Figure 10-
100-4].
Loosen the fuel filter head (Item 3) from the fuel filter
P121906
element (Item 1) [Figure 10-100-4]. Do NOT remove the
hoses from the filter head.
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter to remove trapped water from the filter. Loosen the clamps (Item 4) [Figure 10-100-4].
Remove the fuel filter element (Item 1) from the fuel filter
Securely tighten the drain.
head (Item 3) [Figure 10-100-4].
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
WARNING Put clean oil on the two new fuel filter element O-rings,
install the element, and tighten to 13,5 N•m (10 ft-lb)
AVOID INJURY OR DEATH torque.
sparks or lighted tobacco away from fuel and oil. Install the fuel filter assembly into the clamps and tighten.
Failure to use care around combustibles can cause Connect the electrical connector [Figure 10-100-4].
explosion or fire.
W-2103-0508
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.)
WARNING
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter (Cont’d) After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
Replacing Element (Cont’d) system before starting the engine.
WARNING WARNING
AVOID INJURY OR DEATH AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, Diesel fuel or hydraulic fluid under pressure can
sparks or lighted tobacco away from fuel and oil. penetrate skin or eyes, causing serious injury or
Failure to use care around combustibles can cause death. Fluid leaks under pressure may not be visible.
explosion or fire. Use a piece of cardboard or wood to find leaks. Do
W-2103-0508 not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Close the rear door. W-2072-0807
Start the engine and allow to operate for one minute.

Figure 10-100-5
WARNING

Diesel fuel or hydraulic fluid under pressure can 1
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
W-2072-0807
P121908
Stop the engine and check for leaks at the filter.
Open the air vent plug (Item 1) [Figure 10-100-5] on the
fuel filter assembly three full turns.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

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

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2

ENGINE CRANKCASE OIL
Check the engine oil level every day before starting the Recommended SAE Viscosity Number
engine for the work shift.
Figure 10-110-1
1 Refer to temperature range anticipated before next

oil change
2 Must use API Category CJ-4 or better, or ACEA E9 or
better
Do not use API Category FA-4 engine oil
[1] SAE 10W-30
[2] SAE 15W-40
P109631 [3] Bobcat Synthetic Oil – SAE 5W-40

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

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

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4
Removing And Replacing Oil And Filter
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
1
Operate the engine until coolant reaches normal
operating temperature. Stop the engine.
Figure 10-110-3
2
P109944
P109762A
The oil drain hose (Item 1) storage location is on top of

the fuel tank. Remove the hose from the storage location
and route through the opening (Item 2) [Figure 10-110-
4].
1 2
Figure 10-110-5

P109086B
The oil drain hose is located behind a cover (Item 2)

under the right rear corner of the loader (Inset) [Figure
10-110-3].
Remove the cover mounting bolts (Item 1) and remove

the cover (Item 2) [Figure 10-110-3].
Open the rear door.

1
P-90498A
Remove the oil drain cap (Item 1) [Figure 10-110-5] from

the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.
Install and tighten the oil drain cap [Figure 10-110-5].
Return the oil drain hose to the storage location on top of

the fuel tank [Figure 10-110-4].
Install the cover and the cover mounting bolts [Figure 10-
110-3]. Tighten all bolts.

ENGINE LUBRICATION SYSTEM (CONT’D) Remove the dipstick (Item 1) [Figure 10-110-6] and
check the oil level.
Removing And Replacing Oil And Filter (Cont’d)
Add oil as needed if oil level is not at the top mark on the
Figure 10-110-6 dipstick. Install the dipstick and close the rear door.
WARNING
1 AVOID INJURY OR DEATH
2 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P109631
Remove the oil filter (Item 3) [Figure 10-110-6] and clean

the filter base.

Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only.
Remove the oil fill cap (Item 2) [Figure 10-110-6].
Put oil into the engine and replace the oil fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Start the engine and allow to operate for several minutes.
WARNING
explosion or fire.
W-2103-0508


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

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

MACHINE USE
[1] BOBCAT All-Season Fluid
[2] BOBCAT Synthetic Fluid
[3] BOBCAT Biodegradable Hydraulic / Hydrostatic
1 Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at

operating temperatures.)
[4] VG 100; Minimum VI 130
P100010 [5] VG 46; Minimum VI 150
Bobcat hydraulic fluids are recommended for use in this

Check the fluid level in the sight gauge (Item 1) [Figure machine. If Bobcat hydraulic fluid is not available, use a
10-120-1]. Keep the fluid level within the operating range. good quality hydraulic fluid meeting the viscosity grade
and viscosity index shown in the chart [Figure 10-120-3].
Open the rear door and remove the rear grille. (See (See Hydraulic System on Page SPEC-10-4.)
Removing on Page 50-60-1.)
Figure 10-120-2
WARNING
1
explosion or fire.
W-2103-0508
P115130
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

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

rear grille and close the rear door.

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

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

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter (Earlier Models) on Page 10-120-5.)
and (See Removing And Replacing Hydraulic Charge
Filter on Page 10-120-7.)
P100007
Remove the right side access cover bolts (Item 1)
Figure 10-120-4 [Figure 10-120-5] and remove the access cover. (Lift
arms shown raised for visual clarity.)
NOTE: The hose used to drain the hydraulic reservoir

is located under the fan motor on earlier

models and behind the fan motor on later
1 models.
Figure 10-120-6
Earlier Model Later Model
P115130
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4]. 1
2 2
P109760A P115442A
Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-120-6] near the fitting and disconnect hose
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.
Connect the hose to the fitting when the fluid stops

draining. Install the clamp.
Recycle or dispose of used fluid in an environmentally

safe manner.

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

WARNING Diesel fuel or hydraulic fluid under pressure can
AVOID INJURY OR DEATH Use a piece of cardboard or wood to find leaks. Do
Always clean up spilled fuel or oil. Keep heat, flames, not use your bare hand. Wear safety goggles. If fluid
sparks or lighted tobacco away from fuel and oil. enters skin or eyes, get immediate medical attention
Failure to use care around combustibles can cause from a physician familiar with this injury.
explosion or fire. W-2072-0807
W-2103-0508
Stop the engine and check for leaks.

Install the side access cover and bolts [Figure 10-120-5].
Check the fluid level in the reservoir and add as needed.
Figure 10-120-7 (See Checking And Adding Fluid on Page 10-120-1.)

1
P115129
Remove and clean the hydraulic fill screen (Item 1)

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

controls.

Hydraulic / Hydrostatic Filter Identification
The filter housing is located behind the hydraulic fluid

reservoir.
NOTE: Identification of the hydraulic / hydrostatic

filter used on your machine is necessary to
perform the correct filter replacement
procedure.
Figure 10-120-8
Earlier Model

P109922
Earlier models have a screw type filter cap [Figure 10-

120-8].
Figure 10-120-9
Later Model
P121214C
Later models have a filter cap held in place by two bolts

[Figure 10-120-9].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Remove the filter cap O-ring (Item 3) [Figure 10-120-11]
and discard.
Removing And Replacing Hydraulic / Hydrostatic
Filter (Earlier Models) Install new filter cap O-ring and lubricate with clean oil.
See the SERVICE SCHEDULE for the correct service Install the filter cap and tighten to 25 N•m (18 ft-lb)
interval. (See SERVICE SCHEDULE on Page 10-70-1.) torque.
grille. (See REAR GRILLE on Page 50-60-1.)
Clean the top of the filter housing.

WARNING
Figure 10-120-10 AVOID INJURY OR DEATH
explosion or fire.
W-2103-0508
Start the engine and operate the loader hydraulic

1 controls.

WARNING
P109922

Remove the filter cap (Item 1) [Figure 10-120-10]. Diesel fuel or hydraulic fluid under pressure can
Figure 10-120-11 death. Fluid leaks under pressure may not be visible.
1 not use your bare hand. Wear safety goggles. If fluid
2 W-2072-0807

(See Checking And Adding Fluid on Page 10-120-1.)
3 P100044 P109930
Remove the filter (Item 2) [Figure 10-120-11] and

discard.
Lubricate the O-ring (Item 1) [Figure 10-120-11] on a

new filter with clean oil.
Install new filter ensuring that filter is fully seated in the

housing.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter element ensuring that element is fully
seated in the housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter (Later Models) Remove the filter cap O-rings (Item 3) [Figure 10-120-
13] and discard.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Install new filter cap O-rings and lubricate with clean oil.
Stop the engine, open the rear door, and remove the rear NOTE: The filter cap O-rings are not the same size.
grille. (See REAR GRILLE on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and the bolts [Figure 10-120-12].
Figure 10-120-12 Alternate tightening the bolts to draw the cap down
evenly. Tighten the bolts to 27 - 41 N•m (20 - 30 ft-lb)
torque.
1
WARNING
2

explosion or fire.
W-2103-0508
P121214C
Remove the bolts (Item 1) and slowly pry the filter cap Start the engine and operate the loader hydraulic
(Item 2) [Figure 10-120-12] off the housing by hand. controls.
Figure 10-120-13
1
WARNING
2 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
not use your bare hand. Wear safety goggles. If fluid
3 from a physician familiar with this injury.
W-2072-0807
P121072A P115686B Stop the engine and check for leaks at the filter.

Remove the filter element (Item 2) [Figure 10-120-13] (See Checking And Adding Fluid on Page 10-120-1.)
and discard.
Lubricate the O-ring (Item 1) [Figure 10-120-13] on new

filter element with clean oil.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Earlier Models
Removing And Replacing Hydraulic Charge Filter Figure 10-120-16

Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
1
Figure 10-120-14
P-85489B
1
Put a suitable container below the filter housing and

remove the filter housing (Item 1) [Figure 10-120-16].
2
Figure 10-120-17

P115884
Unhook the three rubber straps (Item1) and remove the

lower fan duct (Item 2) [Figure 10-120-14]. (Earlier
models used four rubber straps.) 1
NOTE: Identification of the hydraulic charge filter
used on your machine is necessary to
perform the correct replacement procedure.
Figure 10-120-15
Earlier Model Later Model

P-85489A
Remove the filter (Item 1) [Figure 10-120-17] and

discard.
Clean the surface of the filter housing and the filter base
where they contact the filter seal.
Put clean oil on the seal of the new filter. Install the filter
on the filter base [Figure 10-120-17].
P109622B P115441A
Install and tighten the filter housing to 65 – 70 N•m (48 –
52 ft-lb) torque [Figure 10-120-16].
Earlier models use a separate filter housing and filter
element. Later models use a spin-on filter [Figure 10-
120-15].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) All Models
Removing And Replacing Hydraulic Charge Filter Recycle or dispose of used fluid in an environmentally
(Cont’d) safe manner.
Later Models
Figure 10-120-18 WARNING

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

may result in decreased cooling.
P115441 Lower the operator cab. (See Lowering on Page 10-30-

3.)

Put a suitable container below the filter, remove the filter Start the engine and operate the loader hydraulic
(Item 1) [Figure 10-120-18], and clean the filter base. controls.
Put clean oil on the new filter gasket, install the new filter,
and tighten the filter to 37 – 45 N•m (27 – 33 ft-lb) torque.
WARNING
W-2072-0807

(See Checking And Adding Fluid on Page 10-120-1.)

Replacing Reservoir Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Figure 10-120-19

P115130
Remove the breather cap (Item 1) [Figure 10-120-19]

and discard.
Install new breather cap.


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

[Figure 10-130-1].

The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-130-2
NA13065S
1
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
2 damage [Figure 10-130-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

P-31233A NA3098 Page 10-70-1.) (See LUBRICATING THE LOADER on
Page 10-140-1.)
The wedges (Item 1) [Figure 10-130-2] must extend
through the holes in the attachment mounting frame.


BOB-TACH (POWER) The wedges (Item 1) [Figure 10-131-2] must extend
through the holes in the attachment mounting frame.
This machine may be equipped with a Power Bob-Tach.
The spring loaded wedges (Item 1) must contact the
Inspection And Maintenance lower edge of the holes in the attachment mounting frame
(Item 2) [Figure 10-131-2].
Figure 10-131-1
If the wedges do not contact the lower edge of the holes
[Figure 10-131-2], the attachment will be loose and can
come off the Bob-Tach.
1
Figure 10-131-3
NA3234
Push and hold the BOB-TACH WEDGES “UP” switch

(Item 1) until wedges are fully raised. Push and hold the

BOB-TACH WEDGES “DOWN” switch (Item 2) [Figure
10-131-1] until the wedges are fully down.
The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-131-2
NA13065S
2
Inspect the mounting frame on the attachment and

Bob-Tach, linkages, and wedges for excessive wear or
damage [Figure 10-131-3]. Replace any parts that are
Both wedges must damaged, bent, or missing. Keep all fasteners tight.
contact lower edge of
holes in the attachment Inspect for cracked welds.
mounting frame.
Lubricate the wedges. (See SERVICE SCHEDULE on
P-31233A NA3098 Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)


LUBRICATING THE LOADER Lubricate the following:
Lubrication Locations Figure 10-140-2

Record the operating hours each time you lubricate the

Bobcat loader.
1
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. (See Removal And

Installation on Page 50-40-1.) OR (See Removal And
P107286
Stop the engine.
Figure 10-140-1 1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-140-2].
1 Figure 10-140-3
2

4
8
2
9 10
11
5
6
3
7 P109934C
P107287
The grease fitting locations [Figure 10-140-1] are shown
in more detail in the following figures.
2. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-140-3].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-6
Lubrication Locations (Cont’d)
Figure 10-140-4 5
P109928
5. Rear Control Link (Both Sides) (2) [Figure 10-140-6].

P107285
Figure 10-140-7
3. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

140-4].

Figure 10-140-5
P107292
6. Front Control Link (Both Sides) (2) [Figure 10-140-7].
P109927
4. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

140-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-140-10
Lubrication Locations (Cont’d)
Figure 10-140-8
7
P107960
9. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

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

Figure 10-140-9
10
8
P107961
P109929
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-
11].
8. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

140-9].

LUBRICATING THE LOADER (CONT’D) Track Roller And Idler Lubrication
Lubrication Locations (Cont’d) Description
If Equipped With Power Bob-Tach The track rollers and idlers have sealed bearings and do
not require lubrication.
Figure 10-140-12
11
P107959

11. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10-
140-12].

PIVOT PINS
Inspection And Maintenance
Figure 10-150-1
P107293
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure

10-150-1].
Check that the locknuts are tightened to 48 – 54 N•m (35

– 40 ft-lb) torque.


LOADER STORAGE AND RETURN TO SERVICE
Storage Return To Service
You may decide to store your Bobcat loader for an After the Bobcat loader has been in storage, perform the
extended period of time. Perform the procedures below procedures below to return the loader to service:
for storage:
• Check the engine oil and hydraulic fluid levels; check
• Thoroughly clean the loader including the engine coolant level.
compartment.
• Install a fully charged battery.
• Lubricate the loader.
• Remove grease from exposed cylinder rods.
• Replace worn or damaged parts.
• Check all belt tensions.
• Park the loader in a dry protected shelter.
• Be sure all shields and guards are in position.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Lubricate the loader.
• Put blocks under the frame to remove weight from the • Check track condition and remove blocks from under
tracks. frame.
• Put grease on any exposed cylinder rods. • Remove cover from exhaust pipe opening.

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

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

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

filters.
• Put all controls into the neutral position.
• Remove the battery. Be sure the electrolyte level is

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

storage condition.


STOPPING THE ENGINE AND LEAVING THE LOADER (Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
Procedure personnel.
Stop the loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Fully lower the lift arms and put the attachment flat on the Deluxe Instrumentation Panel allows
ground. operation of the loader without using a
password. (See Password Lockout Feature on
Figure 10-170-1 Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-170-3

P107184 P-85737A P-85735A
Set the engine speed control to the low idle position Exit the loader using grab handles, safety tread, and
[Figure 10-170-1]. steps (maintaining a three-point contact) [Figure 10-170-
3].
Engage the parking brake.
Figure 10-170-2
WARNING
1 1
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
P-90688A P-90214C
position to make sure the lift, tilt and traction
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) [Figure The seat bar system must deactivate these functions
10-170-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.


EMERGENCY EXIT
The front opening on the operator cab and rear window There are two different procedures for removing the rear
provide exits. window from your machine:
Rear Window Identification 1. This window is equipped with latches (Item 1) [Figure
10-180-1].
Figure 10-180-1
2. This window is equipped with a rubber cord and tag
Latches Rubber Cord (Item 2) [Figure 10-180-1].
NOTE: Use these procedures to remove the rear

2 window only under emergency conditions.
Damage to machine may occur.
1
P-85309B P-64994A
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-180-2 Figure 10-180-4

1
P-85309A P-64994F
Turn both latches (Item 1) [Figure 10-180-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-180-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-180-3 Figure 10-180-5
P-90676 P-90676
Exit through the rear of operator cab [Figure 10-180-3]. Exit through the rear of operator cab [Figure 10-180-5].

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 10-180-6
Figure 10-180-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 10-180-8] up and out

[Figure 10-180-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove. Front Door
OR NOTE: Use this procedure to remove the front door

only under emergency conditions. Damage to
Figure 10-180-7 machine may occur.
Figure 10-180-9
1
P-90669C
P-90725
A kit is available to allow removal of the latch equipped
rear window from outside the machine without tools.
Turn both latches (Item 1) [Figure 10-180-9] down until
Turn both knobs (Item 1) [Figure 10-180-7] they disengage from the door frame.
counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the Push the door out of the operator cab door frame and exit
cab and lift up to remove. through the opening.

EMERGENCY EXIT (CONT’D) Figure 10-180-12
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-180-10
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-180-12] on the door. (Bottom
hinge shown.)
2
Figure 10-180-13

P-85781A 1
NOTE: Later models route the washer fluid hose

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

hose (Item 1) (if equipped) [Figure 10-180-10].
Figure 10-180-11
P-90686A
2
3
Install cast washers (Item 2) on door hinges taking care
to match rectangular surfaces. Hold cast washer firmly
against door and rotate latch (Item 1) [Figure 10-180-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity.)
1
Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
P-85588A P-85589A
the clip into the hole in the gas spring socket. Rotate the
clip to lock into position [Figure 10-180-11].
Rotate and pull the clip (Item 1) out of the gas spring Connect electrical connector and washer fluid hose (if
socket. Pull the gas spring socket (Item 3) straight off the equipped) [Figure 10-180-10].
ball stud fitting (Item 2) [Figure 10-180-11].
Remove the door hinges from the loader.


SEAT BELT Figure 10-190-1
Inspection And Maintenance

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

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

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

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware, or any other obvious
problem should be replaced immediately. 5
The items below are referenced in [Figure 10-190-1].

NA3113
1. Check the webbing. If the system is equipped with a

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

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

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

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

Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.


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

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

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

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

CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

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

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

Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23

Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

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

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

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-14
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-15
HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS) . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . 20-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-2

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK (S/N ALJG11001 - 13367 AND 

B2KZ11001 - 11017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

BOB-TACH (POWER) BLOCK (S/N ALJG13368 AND B2KZ11018 & ABOVE) . . . . . . 20-121-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

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

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


Printable Version Click Here
(PRINTED MARCH 2015)

V-1472legend
LEGEND
1 RESERVOIR: 39 CHARGE PUMP -
19 PULL BUTTON ACTIVATED
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 40 HYDRAULIC PUMP . . . . . . . Gear Type
87,1 L/min (23.0 U.S. gpm) at High Engine Idle
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
41 VARIABLE CAPACITY DISPLACEMENT
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM
3 BIDIRECTIONAL HYDROSTATIC PUMP
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP
42 RELIEF/REPLENISHING VALVE - HIGH
Normally Closed 21 RELIEF VALVE - 24132 kPa (241 bar) PRESSURE: 36500 kPa (365 bar) (5294 psi)
4 FILTER - HYDRAULIC (CANISTER) (3500 psi) (If Equipped)
22 43 RELIEF VALVE - CHARGE INLET:
SPRING LOADED FILTER BY-PASS ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar)
5
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN:

(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER
SPRING LOADED FILTER BY-PASS VALVE: BY-PASS With 345 kPa (3,45 bar)
24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring
at Front Quick Couplers Dealer Copy -- Not for Resale
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
FIXED CAPACITY DISPLACEMENT 45 FRONT AUXILIARY MANUAL PRESSURE
NOTE - If Equipped With Ref. 21: 25
HYDRAULIC MOTOR BLEED-OFF VALVE
25855 kPa (258 bar) (3750 psi)
RELIEF/ANTICAVITATION VALVE - 26 FILTER - HYDRAULIC (CANISTER)
8
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE –
9 RELIEF/ANTICAVITATION VALVE - Fan Filter
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in)
10 SOLENOID ACTIVATED DIRECTIONAL
30 CHECK VALVE - With 1379 kPa 13,8 bar
CONTROL VALVE - AUXILIARY
(200 psi) Spring
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE 32 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 33 NOT USED FOR THIS MODEL
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT
34
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED –
CONTROL VALVE - BICS CONTROL PRESSURE RELEASE (SAPR)
16 FILTER - BICS CONTROL VALVE 36 SOLENOID ACTIVATED DIRECECTIONAL
(SCREEN) CONTROL VALVE – BRAKE
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE
(14.5 psi) Spring SOLENOID ACTIVATED DIRECTIONAL
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift
NOTE: Unless otherwise specified springs have
NO significant pressure value.
Printed in U.S.A. V-1472legend (3-31-15)
107 of 1288
INTEGRATED QUICK COUPLER BLOCK
45
Male
DRIVE MOTOR
45
30 Male
OUT
L
31 HYDRAULIC CONTROL VALVE
29 Female
34
9
10
Z 11
35
A B
21
HYDROSTATIC PUMP 11
8
8
41 Tilt Spool
42 42
13 TILT CYLINDERS
11
M4
M
D C 14
12
BRAKE VALVE -
SPRING APPLIED 43
36
37
Charge
Inlet
8
1 LIFT CYLINDERS
2
NOTE: CUSHIONED
3
20 LIFT CYLINDERS ON
38 B A 11 16 15 LATER MODELS ONLY
37 18
IN 2
M M1 7 6 16
17
42 42 19
1
41 44
OIL COOLER 5 2 RESERVOIR (VENTED)

T
4
40 1
39
VARIABLE SPEED HYDRAULIC 3

FAN MOTOR W/ INTEGRATED FILTER
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
DRAIN / RETURN
35
B A 22
25
P DR
23
Z
34 DRAIN/RETURN MANIFOLD

28
HYDRAULIC/HYDROSTATIC SCHEMATIC
31
29 MANUAL WITH NO OPTIONS
L
T650 (S/N ALJG11001 AND ABOVE)
30
(S/N B2KZ11001 AND ABOVE)
DRIVE MOTOR
(PRINTED MAY 2018)
108 of 1288 7170814 (G)

PRINTED IN U.S.A.

V-1472legend
LEGEND
1 RESERVOIR: CHARGE PUMP -
19 PULL BUTTON ACTIVATED 39 57 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle CONTROL VALVE - BUCKET POSITION
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 40 HYDRAULIC PUMP . . . . . . . Gear Type VALVE (ON/OFF)
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 58 FLOW DIVIDER ADJUSTMENT VALVE
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM 59 PILOTED ACTIVATED DIRECTIONAL CONTROL
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP VALVE - FLOW CONTROL SPOOL
42 RELIEF/REPLENISHING VALVE - HIGH 60 CHECK VALVE - BUCKET POSITION VALVE
43 RELIEF VALVE - CHARGE INLET: 61 PILOTED ACTIVATED DIRECTIONAL
SPRING LOADED FILTER BY-PASS 22 ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) CONTROL VALVE – UNLOADING SPOOL
5
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle 62 HIGH FLOW HYDRAULIC PUMP Gear Type
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid 28,4 L/min (7.5 U.S. gal) at High Engine Idle

(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER 63 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring 64 DUMP VALVE – ON / OFF
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
NOTE - If Equipped With Ref. 21: 25 65 CHECK VALVE - With 34,5 kPa (0,34 bar)
25855 kPa (258 bar) (3750 psi) (5.0 psi) Spring
26 46 PILOT ACTIVATED DIRECTIONAL
8 RELIEF/ANTICAVITATION VALVE - FILTER - HYDRAULIC (CANISTER) 66 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE – CONTROL VALVE - REAR AUXILIARY
POWERED BOB-TACH With Build-up
9 RELIEF/ANTICAVITATION VALVE - Fan Filter Valve: 207 kPa (2,07 bar) (30 psi) 67 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE 47 FILTER - BOB-TACH VALVE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in) 48 RESTRICTION - 2,08 mm (0.08 in) CONTROL VALVE - TWO COIL
10 SOLENOID ACTIVATED DIRECTIONAL 69 RESTRICTOR - 0,8 mm (0.031 in)
30 CHECK VALVE - With 1379 kPa 13,8 bar 49 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring CONTROL VALVE (TWO COIL)
11 LOAD CHECK VALVE 70 LOAD SHUTTLE VALVE - BLEED OFF
31 DRIVE MOTOR SHUTTLE VALVE 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
12 ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL 71 SOLENOID ACTIVATED DIRECTIONAL
51 CHECK VALVE - With 552 kPa)
CONTROL VALVE – 2 Speed Shift CONTROL VALVE - BASE
13 PILOTED ACTIVATED DIRECTIONAL (5,5 bar) (80 psi) Spring
33 FIXED CAPACITY DISPLACEMENT 52 72 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL RELIEF VALVE - 13790 kPa
BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE - ROD
14 PILOTED ACTIVATED DIRECTIONAL (137 bar) (2000 psi)
34 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - LIFT CONTROL 53 CHECK VALVE - With 2068 kPa (20,7 bar) 73 RIDE CONTROL VALVE
BIDIRECTIONAL HYDROSTATIC MOTOR
(300 psi) Spring And With
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – 74 HIGH PRESSURE CHAMBER
0,40 mm (0.016 in) Orifice
54 RESTRICTION - 0,51 mm (0.020 in) 75 LOW PRESSURE CHAMBER
(SCREEN) CONTROL VALVE – BRAKE 55 SHUTTLE VALVE
56 RESTRICTION - 0,51 mm (0.020 in)
38
109 of 1288
45
DRIVE MOTOR Male
L
45
31 30 29 Male
OUT
65
HYDRAULIC CONTROL VALVE
Female
X 9
RIDE CONTROL
(FIELD INSTALLED OPTION) NOTE: CUSHIONED
32 74
LIFT CYLINDERS ON
LATER MODELS ONLY
REAR AUXILIARY COUPLERS (OPTION) 9
33 34
FEMALE MALE 10
LIFT CYLINDERS
75
11
Z Aux Spool
A 35 B 70
6 73
72
71 21
HYDROSTATIC PUMP 68 11
8
E1 E2 A1 A2
69
8 E3
41 Tilt Spool
57
42 42 B
58
67 13
11 59
M4
M
2-SPEED & SAPR 66 60

BRAKE VALVE
(OPTIONAL) D C 14 D2
P in P out 12
38 T
B A
36
T 43 Lift Spool
37
Charge
Dealer Copy -- Not for Resale 61
C2
Inlet
8
BOBTACH VALVE C1 D1
(OPTIONAL)
P
20
B1 A1 B A 50 51 11 16 15
55 BUCKET POSITIONING
37 18 VALVE (OPTIONAL
IN 2
M M1 53 7 6 16
49 17
TILT CYLINDERS
42 42 19
1
44 52
41 56
D 48 54
T
4
40 47 46 1
39

62 63 64
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
35 DRAIN / RETURN
B A
Z 22
25
P
23
33 34 DR
X Printable Version Click Here

28 HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
T650 (S/N ALJG11001 - ALJG13367)
29
30 (S/N T1ML11001 AND ABOVE)
31
(S/N B2KZ11001 - B2KZ11017)
L
DRIVE MOTOR
(PRINTED MAY 2018)
110 of 1288
7170814 (G)
PRINTED IN U.S.A.
- ALJG19960)
- B2KZ12186)
(PRINTED JULY 2017)
V-1472legend
LEGEND
1 RESERVOIR: CHARGE PUMP -
19 PULL BUTTON ACTIVATED 39 57 SOLENOID ACTIVATED DIRECTIONAL
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM 59 PILOTED ACTIVATED DIRECTIONAL CONTROL
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP VALVE - FLOW CONTROL SPOOL
SPRING LOADED FILTER BY-PASS 22 ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) CONTROL VALVE – UNLOADING SPOOL
5
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle 62 HIGH FLOW HYDRAULIC PUMP Gear Type
23

24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring 64 DUMP VALVE – ON / OFF
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
NOTE - If Equipped With Ref. 21: 25 65 CHECK VALVE - With 34,5 kPa (0,34 bar)
25855 kPa (258 bar) (3750 psi) (5.0 psi) Spring
8 RELIEF/ANTICAVITATION VALVE - FILTER - HYDRAULIC (CANISTER) 66 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC
10 SOLENOID ACTIVATED DIRECTIONAL 69 RESTRICTOR - 0,8 mm (0.031 in)
30 CHECK VALVE - With 1379 kPa 13,8 bar 49 SOLENOID ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE 70 LOAD SHUTTLE VALVE - BLEED OFF
31 DRIVE MOTOR SHUTTLE VALVE 50 NOT USED FOR THIS MODEL
12 ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL 71 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – 2 Speed Shift 51 NOT USED FOR THIS MODEL CONTROL VALVE - BASE
33 52 NOT USED FOR THIS MODEL 72 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE - ROD
34 73 RIDE CONTROL VALVE
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 53 RELIEF VALVE - 24132 kPa
15 SOLENOID ACTIVATED DIRECTIONAL HYDRAULIC BRAKE – SPRING APPLIED – (241 bar) (3500 psi)
35 74 HIGH PRESSURE CHAMBER
54 RESTRICTION - 0,254 mm (0.010 in) 75 LOW PRESSURE CHAMBER
(SCREEN) CONTROL VALVE – BRAKE 55 CHECK VALVE
56 NOT USED FOR THIS MODEL
38
111 of 1288
45
DRIVE MOTOR Male
L
45
31 30 29 Male
OUT
65
Female
X 9
RIDE CONTROL
(FIELD INSTALLED OPTION) NOTE: CUSHIONED
32 74
LIFT CYLINDERS ON
LATER MODELS ONLY
33 34
FEMALE MALE 10
LIFT CYLINDERS
75
11
Z
A 35 B 70
6 73
72
71 21
8
E1 E2 A1 A2
69
8 E3
41 Tilt Spool
57
42 42 B
58
67 13
11 59
M4
M
2-SPEED & SAPR 66 60

BRAKE VALVE
P in P out
12
38 T
B A
36
T 43
37
Charge
POWER BOBTACH CYLINDER
(OPTIONAL)
Dealer Copy -- Not for Resale 61
C2
Inlet
POWER BOBTACH
8
VALVE (OPTIONAL) C1 D1
P
55 53 20
B1 A1 B A 11 16 15
BUCKET POSITIONING
37 18 VALVE (OPTIONAL
IN 2
M M1
49 7 6 16
54
17
TILT CYLINDERS
42 42 19
D 1
44 48
41
47
T
46 4
40 1
39

62 63 64
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
35 DRAIN / RETURN
B A
Z 22
25
P
23
33 34 DR

28
31
30 29
T650 (S/N ALJG13368 - ALJG19960)
L
(S/N B2KZ11018 - B2KZ12186)
DRIVE MOTOR
(PRINTED MAY 2018)
112 of 1288
7170814 (G)
PRINTED IN U.S.A.
(PRINTED JULY 2017)

V-1646legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED 39 CHARGE PUMP -
2
SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
RESTRICT FLOW DURING BOOM 59 PILOTED ACTIVATED DIRECTIONAL CONTROL
3 DIFFERENTIAL PRESSURE SWITCH:
DOWN BUT NOT DURING BOOM UP
BIDIRECTIONAL HYDROSTATIC PUMP
103 kPa (1,03 bar) (15 psi) VALVE - FLOW CONTROL SPOOL
22 ANTICAVITATION VALVE CONTROL VALVE – UNLOADING SPOOL
5 SPRING LOADED FILTER BY-PASS 334 +/- 344 kPa (30,3 +/- 3 bar)
VALVE: 172 kPa (1,7 bar) (25 psi)
23 PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle 62 HIGH FLOW HYDRAULIC PUMP Gear Type

BY-PASS With 345 kPa (3,45 bar)
24132 kPa (241 bar) (3500 psi) 24 SPRING LOADED FILTER BY-PASS VALVE:
(50 psi) Spring 64 DUMP VALVE – ON / OFF
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
25 FIXED CAPACITY DISPLACEMENT 45 FRONT AUXILIARY MANUAL PRESSURE
NOTE - If Equipped With Ref. 21:
BLEED-OFF VALVE 65 CHECK VALVE - With 34,5 kPa (0,34 bar)
25855 kPa (258 bar) (3750 psi) HYDRAULIC MOTOR (5.0 psi) Spring
8 RELIEF/ANTICAVITATION VALVE - FILTER - HYDRAULIC (CANISTER)
CONTROL VALVE – HYDRAULIC 66 PILOT ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 69
30 CHECK VALVE - With 1379 kPa 13,8 bar 49 SOLENOID ACTIVATED DIRECTIONAL RESTRICTOR - 0,8 mm (0.031 in)
11 70 LOAD SHUTTLE VALVE - BLEED OFF
LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option 71 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – 2 Speed Shift CONTROL VALVE - BASE
13 PILOTED ACTIVATED DIRECTIONAL 51 ACCUMULATOR – Ride Control Option
33 FIXED CAPACITY DISPLACEMENT 72 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR
14 PILOTED ACTIVATED DIRECTIONAL 52 ORIFICE With Check Valve: CONTROL VALVE - ROD
2,54 mm (0.10 in)
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 53 73 SOLENOID ACTIVATED DIRECTIONAL
RELIEF VALVE - 24132 kPa
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – (241 bar) (3500 psi) CONTROL VALVE – Reversing Fan Option
(SCREEN) CONTROL VALVE – BRAKE 55 CHECK VALVE
56 ORIFICE: 1,6 mm (0.063 in)
38
113 of 1288
45
DRIVE MOTOR Male
L
45
31 30 29 Male
OUT
65
Female
RIDE CONTROL (OPTION)

51
X 9
T2 ACC
T 52
32 NOTE: CUSHIONED
LATER MODELS ONLY
33 34
FEMALE MALE 10 P
LIFT CYLINDERS
11 50
Z
CR2 CR CB
A 35 B 70
6
72
71 21
8
E1 E2 A1 A2
69
8 E3
41 Tilt Spool
57
42 42 B
58
67 13
11 59
M4 M
2-SPEED & SAPR

66 60
BRAKE VALVE
12
38 P in P out T
B A
36
T 43
37 POWER BOBTACH CYLINDER
61
Charge
Inlet
POWER BOBTACH
(OPTIONAL)
8
Dealer Copy -- Not for Resale C2
VALVE (OPTIONAL) C1 D1
P
53 20
55
B1 A1 B A 11 16 15
BUCKET POSITIONING
37 18 VALVE (OPTIONAL)
IN 2
M M1 49 7 16
6
54
17
TILT CYLINDERS
42 42 19
D 1
44 48
41
47
T
46 4
40 1
39
VARIABLE SPEED 3
HYDRAULIC
FAN MOTOR W/
62 63 64 INTEGRATED
FILTER
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
1 4
35 DRAIN / RETURN
B A
3 2
Z 22
25
73 23
33 34 DR P
X
28
30 29 (S/N B2KZ12187 AND ABOVE)
31
L
(PRINTED MAY 2018)
DRIVE MOTOR
7170814 (K)
114 of 1288
PRINTED IN U.S.A.

V-1598legend
LEGEND
1 RESERVOIR: 39 CHARGE PUMP -
87,1 L/min (23.0 U.S. gpm) at High Engine Idle
42 RELIEF/REPLENISHING VALVE - HIGH
22 43 RELIEF VALVE - CHARGE INLET:
SPRING LOADED FILTER BY-PASS ANTICAVITATION VALVE 3413 +/- 172 kPa (34,1 +/- 1,7 bar)
5
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid

(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
NOTE - If Equipped With Ref. 21: 25 FIXED CAPACITY DISPLACEMENT 45 SERVO PISTON SWASH PLATE
25855 kPa (258 bar) (3750 psi) HYDRAULIC MOTOR SOLENOID ACTIVATED DIRECTIONAL
46
RELIEF/ANTICAVITATION VALVE - 26 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – Forward / Reverse
8
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE – 47 FILTER
9 RELIEF/ANTICAVITATION VALVE - Fan Filter FRONT AUXILIARY MANUAL PRESSURE
48
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE BLEED-OFF VALVE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in)
30 CHECK VALVE - With 1379 kPa 13,8 bar
(200 psi) Spring
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE 32 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 33 NOT USED FOR THIS MODEL
34
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED –
(SCREEN) CONTROL VALVE – BRAKE
38
115 of 1288
INTEGRATED COUPLER BLOCK
Male
DRIVE MOTOR
48
30 OUT
Male
L HYDRAULIC CONTROL VALVE

31 48
29 Female
34
9
10
Z
10
35
A B Auxiliary Spool
21
6
HYDROSTATIC PUMP BOBCAT INTERLOCK CONTROL SYSTEM
8 11 (BICS)
41 R TILT BASE
46 TILT ROD
X 47 Tilt Spool
8
45
42 13 TILT CYLINDERS
X
11
LIFT ROD
14
M 47 12
BRAKE VALVE - M
SPRING APPLIED A B LIFT BASE
36 M
37
43 42 Dealer Copy -- Not for Resale
Lift Spool
1
8
2 G
LIFT CYLINDERS
A B
3 M
NOTE: CUSHIONED
38 47 20
M LATER MODELS ONLY
11 15
37
IN
2 18
7 16
42 6
42
X 17
45
1
X 46 Oil Cooler
47 19
41 44
RESERVOIR
T 2 (VENTED)
5 1
R
40
39
VARIABLE SPEED HYDRAULIC 3 4

HYDRAULIC FILTER
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
22
DRAIN / RETURN
35
B A
25
P DR
23
Z
34
28
31
29 HYDRAULIC/HYDROSTATIC SCHEMATIC
L SJC WITH NO OPTIONS
30
DRIVE MOTOR (S/N B2KZ11001 AND ABOVE)
DRAIN / RETURN MANIFOLD
(PRINTED MAY 2018)

116 of 1288
7170815 (G)
PRINTED IN U.S.A.

V-1598legend
LEGEND
1 RESERVOIR: 39 CHARGE PUMP - 58 SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - LIFT 59 RESTRICTION - 0,51 mm (0.020 in)
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 60 SOLENOID ACTIVATED DIRECTIONAL
41 VARIABLE CAPACITY DISPLACEMENT CONTROL VALVE - BUCKET POSITION
3 BIDIRECTIONAL HYDROSTATIC PUMP VALVE (ON/OFF)
42 RELIEF/REPLENISHING VALVE - HIGH 61 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) (3500 psi) (If Equipped) 62 PILOTED ACTIVATED DIRECTIONAL CONTROL
22 43 RELIEF VALVE - CHARGE INLET: VALVE - FLOW CONTROL SPOOL
5 63 CHECK VALVE - BUCKET POSITION VALVE
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid 64 PILOTED ACTIVATED DIRECTIONAL
(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER CONTROL VALVE – UNLOADING SPOOL
7 RELIEF VALVE - MAIN: BY-PASS With 345 kPa (3,45 bar)
SPRING LOADED FILTER BY-PASS VALVE: 65 HIGH FLOW HYDRAULIC PUMP Gear Type
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 28,4 L/min (7.5 U.S. gal) at High Engine Idle
at Front Quick Couplers
NOTE - If Equipped With Ref. 21: 25 FIXED CAPACITY DISPLACEMENT 45 SERVO PISTON SWASH PLATE 66 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
46 67 DUMP VALVE – ON / OFF
8
PORT: 27579 kPa (276 bar) (4000 psi) 47 FILTER 68 CHECK VALVE - With 34,5 kPa (0,34 bar)
27 SENSOR – CHARGE PRESSURE –
Fan Filter (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 FRONT AUXILIARY MANUAL PRESSURE
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE BLEED-OFF VALVE 69 PILOT ACTIVATED DIRECTIONAL
(276 bar) (4000 psi) 49 CONTROL VALVE - REAR AUXILIARY
29 RESTRICTION - 1,5 mm (0.06 in) PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC 70 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
30 CHECK VALVE - With 1379 kPa 13,8 bar POWERED BOB-TACH With Build-up
CONTROL VALVE - AUXILIARY 71 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring Valve: 207 kPa (2,07 bar) (30 psi)
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO COIL
50 FILTER - BOB-TACH VALVE
12 72 RESTRICTOR - 0,8 mm (0.031 in)
ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – 2 Speed Shift 73 LOAD SHUTTLE VALVE - BLEED OFF
13 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
33 52
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE (TWO COIL) 74 SOLENOID ACTIVATED DIRECTIONAL
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) CONTROL VALVE - BASE
34
CHECK VALVE - With 552 kPa) 75 SOLENOID ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL HYDRAULIC BRAKE – SPRING APPLIED – 54
35 CONTROL VALVE - ROD
CONTROL VALVE - BICS CONTROL PRESSURE RELEASE (SAPR) (5,5 bar) (80 psi) Spring
55 RELIEF VALVE - 13790 kPa 76 RIDE CONTROL VALVE
(137 bar) (2000 psi)
(SCREEN) CONTROL VALVE – BRAKE 77 HIGH PRESSURE CHAMBER
56 CHECK VALVE - With 2068 kPa (20,7 bar)
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE (300 psi) Spring And With 78 LOW PRESSURE CHAMBER
(14.5 psi) Spring SOLENOID ACTIVATED DIRECTIONAL 0,40 mm (0.016 in) Orifice
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift 57 RESTRICTION - 0,51 mm (0.020 in) NOTE: Unless otherwise specified springs have
117 of 1288
DRIVE MOTOR Male
L
48
30 29
31 OUT
Male
HYDRAULIC CONTROL VALVE 68

48
Female
9
RIDE CONTROL
78 (FIELD INSTALLED OPTION) 77
32
33 9
34 NOTE: CUSHIONED
REAR QUICK LIFT CYLINDERS ON
FEMALE COUPLERS MALE 10 LATER MODELS ONLY
35 10 LIFT CYLINDERS
Z
Auxiliary Spool
A B 73
76
75
21
74
71 6
8 11 (BICS)
41 R TILT BASE
T
E1 E2 A1 A2
46 72
TILT ROD E3
X 47 Tilt Spool
8
B 61
45
42 13
2-SPEED & X
SAPR BRAKE 70
VALVE 11
(OPTIONAL) LIFT ROD 60 63
69 14 D2
38
B A M 47 REAR AUXILIARY P in P out T 12
36 M 62
A B
VALVE (OPTION)
T LIFT BASE
M
Lift Spool
43 42
8
Dealer Copy -- Not for Resale 64 C2
G
C1 D1
P A B
POWER BOBTACH
M VALVE (OPTIONAL) 16
B1 20
M
47
11 15
37 BUCKET POSITIONING
54 58 VALVE (OPTIONAL)
53 IN
2 18
56 7 16
42 6
42
X 17
55
45 TILT CYLINDERS
1
X 46 Oil Cooler
47 19
41 44 59
52 51 RESERVOIR
T D 57 2 (VENTED) 1
5
R
40
50
49
39

HYDRAULIC FILTER
65
66 67
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
22
35 DRAIN / RETURN
B A
25
Z P DR
23
33 34
32
X Printable Version Click Here

28
SJC WITH ALL OPTIONS
T650 (S/N ALJG11001 - ALJG13367)
30 29 (S/N T1ML11001 AND ABOVE)
31
L DRAIN / RETURN MANIFOLD
(S/N B2KZ11001 - B2KZ11017)
DRIVE MOTOR
(PRINTED MAY 2018)
118 of 1288 7170815 (G)

PRINTED IN U.S.A.
- ALJG19960)
- B2KZ12186)
(PRINTED JULY 2017)
V-1598legend
LEGEND
1 RESERVOIR: 39 CHARGE PUMP - 58 CHECK VALVE
DIRECTIONAL CONTROL VALVE - LIFT 59 NOT USED FOR THIS MODEL
3 BIDIRECTIONAL HYDROSTATIC PUMP VALVE (ON/OFF)
5 63 CHECK VALVE - BUCKET POSITION VALVE
23
7 RELIEF VALVE - MAIN: BY-PASS With 345 kPa (3,45 bar)
SPRING LOADED FILTER BY-PASS VALVE: 65 HIGH FLOW HYDRAULIC PUMP Gear Type
46 67 DUMP VALVE – ON / OFF
8
PORT: 27579 kPa (276 bar) (4000 psi) 47 FILTER 68 CHECK VALVE - With 34,5 kPa (0,34 bar)
27 SENSOR – CHARGE PRESSURE –
Fan Filter (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 FRONT AUXILIARY MANUAL PRESSURE
CONTROL VALVE – HYDRAULIC 70 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - AUXILIARY 71 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring Valve: 276 kPa (2,76 bar) (40 psi)
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO COIL
50 FILTER - BOB-TACH VALVE
12 72 RESTRICTOR - 0,8 mm (0.031 in)
13 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
33 52
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE (TWO COIL) 74 SOLENOID ACTIVATED DIRECTIONAL
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 53 NOT USED FOR THIS MODEL CONTROL VALVE - BASE
34
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 75 SOLENOID ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL HYDRAULIC BRAKE – SPRING APPLIED – 54 NOT USED FOR THIS MODEL
35 CONTROL VALVE - ROD
55 NOT USED FOR THIS MODEL 76 RIDE CONTROL VALVE
(SCREEN) CONTROL VALVE – BRAKE 77 HIGH PRESSURE CHAMBER
56 RELIEF VALVE - 24132 kPa
(241 bar) (3500 psi) 78 LOW PRESSURE CHAMBER
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift 57 RESTRICTION - 0,254 mm (0.010 in) NOTE: Unless otherwise specified springs have
119 of 1288
DRIVE MOTOR Male
L
48
30 29
31 OUT
Male

48
Female
9
RIDE CONTROL
78 (FIELD INSTALLED OPTION) 77
32
33 9
34 NOTE: CUSHIONED
REAR QUICK LIFT CYLINDERS ON
35 10 LIFT CYLINDERS
Z
Auxiliary Spool
A B 73
76
75
21
74
71 6
8 11 (BICS)
41 R TILT BASE
T
E1 E2 A1 A2
46 72
TILT ROD E3
X 47 Tilt Spool
8
B 61
45
42 13
2-SPEED & X
SAPR BRAKE 70
VALVE 11
69 14 D2
38
36 M 62
A B
VALVE (OPTION)
T LIFT BASE
M
43 42
Lift Spool
64 C2
(OPTIONAL) 8
G
C1 D1
P POWER BOBTACH
A B
VALVE (OPTIONAL)
M 16
B1 20
M
47 56
58 11 15 BUCKET POSITIONING
37 VALVE (OPTIONAL)
IN
2 18
7 16
42 6
42 52
X 57 17
45 TILT CYLINDERS
1
X 46 D Oil Cooler
47 19
41 44 51
50 RESERVOIR
T 2 (VENTED)
5 1
R
40 49
39

HYDRAULIC FILTER
65
66 67
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
22
35 DRAIN / RETURN
B A
25
Z P DR
23
33 34
32
X
28
30
T650 (S/N ALJG13368 - ALJG19960)
29
31 (S/N B2KZ11018 - B2KZ12186)
L DRAIN / RETURN MANIFOLD
DRIVE MOTOR
(PRINTED MAY 2018)
120 of 1288
7170815 (G)
PRINTED IN U.S.A.
(PRINTED JULY 2017)

V-1647legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED 39 CHARGE PUMP - 58 CHECK VALVE
DIRECTIONAL CONTROL VALVE - LIFT 59 ORIFICE: 1,6 mm (0.063 in)
RESTRICT FLOW DURING BOOM
3 DIFFERENTIAL PRESSURE SWITCH:
DOWN BUT NOT DURING BOOM UP
BIDIRECTIONAL HYDROSTATIC PUMP VALVE (ON/OFF)
103 kPa (1,03 bar) (15 psi)
ANTICAVITATION VALVE
5 SPRING LOADED FILTER BY-PASS 3413 +/- 172 kPa (34,1 +/- 1,7 bar)
63 CHECK VALVE - BUCKET POSITION VALVE
VALVE: 172 kPa (1,7 bar) (25 psi) (495 +/- 25 psi) at High Engine Idle
23 PROPORTIONAL RELIEF VALVE –
24 SPRING LOADED FILTER BY-PASS VALVE: BY-PASS With 345 kPa (3,45 bar) 65 HIGH FLOW HYDRAULIC PUMP Gear Type
24132 kPa (241 bar) (3500 psi) (50 psi) Spring
25855 kPa (258 bar) (3750 psi) HYDRAULIC MOTOR
46 SOLENOID ACTIVATED DIRECTIONAL 67 DUMP VALVE – ON / OFF
8
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE – 47 FILTER 68 CHECK VALVE - With 34,5 kPa (0,34 bar)
(5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - Fan Filter
48 FRONT AUXILIARY MANUAL PRESSURE
70 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
10 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HYDRAULIC
(200 psi) Spring 71 SOLENOID ACTIVATED DIRECTIONAL
Valve: 276 kPa (2,76 bar) (40 psi)
11 LOAD CHECK VALVE 31 CONTROL VALVE - TWO COIL
DRIVE MOTOR SHUTTLE VALVE 50 FILTER - BOB-TACH VALVE
12 72 RESTRICTOR - 0,8 mm (0.031 in)
13
PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 33
BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE (TWO COIL)
14 PILOTED ACTIVATED DIRECTIONAL 74 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 53 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
CONTROL VALVE – Ride Control Option 75
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – SOLENOID ACTIVATED DIRECTIONAL
PRESSURE RELEASE (SAPR) 54 ACCUMULATOR – Ride Control Option CONTROL VALVE - ROD
CONTROL VALVE - BICS CONTROL
16 FILTER - BICS CONTROL VALVE 36 SOLENOID ACTIVATED DIRECECTIONAL 55 ORIFICE With Check Valve: 76 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) CONTROL VALVE – BRAKE 2,54 mm (0.10 in) CONTROL VALVE - Fan Reversing Option
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE 56 RELIEF VALVE - 24132 kPa
(14.5 psi) Spring (241 bar) (3500 psi)
SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified springs have
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift 57 RESTRICTION - 0,254 mm (0.010 in) NO significant pressure value.

121 of 1288
DRIVE MOTOR Male
L
48
30 29
31 Male
OUT
48
Female
X RIDE CONTROL (OPTION)

54
9 T2 ACC
T 55
32 59
33 9
34 NOTE: CUSHIONED
REAR QUICK P
LIFT CYLINDERS ON
35 10 53 LIFT CYLINDERS
Z
Auxiliary Spool CR2 CR CB CB2
A B 73
75
21
74
71 6
8 11 (BICS)
R TILT BASE
41
T
E1 E2 A1 A2
TILT ROD E3
46 72
X 47 Tilt Spool
8
B 61
45
42 13
2-SPEED & X
SAPR BRAKE 70
VALVE 11
69 14 D2
38
36 M 62
A B
VALVE (OPTION)
T LIFT BASE
M
Lift Spool
43 42
(OPTIONAL)
Dealer Copy -- Not for Resale 64 C2
8
G
C1 D1
P POWER BOBTACH
A B
VALVE (OPTIONAL)
M 20 16
B1
M
47 56
58 11 15 BUCKET POSITIONING
37 VALVE (OPTIONAL)
IN
2 18
7 16
42 6
42 52
X 57 17
45 TILT CYLINDERS
1
X 46 D Oil Cooler
47 19
41 44 51
50 RESERVOIR
T 2 (VENTED)
5 1
R
40 49
39
VARIABLE SPEED 3 4
HYDRAULIC
HYDRAULIC FILTER
65 FAN MOTOR W/
66 67 INTEGRATED
26
FILTER
24
WORKING CIRCUIT
27
CHARGE
PRESSURE
1 4 22
35 DRAIN / RETURN
B A
3 2
25
76 23
Z DR P
33 34
32
X

28
(S/N B2KZ12187 AND ABOVE)
30 29 (PRINTED MAY 2018)

31
DRAIN / RETURN MANIFOLD
DRIVE MOTOR
L
7170815 (K)
122 of 1288
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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

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


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

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anti-cavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

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

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

(See Service Codes List on Page 60-90-2.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down when the pedal is in neutral position. 4, 9, 10, 11
Lift arm bypass control valve stuck. 12
Lift arm bypass control valve stem bent or broken. 13

KEY TO CORRECT CAUSE
1. The fluid level is not correct.

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


CYLINDER (LIFT) Figure 20-20-2
Testing
Figure 20-20-1
P-90617
1
Install a cap (Item 1) [Figure 20-20-2] on the hose and

P-90616 tighten.
Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.

Operate the controls that lower the lift arms.
WARNING If there is any leakage from the fitting on the cylinder

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

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

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

WARNING
Lift and block the loader. (See Procedure on Page 10-10-
1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
1
IMPORTANT

When repairing hydrostatic and hydraulic systems,
2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-90824
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

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

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

Removal And Installation (Cont’d)

DANGER
Figure 20-20-5
1 P-90328
AVOID DEATH
2 tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
P-90602A
unless supported by an approved lift arm
D-1009-0409
Remove the retaining nut and bolt (Item 1) [Figure 20-
20-5] from the pin (Item 2) on the rod end of the cylinder.

Installation: Tighten the retainer nut and bolt to 48 - 54
N•m (35 - 40 ft-lb) torque. WARNING
Figure 20-20-6
W-2059-0598
1
P-90611
With a slide hammer, remove the pin (Item 1) [Figure 20-

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

CYLINDER (LIFT) (CONT’D) Open the rear door.
Removal And Installation (Cont’d) NOTE: When removing the left side lift cylinder the
battery will need to be removed to gain access
Figure 20-20-7 to the lower retaining nut and bolt.
Remove the battery (If required). (See Removal And

Figure 20-20-9
1
1
P-90605
1
Install a sling in the middle of the Bob-Tach as shown in
(Item 1) [Figure 20-20-7].

P-90834
Using a chain hoist raise the lift arms and install an
approved lift arm support device on the cylinder that is
connected to the lift arm. Remove the retaining nut and bolt (Item 1) [Figure 20-
20-9] from the pin on the base end of the lift cylinder.
Figure 20-20-8
N•m (35 - 40 ft-lb) torque.
2 Figure 20-20-10
1
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder

and install a strap (Item 2) [Figure 20-20-8] to secure the P-90825
cylinder.
Remove the grease fitting (Item 1) [Figure 20-20-10]
from the base end of the lift cylinder.
Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.

Figure 20-20-11
P-90827

20-11] from the base end of the lift cylinder.

Figure 20-20-12
P-90823
Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.

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

7
2 8
9
1
7
11
12
13
7
10
14
15
NA1413S

CYLINDER (LIFT) (CONT’D) Figure 20-20-15
Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

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

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

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

Figure 20-20-16
P-48033
Use a spanner wrench to loosen the head (Item 1)

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

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

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

the cylinder head.

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

cylinder head.

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

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
P-48038
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
installation. 20-20] on the cylinder piston.
Figure 20-20-19 Figure 20-20-21

1
P7424 P-48043 P7427
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-20-21].
fits the piston [Figure 20-20-19].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-20-21] must be installed
on the piston. toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-21].

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

P7425 20-20-24] on the cylinder head.
Figure 20-20-25
Install the rod seal in the head [Figure 20-20-22].

Figure 20-20-23
1
2
3
2 4
P-48036
P-48041 P-48042 NOTE: Clean and dry the rod threads. Install a NEW
NUT with preapplied Loctite® included in the
seal kit or if a new nut is not available use
Install the wiper seal, with the wiper side of the seal (Item Loctite® #242 on threads.
1) toward the outside of the head (Item 2) [Figure 20-20-
23]. Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-25].
Tighten the nut (Item 4) [Figure 20-20-25] to 1491 N•m

(1100 ft-lb) torque.

Assembly (Cont'd)
Figure 20-20-26
P-48035
Put the base end of the hydraulic cylinder in a vise.

Using a spanner wrench, tighten the head (Item 1)
[Figure 20-20-26] to 373 N•m (275 ft-lb) torque.


CYLINDER (TILT) Figure 20-21-2
Testing
Figure 20-21-1
2
1 1
P106670
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

P-85553 hose and tighten.
Remove the attachment. Roll the Bob-Tach fully back. engine and press the PTOL button.
Stop the engine. Raise the seat bar.

Operate the controls that rolls the Bob-Tach back.
If there is any leakage from the fitting on the cylinder

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

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

goes to the base end of the cylinder.

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

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

Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Figure 20-21-6

Remove the retainer nut and bolt (Item 1) [Figure 20-21-

3] from the rod end pivot pin.
1
Figure 20-21-4
P-85648
Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.
Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].
Installation: Tighten the retainer nut and bolt to 258 N•m

P-85649 (190 ft-lb) torque.
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

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

CYLINDER (TILT) (CONT’D) Figure 20-21-10
Base End Pivot Pin Removal And Installation
Figure 20-21-8
P-85567
1
Inspect pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9

1
P-85566
Remove the cylinder from the cylinder base pin (Item 1)

[Figure 20-21-8]. (See Removal And Installation on Page
20-21-2.)
Use a 22 mm (.875) shaft (Item 1) [Figure 20-21-9] and a

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

CYLINDER (TILT) (CONT’D)
Parts Identification (Earlier Models)
1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston
10. Head 5
6
11. Wiper
12. Rod
13. Bushing
2
4
3

8
1
4 9
3
8
4
10
8
11
12
13
NA2481S

CYLINDER (TILT) (CONT'D)
Parts Identification (Later Models)
1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston 5
10. Collar 6
11. Head
12. Wiper
13. Rod
14. Bushing 4 2
3

8
1
9
4
3 10
8
4
11
12
13
14
NA8189S

CYLINDER (TILT) (CONT'D) Figure 20-21-13
Earlier
Disassembly Models
3
Use the following tools to disassemble the cylinder: 2
MEL1074 - O-ring Seal Hook

1
MEL1075 - Adjustable Gland Nut Wrench
Figure 20-21-11
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].
1
2 Figure 20-21-14
Later
2 Models

4
P-85651B
1
Remove the bushing (Item 1) [Figure 20-21-11] with a 3
driver tool and hammer.
An identifying mark (Item 2) [Figure 20-21-11] on the rod

end indicates a later model cylinder. P109554
Figure 20-21-12
Remove the nut (Item 1), piston (Item 2), collar (Item 3)
and head (Item 4) [Figure 20-21-14].
P106021
Use an Adjustable Gland Nut Wrench to loosen the head

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

1
Figure 20-21-15
Earlier
Models
2
1
P109556
Remove the O-ring (Item 1) and the seal (Item 2) [Figure

20-21-17] from the cylinder head.
P-48073B
Figure 20-21-18
Figure 20-21-16
Later

Models
1
1
P-48040
P109555
Remove the wiper seal (Item 1) [Figure 20-21-18] from
the cylinder head.
Remove the seal (Item 1) [Figure 20-21-15] and [Figure
20-21-16] from the piston.

CYLINDER (TILT) (CONT'D)
Figure 20-21-19
P-48042
Remove the rod seal (Item 1) [Figure 20-21-19] from the

cylinder head.

Assembly Earlier
Models
Use the following tools to assemble the cylinder:
1
MEL1396-1 - Universal Seal Expander
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench

P-48073B
Figure 20-21-22
Lubricate all O-rings and seals with hydraulic fluid during
installation. Later
Models
Figure 20-21-20
1

P109555
Install the seal (Item 1) [Figure 20-21-21] and [Figure

P7424 20-21-22] on the cylinder piston.
Figure 20-21-23
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it

on the piston.
N-22358
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-21-23].

Assembly (Cont'd)
Figure 20-21-24 2
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
26].
Install the rod seal on the rod seal tool [Figure 20-21-24]. Figure 20-21-27

(Item 1) [Figure 20-21-24] must be installed 1
2
toward the inside of the cylinder.

21-24].
Figure 20-21-25
P109556
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-27] on the cylinder head.
P7425
Install the rod seal in the head [Figure 20-21-25].

CYLINDER (TILT) (CONT'D) NOTE: Clean and dry the rod threads. Install a NEW
Assembly (Cont'd) seal kit or if a new nut is not available use
Loctite® #242 on threads.
Figure 20-21-28
Tighten the nut (Item 4) [Figure 20-21-29] to 1491 N•m
Earlier
Models (1100 ft-lb) torque.
1
2 Put the base end of the hydraulic cylinder in a vise.
Figure 20-21-30
3
P-48071
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-28].

NOTE: Clean and dry the rod threads. Install a NEW P106021
seal kit or if a new nut is not available use
Loctite® #242 on threads. Using an Adjustable Gland Nut Wrench, lightly lubricate
with grease and tighten the head (Item 1) [Figure 20-21-
Tighten the nut (Item 3) [Figure 20-21-28] to 1152 N•m 30] to 373 N•m (275 ft-lb) torque.
(850 ft-lb) torque.
Figure 20-21-31
Figure 20-21-29
Later
3 Models
1
4
2
P-85651B
P109554
Install the bushing (Item 1) [Figure 20-21-31] using a

NOTE: Lube chamfer on shaft with oil or grease driver tool and hammer.
before installing the collar.
Install the head (Item 1), collar (Item 2), piston (Item 3)
and nut (Item 4) [Figure 20-21-29].

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

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

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

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

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

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

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

CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].

Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -
24 ft-lb) torque.
Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-85569
Remove the bolts and washers (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

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

1. Tube
2. Nut
3. Piston
4. O-ring
5. Seal
6. Spacer
7. Back-up ring
8. Head
9. Wiper 1
10. Rod
2
3

4
5
6
5
4
8
5
9
4
7
10
PE3954S

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

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

MEL1074 - O-ring Seal Hook
Spanner Wrench 4
2
1
Use a spanner wrench to loosen the head [Figure 20-22-

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

[Figure 20-22-9] are no longer available parts.
The seal kit will contain a one piece seal that
is used in place of the O-ring and back-up
ring.
P16294
Remove the head and rod assembly from the cylinder

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

Assembly
3 1
2
Use the following tools to assembly the cylinder:
MEL1396 - Seal Installation Tool

Piston Ring Compressor
Spanner Wrench

4
P16295
Lubricate all O-rings and seals with hydraulic fluid during Piston: Install the O-ring (Item 1) and seal (Item 2) on the
installation. piston (Item 3) [Figure 20-22-11].
Figure 20-22-10 NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
toward the rod.

Figure 20-22-12
P7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

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

must be toward the inside of the cylinder.

Assembly (Cont’d)
2
Figure 20-22-13 1
P106031
Install the O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the seal (Item 2) [Figure 20-22-15] into the groove
on the head.
22-13]. Figure 20-22-16

Figure 20-22-14 3
2 4
1
P16294
P7425
NOTE: Clean and dry the rod threads. Install a NEW
Install the rod seal in the head [Figure 20-22-14]. seal kit or if a new nut is not available use
Loctite® #242 on threads.
Install the wiper seal with the wiper toward the outside of
the head. Install the head (Item 1), and spacer (Item 2) [Figure 20-
22-16].
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 190 N•m (140 ft-lb) torque.

Assembly (Cont'd)
Figure 20-22-17
P-85647
Put the base end of the hydraulic cylinder in a vise.

Tighten the head using a spanner wrench [Figure 20-22-
17] to 183 N•m (135 ft-lb) torque.


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

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

P107749A
The relief valves are adjustable and located on the

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

MAIN RELIEF VALVES (CONT’D)
Testing
WARNING
WARNING Hydraulic fluid escaping under pressure can have
When the engine is running during service, the and possible death if proper medical treatment by a
driving and steering controls must be in neutral and physician familiar with this injury is not received
the parking brake engaged. Failure to do so can immediately.
cause injury or death. W-2145-0290
W-2006-1209
Figure 20-30-3
The tools listed will be needed to do the following
procedure:
1
MEL1355-3 - Pressure gauge 34,5 MPa (345 bar) (5000
psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased
locally. Must be rated for pressures above 34,5 MPa (345

bar) (5000 psi). 3
3
Figure 20-30-2 2
P-43196D
1 3
Assemble the gauge (Item 1), hose (Item 2) and the
correct test coupler (Item 3) [Figure 20-30-3]. Tighten all
fittings.
Raise the operator cab. (See Raising on Page 10-30-2.)

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

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

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

[Figure 20-30-4].

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

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

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

245 bar) (3450 - 3550 psi). Press the auxiliary hydraulics button (Item 1) [Figure 20-

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

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

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

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

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

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

P107744 ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
Loosen the locknut (Item 1) [Figure 20-30-7].
Figure 20-30-8

Turn the adjustment screw (Item 2) [Figure 20-30-7] in or
out until the pressure is correct. Turning the screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

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

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

P107747
[Figure 20-30-9] from the relief valve.

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

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

Install new O-rings (Item 1) and back-up ring (Item 2)
Figure 20-30-11 [Figure 20-30-12]. Install the relief valve and tighten.
Installation: Tighten the relief valve to 51 - 62 N•m (38 -

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

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

11].

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

frame on the right hand side, below the operator’s cab.

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

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

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

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

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

DANGER Installation on Page 50-100-7.)
NOTE: Mark all tubelines, hoses, and electrical

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

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

P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2

support. Replace if damaged. 3
D-1009-0409
2
WARNING
1
support device. Failure to use an approved lift arm P114648
W-2059-0598 Disconnect the harness (Item 1) [Figure 20-40-2] from
the bottom of the filter.
Remove the two bolts (Item 2) and reposition the fuel

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

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

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(CONT’D)
Figure 20-40-3
1
1
P114647
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
P114644 to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
Remove the fuel tank vent hose (Item 1) [Figure 20-40-3] only be removed by first removing it from the fitting (Item
from the filler neck. 1) [Figure 20-40-5].

3 1
1
2
2
P114645 P-90269
Remove the nut / bolt (Item 1), reposition clamp (Item 2) Disconnect the wire harness connectors (Item 1) [Figure
and remove the two nuts / bolts (Item 3) [Figure 20-40- 20-40-6] from the control valve.
4]. Remove the filler neck.
Disconnect the hose (Item 2) [Figure 20-40-6] that
routes from the control valve to the drain manifold.

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

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

that route from the control valve to the front auxiliary
hydraulics.

routes from the control valve to the brake valve. Figure 20-40-10

routes from the control valve to the fan motor.
Figure 20-40-8
1
1
P-90273
P-90271

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

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

routes from the bottom of the control valve to the outlet
P-90274 fitting of the hydraulic pump.
Figure 20-40-14
Disconnect the three tubelines (Item 1) [Figure 20-40-

11] that route from the control valve to the junction block
at the rear of the loader.
Figure 20-40-12
1
1
2
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-40-14].
P-90275
Remove the control valve from the loader.

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

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

(CONT’D)
Mount Bracket Removal And Installation
Figure 20-40-15
P-90280
Support the mount bracket (Item 1) [Figure 20-40-15].

Figure 20-40-16
P-90279
Remove the two control valve mount bolts (Item 1)

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

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

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

F1 H1 J1 J3
C1
NA5826

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

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

tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.

Figure 20-40-20
1
1
P107872
2
Remove the charge tubeline (Item 1) [Figure 20-40-18]
from the BICS™ valve fitting on the top of the lift load
check valve. 3
4
P107716
Remove the O-rings (Item 1) and back-up ring (Item 2)

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

load check valve (Item 4) [Figure 20-40-20].
Inspect the orifice (Item 5) [Figure 20-40-20] to make

sure it is not plugged.

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

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

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

poppet to make sure it is not plugged.

At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-40-
the tilt section load check valve (Item 1) [Figure 20-40- 22] and lubricate with oil before installing. Tighten the
21]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

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

interchangeable.

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

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

and the port relief / anti-cavitation seat (Item 1) [Figure
20-40-25].

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

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

Installation (Tilt, Base End)
Figure 20-40-27
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-29]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)

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

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

to 47 N•m (35 ft-lb) torque.

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

auxiliary port relief valve (Item 1) [Figure 20-40-33].
P107628
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-31] Figure 20-40-34

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

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

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

P107628

Figure 20-40-36
1
1
2
P107629


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

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

Figure 20-40-40
1
P107633

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

plug.

HYDRAULIC CONTROL VALVE (STANDARD) End Cap Block Removal And Installation
(CONT’D)
Figure 20-40-45
Rubber Boot Removal And Installation
Figure 20-40-43
1
2
1
1
P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-45] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-40-43] on

the rubber boot retainer plate. Figure 20-40-46
Installation: Lubricate the screws and tighten to 10,4 -

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

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

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

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

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

20-40-47].

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

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

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

20-40-49] from the lift spool.

(CONT’D)
Lift Spool And Detent Removal And Installation

(Cont’d)
Figure 20-40-50
P107846
NOTE: Do not remove the sleeve detent (Item 1) or

1 retaining ring (Item 2) [Figure 20-40-52] from
the spool centering block. If removed, the
P107779 sleeve detent must be inserted with the
original orientation.

Remove the four screws (Item 1) [Figure 20-40-50] from Figure 20-40-53
the spool centering block.
Figure 20-40-51
2
2
P107845A
1
P107778 NOTE: If removed, use the following for correct

installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-40-53]
Remove the spool centering block (Item 1) [Figure 20- so it faces the opening of the spool centering
40-51]. block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
Remove the O-ring (Item 2) [Figure 20-40-51]. [Figure 20-40-53] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

(CONT’D)

(Cont’d)
Figure 20-40-54
P107739
2
Clamp the linkage end of the spool in a vise [Figure 20-
40-56].
1
P107790 NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly (Item 1) and O-ring (Item
2) [Figure 20-40-54] from the control valve.
Figure 20-40-55
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-57
2
1
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-40-55]

from the linkage end of the valve.
P107674A
Install the spring tool (Item 1) [Figure 20-40-57] over the

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

(Item 2) [Figure 20-40-57] from the centering
spring, as it is under spring pressure.

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

(Cont'd)
Figure 20-40-58
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly

2 (Item 2) [Figure 20-40-60].
P107674 Figure 20-40-61

Remove the spring assembly / spring tool (Item 1) from
the spool (Item 2) [Figure 20-40-58]. 2
3 1
NOTE: The detent adapter has two detent balls (Item 4
3) held under pressure from a detent spring
(Item 4) [Figure 20-40-60]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-40-59
P107677
1 Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-61].
P107675
Remove the detent adapter (Item 1) [Figure 20-40-59]

from the spring assembly.

(CONT’D)

(Cont'd)
Figure 20-40-62
1
N-18967
Clamp the collar (Item 1) [Figure 20-40-64] in a vise.
Figure 20-40-65
N-18918

Remove the stud from the end of the spool [Figure 20-
40-62]. 3
Figure 20-40-63 2
P107677
Apply grease on all the detent component surfaces

0.60 inch before assembly [Figure 20-40-65].
(15,2 mm)
Install the spring (Item 1) and detent balls (Item 2) into
B-14712B the adapter (Item 3) [Figure 20-40-65] and compress
with the detent pliers (Item 1) [Figure 20-40-66].
Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-63].

(CONT’D)

(Cont'd)
Figure 20-40-66
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-40-68].
N-18968A Remove the spring tool.
Inspect the alignment of the detent adapter and the

Install the detent adapter to the collar [Figure 20-40-66]. washer.
NOTE: The collar and the detent adapter are held Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the NOTE: The adapter must fit in the center of the
detent adapter and collar together to prevent washer.
the detent balls and spring from falling out.
Figure 20-40-69
Figure 20-40-67
2
P107790
P107675
Lubricate and install a new O-ring (Item 1) [Figure 20-40-

Install the spring tool (Item 1) [Figure 20-40-67] over the 69].
washer, spring, collar, and detent adapter.
Lubricate and install a new O-ring (Item 2) [Figure 20-40-
69].
Install the lift spool assembly (Item 3) [Figure 20-40-69]

in the spool bore.

(CONT’D)

(Cont'd)
Figure 20-40-70
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

2 20-40-72] on the lift spool.
P107779 Figure 20-40-73

Install the spool centering block (Item 1) [Figure 20-40-
70].
Install the four mounting screws (Item 2) [Figure 20-40-

70].
1
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-71
P107776
1
Install an O-ring (Item 1) [Figure 20-40-73] on the control

valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-40-71] on the

linkage end of the valve.

(CONT’D)

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

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

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-75
P107666
Connect the tubeline (Item 1) [Figure 20-40-75].

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

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

2
79] and lubricate the O-ring lightly with grease or oil
P107777 before installation of the spool centering block.

Figure 20-40-80
20-40-77] from the tilt spool.
Installation: Install the spacer (Item 1) and an O-ring

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

20-40-80].
1
P107779 80] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Remove the four screws (Item 1) [Figure 20-40-78] from


11,6 N•m (95 - 105 in-lb) torque.

(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-81
1
P107647
Remove the bolt (Item 1) [Figure 20-40-83] holding the

centering spring to the spool.
P107781
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-40-81].

Remove the spring tool from the spring assembly.
Assembly: Always use a new spool seal.
Figure 20-40-84
Figure 20-40-82
2 1
3
1 4
N-18944B
P107646
Inspect the adapter (Item 1), collar (Item 2), spring (Item
Put the linkage end of the spool in the vise [Figure 20- 3), and washer (Item 4) [Figure 20-40-84].
40-82].
NOTE: Protect spool before clamping in vise.

centering spring.

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

3 (Item 2) [Figure 20-40-86] from the auxiliary spool.
P107782
20-40-86] from the auxiliary spool.
(Item 2) [Figure 20-40-85] from the auxiliary spool.

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

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

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

[Figure 20-40-89] from the solenoid stem.
P107876
Use an ohmmeter to measure the solenoid coil
resistance.
Remove the screws (Item 1) [Figure 20-40-88] from both

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

in-lb) torque.

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

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-90] from the Figure 20-40-93

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

2
Figure 20-40-91
N-18694

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

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

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

20-40-96] is threaded for easier removal and installation.
P107785
Figure 20-40-97
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-40-

94]. 1 3
2
Figure 20-40-95
P107767
Remove the O-ring (Item 1) [Figure 20-40-97].
Remove and inspect the spring (Item 2) and BICS™

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

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

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

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

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

Remove the tilt spool lock solenoid (Item 2) [Figure 20- 1 3
40-98].
2
Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-99
P107767

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

from the front of the control valve.


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

104].
Remove the fitting (Item 1) [Figure 20-40-102] from the Figure 20-40-105

valve.
Figure 20-40-103
1 2
1
P107745A
P-51437 Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-40-105] from the main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
103].
NOTE: This orifice is not removable from the valve

casting.

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

40-106] is an optional item and may not be
installed.
Figure 20-40-106
P107693
Remove the tubeline (Item 1) [Figure 20-40-108].
Figure 20-40-109

P107870

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

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


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

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

lb) torque.


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

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

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

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)

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

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

on Page 50-100-2.) P114644
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. Remove the fuel tank vent hose (Item 1) [Figure 20-41-3]
from the filler neck.
NOTE: Cap and plug all hydraulic connection points
when tubelines or hoses are removed. Figure 20-41-4
Clean area around control valve.

Open rear door.
3
Figure 20-41-2
3 2
P114645
2
Move the hose clamp (Item 1) to the middle of the hose

1
(Item 2) [Figure 20-41-4] and place the fuel inlet
assembly off to the side.
P114648
Disconnect the harness (Item 1) [Figure 20-41-2] from

the bottom of the filter.
Remove the two bolts (Item 2) and reposition the fuel

filter assembly (Item 3) [Figure 20-41-2].

(CONT’D)
Figure 20-41-5 2
1 1
P107219

routes from the control valve to the brake valve.
P114647
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed

Figure 20-41-8
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-41-5].
Figure 20-41-6 1
P-90271
2

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

20-41-6] from the control valve.

routes from the control valve to the drain manifold.

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

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

11] that route from the control valve to the junction block
P-90272 at the rear of the loader.
Figure 20-41-12

Disconnect the two tubelines (Item 2) [Figure 20-41-9]
that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-41-10
P-90275

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

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

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

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

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

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

Figure 20-41-17
Figure 20-41-15
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-41-17] away from

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

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

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out Of Loader)
(CONT’D)
Actuator Removal And Installation (In Loader)
(Cont’d) Figure 20-41-19
Figure 20-41-18 1
1
2
1
P107802
P-54568
Remove the two mount bolts (Item 1) [Figure 20-41-19]
from the tilt actuator.

Remove the O-ring (Item 1) [Figure 20-41-18] on the
face of the actuator. Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Inspect the linkage pin (Item 2) [Figure 20-41-18] and
replace as needed. Figure 20-41-20
NOTE: Repeat this procedure to remove the lift

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

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

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

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

N•m (90 - 100 in-lb) torque.

Using a punch and a hammer, remove the actuator Figure 20-41-24
linkage pin (Item 1) [Figure 20-41-21] from the actuator
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-22
1
1
P107805
2 Slide the actuator mount bracket (Item 1) [Figure 20-41-

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

face of the actuator.

replace as needed.

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

Using a punch and a hammer, remove the actuator Installation: Tighten the mounting bolts to 10,2 - 11,3
linkage pin (Item 1) [Figure 20-41-25] from the actuator N•m (90 - 100 in-lb) torque.
and the tilt spool.
Remove the actuator and linkage pin from the valve.
Figure 20-41-26
P-54340

face of the actuator.

replace as needed.

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

H1
J3
J1
NA5825

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

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

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

Figure 20-41-30 1
P107848
2
Remove the charge tubeline (Item 1) [Figure 20-41-31]

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

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

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

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

(Cont’d)
Figure 20-41-32
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
34].

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

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

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

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-38].

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

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

Installation (Tilt, Base End)
Figure 20-41-40
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-42]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)

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

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


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

P107628

Figure 20-41-45
1
1
2
P107629


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

P107628

Figure 20-41-49
1
1
2
P107629


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

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

Figure 20-41-53
1
P107633

plug.
P107633

plug.

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

P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-56] from Remove the O-ring (Item 1) [Figure 20-41-58].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-41-56].
Figure 20-41-59
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-57
1
P107753
1
P107852 20-41-59] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-57]

from the control valve.

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

1 2) [Figure 20-41-62] from the control valve.
P107854
Figure 20-41-63
Remove the four screws (Item 1) [Figure 20-41-60] from


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

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

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

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

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

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-

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

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

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

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

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

with oil before installation of the spool centering block.

(CONT’D)
Tilt Spool Disassembly And Assembly

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

41-72].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-41-73
P107647


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

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

1 (Item 2) [Figure 20-41-77] from the auxiliary spool.
P107758
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.
(Item 2) [Figure 20-41-75] from the auxiliary spool.

Figure 20-41-78
retainer on the opposite end also.
Figure 20-41-76
1
2
P107761
1
P107759


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

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-41-79]. Remove the solenoids (Item 2) [Figure 20-41-80].

Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -
23.9 in-lb) torque.
Figure 20-41-81
P107798

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

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

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

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

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-82] from the Figure 20-41-85

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

2
Figure 20-41-83
N-18694

[Figure 20-41-85] from the stem.
Clean all parts in solvent and dry with compressed air.

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

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

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

86]. 1 3
Figure 20-41-87 2
1
P107767

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

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


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

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

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

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

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

valve.
Figure 20-41-94
2
1 1
P107745A
Remove the O-rings (Item 1) [Figure 20-41-96] from the

P-51437 main relief valve.

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

casting.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Check Valve Removal And Installation
(CONT’D)
Figure 20-41-99
Figure 20-41-97
1 1
P107848
P107863 Remove the tubeline (Item 1) [Figure 20-41-99].
Figure 20-41-100

97].
Figure 20-41-98
2 1
P107864
1
Remove the check valve fitting (Item 1) [Figure 20-41-
P107627 100] from the hydraulic control valve.


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

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

lb) torque.

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

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

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90° clockwise. Then pull up and hold the lift arm
bypass control knob until the lift arms slowly lower. The
valve releases the hydraulic fluid from the base end of the
lift cylinder(s) which allows the lift arm to slowly come
down to the transport position.
Figure 20-50-1

P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob should return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure

20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
W-2059-0598
Lower the lift arms.
Raise the operator cab. (See Raising on Page 10-30-2.) 1
P-85671
Disconnect and cap the hydraulic tubeline and hose (Item

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

20-50-3].
Installation: Tighten the mounting nuts and bolts to 21 -

23 N•m (180 - 200 in-lb) torque.
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Reverse the removal procedure to install the lift arm lb) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.


HYDRAULIC PUMP This procedure will require one operator in the cab and
one operator running the tester.
Description
Start the engine and run at low idle rpm. Press the
The hydraulic pump is attached to the end of the Auxiliary hydraulics button. Engage the front auxiliary
hydrostatic pumps and is located on the right side of the with the trigger on the right handle or joystick. Make sure
loader between the hydraulic control valve and the the tester is connected correctly. If no flow is indicated on
engine. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic pump is a combination of gear pumps that full rpm*.
provide hydraulic flow to several hydraulic systems.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump has a dedicated charge pump. This control clockwise on the tester so it reads about 6895
supplies flow to the hydraulic fan motor and charge kPa (69 bar) (1000 psi).
pressure to the hydrostatic pump.
NOTE: DO NOT EXCEED 25511 kPa (255 bar) (3700
A seal kit is available to service the hydraulic pump. If any psi).
of the main components of the pump are damaged, the
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
Pump Test At Quick Couplers should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
The tools listed will be needed to do the following restriction on the flow. The gpm should drop off slightly
procedure: until the pressure reaches approximately 21374 kPa (214

bar) (3100 psi). At approximately 21374 kPa (214 bar)
MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter (3100 psi) the flow should start decreasing rapidly until
MEL10006 - Fitting Kit the pressure reaches 23787 - 24132 kPa (238 - 241 bar)
(3450 - 3500 psi). At 23787 - 24132 kPa (238 - 241 bar)
Figure 20-60-1 (3450 - 3500 psi) the flow should be at zero U.S. gpm.
Turn the restrictor (Item 2) [Figure 20-60-1]
1 counterclockwise to free flow. Shut the auxiliary
hydraulics off.
If flow and pressure specifications are not obtained, go to

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

for system relief pressure and full rpm.
2 P-90171
NOTE: When testing the hydraulic flow of a machine,

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

the front auxiliary quick couplers.

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

procedure:
MEL1563 - Remote Start Tool Kit 2

MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter
MEL10006 - Fitting Kit
1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

support device. (See Installing on Page 10-20-2.)
WARNING
1 2
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

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

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

control on the tester to about 6895 kPa (69 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the Remote Start Tool engage the auxiliary

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

%=

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


Earlier Models
Direct Pump Test (Charge Section)

procedure:
1
MEL1563 or 7217666 - Remote Start Tool Kit
WARNING
P114639

of the frame before running the engine for service. Figure 20-60-5
fall or move and cause injury or death. Later Models
W-2017-0286
1

1.)

WARNING
P115656
support device. Failure to use an approved lift arm Disconnect the inlet hose (Item 1) [Figure 20-60-4] or
support device can allow the lift arms or attachment [Figure 20-60-5].
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.
Connect the Remote Start Tool. (See REMOTE START

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

HYDRAULIC PUMP (CONT’D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-60-6 rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

1 2 approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
P-90580

Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-4] *Refer to the Hydraulic Schematics for pump flow and

of the pump. Connect the OUTLET hose (Item 2) [Figure rpm.
20-60-6] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-60-4].
IMPORTANT
I-2024-0284

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

WARNING
Figure 20-60-7
W-2059-0598 1
1
1
DANGER 1
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-7] from the hydraulic pump.
P-90328 Remove the Power Bob-Tach block (if equipped). (See

AVOID DEATH
• Keep out of this area when lift arms are raised 2
D-1009-0409
2
IMPORTANT 1
When repairing hydrostatic and hydraulic systems, 3

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

Page 10-10-1.)


NOTE: The engine / Hydro is shown removed for

photo clarity.
Figure 20-60-9
P-43940 P-43938A
1
Replace the O-ring (Item 1) [Figure 20-60-11] on the
hydraulic pump.
Reverse the removal procedure to install the hydraulic

P106593 pump.

Remove the bracket mounting nut / bolt (Item 1) [Figure
20-60-9].
Installation: Tighten the nut / bolt to 34 - 38 N•m (25 - 28

ft-lb) torque.
Figure 20-60-10
P106594
Remove the two mounting bolts (Item 2) [Figure 20-60-9]

and [Figure 20-60-10].
Installation: Clean threads and apply Loctite® #242 to

the mounting bolts and tighten to 75 - 85 N•m (55 - 60 ft-
lb) torque.
Remove the hydraulic pump.

HYDRAULIC PUMP (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-12 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

1 down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.

P100685
Figure 20-60-13
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-12] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-13].

HYDRAULIC PUMP CONT’D)
Figure 20-60-14
1. Bolt 13. Auxiliary Pump Center Section

2. Charge Pump End Section 14. Auxiliary Pump End Section
3. Section Seal 15. Shaft Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
7
8

9
3
10
3 2
4
6 5
8
4
11
7
8
3 12
4
6 13
4 8
10
11
15 3
14
P-66540

HYDRAULIC PUMP (CONT'D)
Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

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

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

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

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

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

HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6895
The high flow hydraulic pump has an additional pump kPa (69 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25511 kPa (255 bar) (3700
from a button on the panel in the cab. psi).
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.

gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The U.S. gpm should drop off
slightly until the pressure reaches approximately 21374
The tools listed will be needed to do the following kPa (214 bar) (3100 psi). At approximately 21374 kPa
procedure: (214 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter (238 - 241 bar) (3450 - 3500 psi). At 23787 - 24132 kPa
MEL10006 - Fitting Kit (238 - 241 bar) (3450 - 3500 psi) the flow should be at
zero U.S. gpm. Turn the restrictor (Item 2) [Figure 20-61-
Figure 20-61-1 1] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

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

hoses must be at least 19,1 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester.

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

procedure:
MEL1563 or 7217666 - Remote Start Tool Kit 2

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

WARNING 2
1
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

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

FREE FLOW (U.S. gpm) support device. (See Installing on Page 10-20-2.)

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

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

7217666 on Page 10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
Figure 20-61-4
Earlier Models
1 2
1
P-90580

P114639 the tester to the OUTLET hose (Item 1) [Figure 20-61-4]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-6] from the tester to the inlet fitting on the fan (Item
Figure 20-61-5 1) [Figure 20-61-4].
Later Models

1
IMPORTANT
I-2024-0284
P115656
Disconnect the inlet hose (Item 1) [Figure 20-61-4] or

[Figure 20-61-5].

HYDRAULIC PUMP (HIGH FLOW) (CONT’D)
Direct Pump Test (Charge Section) (Cont’d)
tester, the hoses are connected wrong. With the hoses
rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=

*Refer to the Hydraulic Schematics for pump flow and

rpm.

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-7] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:

MEL10003 or MEL1744 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

1.)

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
Direct Pump Test (High Flow Section) (Cont'd) button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
Figure 20-61-8 flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.
1 Warm the fluid to 60°C (140°F) by turning the restrictor

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

psi).
2 gpm) at full rpm. Increase the restriction and the flow
should drop to zero U.S. gpm between 24132 kPa (241
bar) (3500 psi) and 25511 kPa (255 bar) (3700 psi).
P-90183
If pressure readings are not obtained go to the High Flow
Valve, relief valve adjustment procedure.(See High Flow
Disconnect the high flow pump OUTLET hose (Item 1) Relief Valve Removal And Installation on Page 20-61-9.)
from the high flow check valve INLET fitting (Item 2)

[Figure 20-61-8]. Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.
Figure 20-61-9
%= HIGH PRESSURE FLOW (U.S. gpm) X100
1 2
P-90580

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-8]. Connect the OUTLET hose (Item 2)
[Figure 20-61-9] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-8].
Lower the cab.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-11
High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241 bar) (3500

psi) stop the engine. The relief screw (Item 1) [Figure 20-
P-45443
61-12] will need to be turned clockwise a 1/4 turn and
retested with the procedure above. (1/4 turn equals
approximately 1379 kPa (13,8 bar) (200 psi).)
1
NOTE: If the relief screw has been turned in 1/4 turn 2
and the pressure remains the same, go to the
high flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-9.) If relief
valve has been checked and is okay, go to the P-64022
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-15.) Locate the high flow relief valve (Item 1) [Figure 20-61-
11] along the right side of the engine.
Remove the track from the right side of the loader. (See
Track Removal And Installation on Page 40-20-4.) OR Remove the plug (Item 2) [Figure 20-61-11] located on
(See Track Removal And Installation on Page 40-21-4.) the bottom of the high flow relief valve.

Figure 20-61-10 Figure 20-61-12
1 1
1
1
1
P-90352 P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-10] NOTE: [Figure 20-61-12] shows adjusting the relief
from the access cover and remove the cover from the screw on a wheeled machine for photo clarity.
loader.
If the pump reaches 25511 kPa (255 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned counterclockwise 1/4 turn and retested with the
procedure above.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-14
High Flow Relief Valve Removal And Installation
WARNING
Failure to use jackstands can allow the machine to 1
W-2017-0286
Remove the track from the right side of the loader. (See P-64022
Track Removal And Installation on Page 40-20-4.) OR
(See Track Removal And Installation on Page 40-21-4.)
Locate the high flow relief valve through rear door along
Figure 20-61-13 the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-14] from

the pump.

Installation: Tighten the relief valve to 41 - 47 N•m (30 -
35 ft-lb) torque.
1 1
Figure 20-61-15
1
1 1 1
P-90352 3
Remove the mounting bolts (Item 1) [Figure 20-61-13] 2

from the access cover and remove the cover from the
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-15].
If the relief valve is bad, it must be replaced as a

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

20-61-15].

Solenoid Removal And Installation 2
Figure 20-61-16
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 18] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-18].
connector (Item 1) [Figure 20-61-16] from the high flow

pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-17
Figure 20-61-19
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-17].

Replace the O-rings (Item 1) and back-up ring (Item 2)
Remove the solenoid (Item 2) [Figure 20-61-17]. [Figure 20-61-19].
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -

72 in-lb)

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
WARNING Figure 20-61-20
Never work on a machine with the lift arms up unless 1

1
W-2059-0598
DANGER 1
1
P-90184

Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-20] from the front of the hydraulic pump.
Figure 20-61-21
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P-90185

clean the work area before disassembly and keep all Disconnect and cap the hoses (Item 1) [Figure 20-61-21]
parts clean. Always use caps and plugs on hoses, from the back of the hydraulic pump.
damage the system. Remove the Power Bob-Tach block (if equipped). (See
I-2003-0888 Removal And Installation on Page 20-120-1.)
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


NOTE: The engine / Hydro is shown removed for

photo clarity.
Figure 20-61-22
2
1
P-43940 P-43938A

hydraulic pump.
Reverse the removal procedure to install the hydraulic

P114353 pump.

Loosen the two mounting bracket bolts (Item 1) and
remove the nut / bolt (Item 2) [Figure 20-61-22].
Figure 20-61-23
1
2
3
P-90509A
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

Remove the two mounting bolts (Item 2) [Figure 20-61-

23] from the hydraulic pump.
Installation: Clean threads and apply Loctite® #242 to

the mounting bolts and tighten the mounting bolts to 75 -
85 N•m (55 - 60 ft-lb) torque.
Remove the hydraulic pump (Item 3) [Figure 20-61-23]

from the loader.

HYDRAULIC PUMP (HIGH FLOW) CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-61-25 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

1 down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.

P100685
Figure 20-61-26
P100352
Attach a push button (MEL1712) (Item 1) [Figure 20-61-

25] to the starter terminal S (Item 1) and the positive
battery cable (Item 2) [Figure 20-61-26].

Figure 20-61-27
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal
13
17. Center Housing

4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

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

the Parts Identification page [Figure 20-61-27 on Page
14] for proper placement of components along with the
information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 7)

NOTE: Position the wear plate (Item 4) [Figure 20-61-

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

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

replaced along with the O-rings and back-up
rings.


HYDRAULIC / HYDROSTATIC FILTERS (EARLIER Figure 20-70-1
MODELS)
Description 2
The hydraulic / hydrostatic filters help to remove

contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
2
The main filter removes contaminants before entering
gear pumps including fluid returning from the main valve. 1
2
The charge flow filter removes contaminants after the
P114903
charge pump.
Housing Removal And Installation Raise the lift arms and install an approved lift arm

DANGER Drain the fluid from the reservoir. (See Removing And


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

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

HYDRAULIC / HYDROSTATIC FILTERS (EARLIER
MODELS) (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
1
1
P122067
Remove and plug the three hoses (Item 1) [Figure 20-

70-2] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-70-3
P114650
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC / HYDROSTATIC FILTERS (LATER
MODELS)
Description
The hydraulic / hydrostatic filters help to remove

contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

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

gear pumps including fluid returning from the main valve.
The charge flow filter removes contaminants after the

charge pump.

HYDRAULIC / HYDROSTATIC FILTERS (LATER Figure 20-71-1
MODELS) (CONT’D)
Housing Removal And Installation
DANGER
P122360
P-90328
AVOID DEATH
71-1] from the hydraulic / hydrostatic filter sender.
Figure 20-71-2

D-1009-0409
WARNING
the lift arms are secured by an approved lift arm 1
support device can allow the lift arms or attachment P122361
W-2059-0598
Disconnect and plug the three hoses (Item 1) [Figure 20-
71-2] from the hydraulic / hydrostatic filter housing.
Drain the fluid from the reservoir. (See Removing And


HYDRAULIC / HYDROSTATIC FILTERS (LATER
MODELS) (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-71-3
1 1
P122067
Remove and plug the three hoses (Item 1) [Figure 20-

71-3] from the bottom of the hydraulic / hydrostatic filter
housing.
Figure 20-71-4
P122362
Remove the hydraulic / hydrostatic filter housing from the

loader.


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

loader’s hydraulic / hydrostatic fluid. The reservoir 2
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the

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

P109638
Remove the two nuts / bolts (Item 1) [Figure 20-80-2].
Remove the hydraulic fluid reservoir from the loader.
Remove the rear grille. (See Removing on Page 50-60-
1.) Installation: Tighten the nuts and bolts to 21,7 - 24,4

Drain the fluid from the reservoir. (See Removing And
Remove the Hydraulic / Hydrostatic Filter Housing. (See

Housing Removal And Installation on Page 20-70-1.)
Figure 20-80-1
P114642
Remove the clamps and the hoses (Item 1) [Figure 20-

80-1].

HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-3
P109639

Remove the hydraulic fluid reservoir breather cap (Item
2) [Figure 20-80-2] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

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

replacing.

OIL COOLER Removal And Installation
Description The oil cooler and radiator are removed from the loader
as a unit. (See Radiator / Oil Cooler Removal And
The oil cooler is used to cool the loaders hydraulic and Installation on Page 70-40-1.) or (See Radiator / Oil
hydrostatic oil. Oil passages are coiled into a heat Cooler Removal And Installation on Page 70-41-1.)
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.


BUCKET POSITION VALVE Disconnect the harness (Item 1) from the bottom of the
filter. Remove the two bolts (Item 2) and reposition the
Description fuel filter assembly (Item 3) [Figure 20-100-1].
The Bucket Position Valve is an option that allows the Figure 20-100-2
operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower

right rear side of the loader frame. 1
See Hydraulic Schematic for more circuit information.
DANGER P114644
Remove the fuel tank vent hose (Item 1) [Figure 20-100-

2] from the filler neck.

Figure 20-100-3
P-90328
AVOID DEATH 3
can cause lift arms to drop. 1
unless supported by an approved lift arm 2
D-1009-0409

P114645
Remove the nut / bolt (Item 1), reposition clamp (Item 2)
Figure 20-100-1
and remove the two nuts / bolts (Item 3) [Figure 20-100-
3].
Cover the fuel tank inlet.
P114648

BUCKET POSITION VALVE (CONT’D) Solenoid Testing
Removal And Installation (Cont’d) Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
Figure 20-100-4 information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.

3
2 DANGER
1 P-90197
Disconnect the wire harness connector (Item 1) [Figure P-90328

20-100-4], from the bucket position shut-off the solenoid. AVOID DEATH

Disconnect the cap the two tubelines (Item 2) [Figure 20- tubeline, hose, fitting, component or a part failure
100-4]. can cause lift arms to drop.
Remove the solenoid nut, coil, and stem (Item 3) from the unless supported by an approved lift arm
bucket positioning valve [Figure 20-100-4]. support. Replace if damaged.
D-1009-0409
Installation: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
torque. Overtightening may cause valve failure. Figure 20-100-6
NOTE: The engine is shown removed for photo

clarity.
Figure 20-100-5
3
1 2
2
P114648
Disconnect the harness (Item 1) from the bottom of the

filter. Remove the two bolts (Item 2) and reposition the
N-18191 fuel filter assembly (Item 3) [Figure 20-100-6].
Inspect the solenoid stem and replace the O-rings (Item

1) and the back-up ring (Item 2) [Figure 20-100-5].

BUCKET POSITION VALVE (CONT’D) Figure 20-100-9
Figure 20-100-7
1 P-90197
NOTE: The engine is shown removed for photo

P114644 clarity.
NOTE: Mark all hoses and tubelines for correct

Remove the fuel tank vent hose (Item 1) [Figure 20-100-
installation.
7] from the filler neck.

Disconnect the electric solenoid connector (Item 1)
Figure 20-100-8
[Figure 20-100-9].
Figure 20-100-10
1
1
2
P114645
4 3
Remove the nut / bolt (Item 1), reposition clamp (Item 2)
P-90188
and remove the two nuts / bolts (Item 3) [Figure 20-100-
8].
Disconnect and cap the tilt base inlet hose (Item 1), the
Cover the fuel tank inlet. tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-10]
that route from the control valve.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-13
Figure 20-100-11
P-90190A
2
1
Remove the mounting nuts / bolts (Item 1) [Figure 20-
P-90189A 100-13].
Remove the bucket position valve from the loader.

Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-11]

from the valve block.
Figure 20-100-12
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-12] that route from the lift cylinders.

BUCKET POSITION VALVE (CONT’D) Figure 20-100-16
Figure 20-100-14
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-16]. Inspect for
wear, inspect the O-ring and replace as needed.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-14]. ft-lb) torque.

Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-17
lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up rings and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3
Figure 20-100-15
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-17].
Inspect all parts and replace as needed. Install a new O-

P-90195 ring on the plug before installing.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

Remove the flow adjustment valve and O-ring (Item 1) ft-lb) torque.
[Figure 20-100-15].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new O-rings before any parts

are installed into the valve. Inspect the parts
for wear or damage and replace as needed.


REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts fluid from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.
Figure 20-110-3

P9137

resistance is 8.6 - 9.5 ohm.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
resistance for the solenoid coil with a molded connector
is 8.1 - 9.9 ohm.

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-5
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-5].
tubeline, hose, fitting, component or a part failure Figure 20-110-6

D-1009-0409
1
Put jackstands under the rear corners of the loader.


Replacing Hydraulic Fluid on Page 10-120-2.) P100810
Figure 20-110-4 Disconnect the accessory wiring harness (Item 1)

[Figure 20-110-6] from the main harness.
Figure 20-110-7
1
1
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20- P-90581

110-4]
Remove the two bolts (Item 1) and remove the valve
(Item 2) [Figure 20-110-7].

REAR AUXILIARY DIVERTER VALVE (CONT’D)

IMPORTANT
Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct When repairing hydrostatic and hydraulic systems,
assembly. clean the work area before disassembly and keep all
Inspect cartridges, check valves, solenoid valves and tubelines and ports to keep dirt out. Dirt can quickly
sealing washers for contamination or damage. Wash all damage the system.
parts in clean solvent. Use air pressure to dry them. I-2003-0888
Install new O-rings and back-up rings.
Figure 20-110-10
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
Figure 20-110-8

1 P-48755
1
Figure 20-110-11
P-48751
Figure 20-110-9
2
2 2
1
1
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-10]

P-48752
and [Figure 20-110-11] from diverter valve and replace
the O-rings and back-up rings (Item 2) [Figure 20-110-
Several plugs (Item 1) [Figure 20-110-8] and [Figure 20- 11].
110-9] are located all over the diverter valve and can be
removed for clean out purposes. Assembly: Put oil on the O-rings and back-up rings.
Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.
Assembly: Put oil on O-rings and back-up rings. Tighten
to 13,6 N•m (10 ft-lb) torque.

Disassembly And Assembly (Cont'd)
Figure 20-110-12
P-48753
1
Remove the relief valve (Item 1) [Figure 20-110-14].

P-48755
Figure 20-110-15
Figure 20-110-13

2
2
1
1
P-48754
P-48757
Replace the O-rings and back-up rings (Item 1) [Figure
20-110-15].
Remove the differential sensing valve (Item 1) [Figure
20-110-12] and [Figure 20-110-13] from diverter valve Assembly: Put oil on O-rings and back-up rings. Tighten
and replace the O-rings and back-up rings (Item 2) to 27 - 34 N•m (20 - 25 ft-lb) torque.
[Figure 20-110-13].

to 68 - 75 N•m (50 - 55 ft-lb) torque.

Figure 20-110-16
1
P-48761
NOTE: Before removing the solenoid coils mark the

P-48759 coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-18] from the

Figure 20-110-17 solenoid valve stems.

Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-16] and [Figure

20-110-17] from the solenoid valve stem.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

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

(Item 3) [Figure 20-110-17].

Figure 20-110-19 1
P-48763A
Figure 20-110-22
P-48762
Figure 20-110-20

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

P-48763 110-21] and [Figure 20-110-22] and replace the O-rings
Remove the solenoid valve stem (Item 1) [Figure 20- Assembly: Put oil on O-rings and back-up rings. Tighten
110-19] and [Figure 20-110-20] and replace the O-rings to 41 - 47 N•m (30 - 35 ft-lb) torque.

to 27 - 34 N•m (20 - 25 ft-lb) torque.

Figure 20-110-23
P-48765
Remove the plug (Item 1) [Figure 20-110-25].

P-48765
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-110-23]. Figure 20-110-26

Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-24
P-48786
1 Remove the orifice (Item 1) [Figure 20-110-26].

P-48766
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-110-
24] for dirt and debris.
Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)

torque.

REAR AUXILIARY DIVERTER VALVE (CONT’D)
Figure 20-110-27
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].

Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.
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 rings.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.

BOB-TACH (POWER) BLOCK (S/N ALJG11001 - 13367 Removal And Installation
AND B2KZ11001 - 11017)
Description
The Power Bob-Tach is an option that allows the operator

WARNING
to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments. Never work on a machine with the lift arms up unless
The Power Bob-Tach is operated by a switch on the right support device. Failure to use an approved lift arm
switch panel. support device can allow the lift arms or attachment
The Power Bob-Tach block is mounted on the right side W-2059-0598
of the machine in front of the engine on the back side of
the hydraulic pump.
DANGER

P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (S/N ALJG11001 - 13367 Figure 20-120-2
AND B2KZ11001 - 11017) (CONT’D)
1
NOTE: Earlier models shown. The photos may appear

different for later models but the procedure is
the same. 2 4
NOTE: After repairing a machine that required the

Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function 3
3
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical 3
P-90969
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function Mark the hydraulic hoses for proper installation.
correctly.
Disconnect and cap the outlet hose (Item 1) [Figure 20-
Lift and block the loader. (See Procedure on Page 10-10- 120-2] from block.
1.)
Remove the hydraulic muffler (if equipped) (Item 2)

Raise the lift arms and install an approved lift arm [Figure 20-120-2] from block.
Disconnect and cap the hoses (Item 3) [Figure 20-120-2]
Raise the operator cab. (See Raising on Page 10-30-2.) from block.
Drain the hydraulic reservoir. (See Removing And Remove the four mounting bolts (Item 4) [Figure 20-120-
Replacing Hydraulic Fluid on Page 10-120-2.) 2] from block.
Figure 20-120-1 Installation: Tighten the mounting bolts to 48 - 54 N•m

(35 - 40 ft-lb) torque.
Remove the Power Bob-Tach block.
P-90968
Disconnect and cap the two electrical solenoid

connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness.

AND B2KZ11001 - 11017) (CONT’D)
2
IMPORTANT
1
damage the system.
I-2003-0888
P100769
Figure 20-120-3
Clean the block (Item 1) [Figure 20-120-4] to remove dirt
before disassembly. Block ports are labeled for correct
assembly.

1

Installation: Tighten the plug to 67,8 N•m (50 ft-lb)
torque.
Figure 20-120-5
3
P100820
Do not remove these plugs (Item 1) [Figure 20-120-3]. 1
NOTE: Do not remove the two plugs located next to 2

the outlet port. A new Power Bob-Tach valve
will be required if tampered with. All other
plugs can be removed.
4
P100770
Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-5] and inspect. Replace damaged parts
as needed.

plug.

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-6
1
2
1
P107069
Remove the spool (Item 1), the spring (Item 2) and the
orifice (Item 3) [Figure 20-120-7]. Inspect the spring,
P100823 spool, orifice and replace as needed.
Installation: Clean threads on the orifice and apply

Remove the plug (Item 1) [Figure 20-120-6], replace the Loctite® 603. Install the orifice.

O-ring.
Figure 20-120-8
torque.
P100826
Remove the plug (Item 1) [Figure 20-120-8], replace the

O-ring.

torque.

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-9
2
P100773
1
Remove the first solenoid coil (Item 1) and the second
solenoid coil (Item 2) [Figure 20-120-11].
P100821
Figure 20-120-12
Remove the orifice screw (Item 1) [Figure 20-120-9].

Installation: Tighten the orifice screw to 8,1 - 10,8 N•m
Figure 20-120-10
1
1 P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

12].
Installation: Tighten the solenoid coil stem to 27,14 N•m

P100774 (20 ft-lb) torque.
NOTE: Mark the solenoid coil orientation for ease of

installation.
Remove the solenoid coil nut (Item 1) [Figure 20-120-

10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-13
2 2 2
P100829
1 1 1 1
Replace the O-ring (Item 1) [Figure 20-120-15].
P100776 Figure 20-120-16
Inspect the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-13].

Figure 20-120-14 1
P100840
Remove the plug (Item 1) [Figure 20-120-16], replace

the O-ring.
P100828 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.
Remove the fitting (Item 1) [Figure 20-120-14].

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-17
2
1
P100843
1
Remove the shuttle seat (Item 1) and check ball (Item 2)
[Figure 20-120-19]. Inspect the shuttle seat and check
P100841 ball, replace as needed.
Figure 20-120-20
Remove the filter assembly (Item 1) [Figure 20-120-17],
inspect and replace as needed.

Figure 20-120-18
P100845

P100842 the O-ring.
Installation: Tighten the plug (Item 1) to 30 N•m (22 ft-lb)

Remove the plug (Item 1) [Figure 20-120-18], replace torque.
the O-ring.
Installation: Tighten the plug (Item 1) to 17,6 N•m (13 ft-

lb) torque.

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-21
P100837

the O-ring.
P100839
lb) torque.

the O-ring. Figure 20-120-24

lb) torque.
Figure 20-120-22
2
1 P100838
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-24], inspect and replace as needed.
P100835
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-22], inspect and replace as needed.

AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-25
P100847
Remove pilot piston (Item 1) [Figure 20-120-27].
P100846 Figure 20-120-28

the O-ring.
2 2
torque.
1
Figure 20-120-26
P100834
1
Inspect the pilot piston (Item 1), the back-up rings (Item
2) and the O-ring (Item 3) [Figure 20-120-28] for damage
and replace as needed.
P100853
Using a small diameter tool remove the pilot piston (Item

1) [Figure 20-120-26].

AND B2KZ11001 - 11017) (CONT’D)

1
Figure 20-120-29
P100850

the O-ring.
P100852
torque.

the O-ring. Figure 20-120-32

lb) torque.
Figure 20-120-30
1
2 P100851

the O-ring.
P100849
lb) torque.
Remove the annular orifice shaft (Item 1) and the annular
orifice shaft guide (Item 2) [Figure 20-120-30], inspect
and replace as needed.

BOB-TACH (POWER) BLOCK (S/N ALJG11001 - 13367
AND B2KZ11001 - 11017) (CONT’D)
Figure 20-120-33
P100854

make sure the Bob-Tach wedges function
Maintenance Manual, the electrical
inspection to verify the wedges function
correctly.


BOB-TACH (POWER) BLOCK (S/N ALJG13368 AND
B2KZ11018 & ABOVE)
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right

switch panel.
The Power Bob-Tach block is mounted on the right side

of the machine in front of the engine on the back side of
the hydraulic pump.

BOB-TACH (POWER) BLOCK (S/N ALJG13368 AND Figure 20-121-2
B2KZ11018 & ABOVE) (CONT'D)
Testing Relief Valve
1
WARNING
not use your bare hand. Wear safety goggles. If fluid P106674
W-2072-0807 Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
Figure 20-121-3
WARNING

explosion or fire. 1
W-2103-0508
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-121-1 P122238
Install the gauge (Item 1) [Figure 20-121-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH “WEDGES DOWN” Switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

121-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

Testing Relief Valve (Cont’d)
Figure 20-121-4
P122229
NOTE: Relief valve removed from block for photo

clarity.
If adjustment is required loosen the jam nut (Item 1) and

turn the adjusting screw (Item 2) [Figure 20-121-4]
clockwise to increase pressure or counterclockwise to
decrease pressure.
Test the relief valve setting after adjustment has been

made.

BOB-TACH (POWER) BLOCK (S/N ALJG13368 AND NOTE: After repairing a machine that required the
B2KZ11018 & ABOVE) (CONT'D) Power Bob-Tach valve electrical connectors
Removal And Installation make sure the Bob-Tach wedges function
WARNING Maintenance Manual, the electrical

Never work on a machine with the lift arms up unless inspection to verify the wedges function
the lift arms are secured by an approved lift arm correctly.
support device can allow the lift arms or attachment Lift and block the loader. (See LIFTING AND BLOCKING
to fall and cause injury or death. THE LOADER on Page 10-10-1.)
W-2059-0598

DANGER
Remove the fan duct panels. (See Removal And

Figure 20-121-5
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 1
D-1009-0409
P122161
IMPORTANT
Disconnect the two wire connectors (Item 1) [Figure 20-
When repairing hydrostatic and hydraulic systems, 121-5] from the solenoid coils.
damage the system.
I-2003-0888

Figure 20-121-6
2 2
P122162
Disconnect and cap the hose (Item 1) [Figure 20-121-6]

from block.
Disconnect and cap the hoses (Item 2) [Figure 20-121-6]

from block.
Figure 20-121-7
1 1
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-121-

7].
Installation: Tighten the mounting bolts to 48 - 54 N•m

Remove the Power Bob-Tach block.

IMPORTANT 3

1
damage the system. 2
I-2003-0888
4 P122197
Figure 20-121-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.

torque.

1
plug.
Figure 20-121-10
1
P122196
Do not remove these plugs (Item 1) [Figure 20-121-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
1
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-121-10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.


2
Figure 20-121-11
2
1
3 P122201
Replace the O-rings (Item 1) and the back-up rings (Item

1 2) [Figure 20-121-13].
P122199
Figure 20-121-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-121-

11].
Figure 20-121-12
2 1
P122202
1 Remove the fitting (Item 2) [Figure 20-121-12] and

replace the O-ring (Item 1) [Figure 20-121-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-121-

12].
Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-121-15
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-17]. Inspect and replace
P122203 as needed.
Figure 20-121-18
Remove the plug (Item 1) [Figure 20-121-15] and

replace the O-ring.

torque. 1
Figure 20-121-16
P122205

1
torque.
P122205

torque.

Figure 20-121-19
2
3 1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert

1 (Item 2) [Figure 20-121-21]. Inspect and replace as
P122207 needed.
Figure 20-121-22
Remove the O-ring (Item 1), the spring (Item 2) and the
check ball (Item 3) [Figure 20-121-19]. Inspect and

replace as needed.
Figure 20-121-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
P122208 Installation: Tighten the relief valve to 20 N•m (15 ft-lb)

torque.

torque.

Figure 20-121-23
P122212
Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-121-23].

Figure 20-121-24
P122213

make sure the Bob-Tach wedges function
Maintenance Manual, the electrical
inspection to verify the wedges function
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535

If unable to identify the supplier part number on the male
coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONT’D)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONT’D)
Disassembly And Assembly (FFI/FI) (Cont’d)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7].

1
Remove the O-rings (Item 2) [Figure 20-130-7] from the
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and replace the seal

(Item 1) [Figure 20-130-8].

(CONT’D)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
Remove the springs (Item 1) [Figure 20-130-13].
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].

Installation: Tighten the coupler fittings (Item 1) [Figure
20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

(CONT’D)
Disassembly And Assembly (FFH/FH) (Cont’d)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].

Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assembly if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.


AUTOMATIC RIDE CONTROL
Description
The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

AUTOMATIC RIDE CONTROL (CONT'D)

WARNING
Open the rear door.
Remove the rear grille and engine cover. (See Removing
on Page 50-60-1.)
explosion or fire.
WARNING W-2103-0508

support device. Failure to use an approved lift arm WARNING
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.

See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Drain the hydraulic fluid reservoir. (See Removing And

Figure 20-140-1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 3
D-1009-0409
2
IMPORTANT P121154
When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

AUTOMATIC RIDE CONTROL (CONT'D) Figure 20-140-4
Figure 20-140-2 2
P122354
Reposition the clamp (Item 1) and remove the fuel fill

P122353
hose (Item 2) [Figure 20-140-4] from the tank.
Cover the fuel tank inlet.

Figure 20-140-5
Figure 20-140-3

1
P128342
P122355
Disconnect the three connectors (Item 1) [Figure 20-

Remove the hose (Item 1) [Figure 20-140-3]. 140-5] from the manifold.


2
Figure 20-140-6
1
1
P128335
Remove the two nuts (Item 1) and the accumulator /

P128096 manifold assembly (Item 2) [Figure 20-140-8].
Remove the hose (Item 1) [Figure 20-140-6].

Figure 20-140-7
P128339
Remove the two hoses (Item 1) [Figure 20-140-7] from

the manifold.

AUTOMATIC RIDE CONTROL (CONT'D)
Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
reduced ride control performance, or loss of I-2003-0888
ride control function.
Remove the automatic ride control assembly. (See


WARNING
procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

WARNING
W-2059-0598
RIDE CONTROL ACCUMULATOR INSTALLED
DANGER circuit before servicing.
W-3015-0816
Figure 20-140-9
P-90328
AVOID DEATH 1
D-1009-0409
P128321
Remove the cap (Item 1) [Figure 20-140-9] from the

accumulator.

Checking The Pressure In The Accumulator (Cont’d)
Figure 20-140-10 1
2
1
P128489
Turn the T-handle (Item 1) [Figure 20-140-12] counter

P128322 clockwise until the gauge begins to move (DO NOT
TURN THE T-HANDLE MORE THAN THREE TIMES).
Loosen the Allen screw (Item 1) [Figure 20-140-10] Pressure in the accumulator should be 915 psi [63 bar].
approximately 1/4 turn.

Close the valve by turning the T-handle (Item 1) [Figure
Figure 20-140-11 20-140-12] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-12].
Remove the tool / gauge from the accumulator.

2
Tighten the Allen screw (Item 1) [Figure 20-140-10] to 20
N•m (15 ft-lb) torque.
1
P128488
Make sure the manual bleed valve (Item 1) is closed.

Install the tool / gauge (Item 2) [Figure 20-140-11] onto
the accumulator.

AUTOMATIC RIDE CONTROL (CONT'D) Remove the cap (Item 1) [Figure 20-140-13] from the
accumulator.
Adding Nitrogen To The Accumulator
Figure 20-140-14
Remove the automatic ride control assembly. (See

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
P128322
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present. Loosen the Allen screw (Item 1) [Figure 20-140-14]
• Engine is running. approximately 1/4 turn.
W-2505-0604

Figure 20-140-15
WARNING 1
RIDE CONTROL ACCUMULATOR INSTALLED

circuit before servicing.
W-3015-0816
2 P128488
Figure 20-140-13 Install the tool / gauge (Item 1) [Figure 20-140-15] onto
the accumulator.
Make sure the manual bleed valve (Item 2) [Figure 20-

140-15] is closed.
P128321

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-16
2
1
P128491
Turn the T-handle (Item 1) [Figure 20-140-18] counter

P128490 clockwise until the gauge begins to move (DO NOT
TURN THE T-HANDLE MORE THAN THREE TIMES).
Install the hose (Item 1) [Figure 20-140-16] to the tool on Pressure in the accumulator should be 915 psi [63 bar].
the accumulator.

Slowly open the valve on the nitrogen tank. Close the
Figure 20-140-17 valve by turning the T-handle (Item 1) [Figure 20-140-18]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1 Close the valve by turning the T-handle (Item 1) [Figure
20-140-18] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-18].
Remove the hose from the tank and the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-14] to 20

P128327
Install the other end of the hose / fitting (Item 1) [Figure

20-140-17] to the nitrogen tank.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR (SIX TRACK SPROCKET NUTS) . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
HYDROSTATIC DRIVE MOTOR (EIGHT TRACK SPROCKET NUTS) . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK SPROCKET BOLTS) . . . . . . . . . . 30-22-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
Parts Identification (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-5
Parts Identification (MCR6T) (Two-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-6
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Sender Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-40-3
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-13

HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-5
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-7
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-22
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-25
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . 30-50-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Tensioner Pulley Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5

TWO-SPEED / BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2

HYDROSTATIC SYSTEM INFORMATION Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
The hydrostatic system consists of a tandem hydrostatic most common. Many of the recommended procedures
pump and two hydrostatic motors. The hydrostatic must be done by authorized Bobcat Service Personnel
system allows forward and reverse motion of the loader. only.
The hydrostatic pump is connected to the engine by a If a service code appears in the left instrument panel.
drive belt and provides fluid to the hydrostatic motors. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2

No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5, 9
The hydrostatic system is overheating. 6,7,8
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.
5. Track tension is too tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct rpm.
9. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.


HYDROSTATIC DRIVE MOTOR (SIX TRACK
SPROCKET NUTS)
Description
The hydrostatic drive motors are driven by the hydrostatic

pump. Machines equipped with SJC are monitored by a
sensor (if equipped) mounted onto the motor housing.
The sensor is used for detection of motion and for rate of
speed for the SJC option. Standard machines use the
same motor but have a plate and O-ring that covers the
sensor hole.
The hydrostatic drive motors contain a spring applied

pressure release braking system to stop the loader. In
addition there is a separate fluid chamber in the motor
that is filled with high performance synthetic fluid for
maximum durability, this fluid has a recommended
service interval. (See SERVICE SCHEDULE on Page 10-
70-1.)
There are two hydrostatic drive motors and they are

located on the track carriage.

HYDROSTATIC DRIVE MOTOR (SIX TRACK Removing And Replacing Fluid
SPROCKET NUTS) (CONT’D)
For the correct service interval (See SERVICE
Machine Identification SCHEDULE on Page 10-70-1.)
The loader specifications can be different based on drive Park the loader so that the plug in the hydrostatic drive
motor configurations. Look at the drive motor and motor is at the bottom.
sprocket on your machine to determine which
specification section is correct for your model. Remove the plug and let the fluid drain from the
hydrostatic drive motor.
Figure 30-20-1
Figure 30-20-2

P121581A
P-90680B
These drive motor and sprocket assemblies have six nuts

(Item 1) [Figure 30-20-1]. Rotate the hydrostatic drive motor so that the plug (Item
1) [Figure 30-20-2] is at the top. Add high performance
synthetic fluid (P/N 7024981). (See Capacities on Page
SPEC-10-5.)
NOTE: Earlier and later drive motors use different

fluids that are not compatible. The drive
motors will be damaged if the wrong fluid is
used.
Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.
Repeat for the other hydrostatic drive motor.
Recycle or dispose of the used fluid in an

environmentally safe manner.

HYDROSTATIC DRIVE MOTOR (SIX TRACK Remove the track. (See Track Removal And Installation
SPROCKET NUTS) (CONT’D) on Page 40-20-4.)
Removal And Installation Figure 30-20-3
1
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1 1
damage the system.
I-2003-0888
Place the loader on jackstands. (See Procedure on Page

10-10-1.) P-85927
Remove the mounting bolts (Item 1) [Figure 30-20-3]

DANGER from the access cover and remove the cover from the
loader.

Remove the sprocket. (See Sprocket Removal And
Installation (Single Speed) on Page 40-20-12.) OR (See
Sprocket Removal And Installation (Single Speed) on
Page 40-21-13.)
(SJC equipped machines only) Disconnect and remove

the speed sensor (SJC). (See Removal And Installation
P-90328 on Page 60-80-3.)
AVOID DEATH
NOTE: Speed sensor removal is recommended to
prevent damage while removing the
hydrostatic motor from the track carriage.
NOTE: Speed sensors have been eliminated on late
model machines. Earlier models may or may
D-1009-0409
not have been upgraded to eliminate the
sensors.
WARNING
W-2059-0598


HYDROSTATIC DRIVE MOTOR (SIX TRACK Figure 30-20-6

1 1
Figure 30-20-4
1 P-85991
With an arm hoist support the hydrostatic motor.

3
Remove the ten hydraulic motor mounting bolts (Item 1)
P-85992 [Figure 30-20-6].
Remove the case drain hydraulic hose (Item 1) [Figure Installation: Tighten the motor mounting bolts to 258

30-20-4] from the motor. N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-20- Remove the hydrostatic motor from the loader.
4] from the motor.
Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-20-4].
Installation: Fill the main drive hose ports on the motor

with new hydraulic fluid before installing the drive hoses.
Figure 30-20-5
2 3
4 1
P100901
Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-20-5]. Retighten all bolts to 48 - 54 N•m (35 -
40 ft-lb) torque in the same sequence.

HYDROSTATIC DRIVE MOTOR (SIX TRACK SPROCKET NUTS) (CONT’D)
7
4 6
5 3
4
2 3
21
1
20
8 19
10
18
9
15 13

14
16
14
11 13
12
17 3
29 30
22 22
1 28
6 20 2
8 20
22 1 8
23 23 8
1 8 24 6 25
20
26
8 1
8 1 34 1
33 8
27
6
3
22
31 25
P-90205

HYDROSTATIC DRIVE MOTOR (SIX TRACK SPROCKET NUTS) (CONT’D)
Parts Identification (Cont’d)
REF. DESCRIPTION
1. Plug
2. Shaft
3. Seal
4. Bearing
5. Housing / Front
6. Washer
7. Rings
8. O-ring
9. Nut
10. Stud
11. Rpm Target Disk
12. Roll Pin
13. Snap Ring
14. Retainer
15. Roller
16. Piston

17. Block
18. Cam
19. Distributor
20. Spring
21. Seal W / O Ring
22. Shim
23. Poppet
24. Spool
25. Bolt
26. Pin
27. Housing / Rear
28. Housing / Brake
29. Disc / Outer
30. Disc / Inner
31. Bushing
32. Piston
33. Gasket
34. Cover

Figure 30-20-7
1
N-18295
1
Remove the twenty four mounting bolts (Item 1) and the

brake cover plate (Item 2) [Figure 30-20-9].
P-48683
NOTE: Remove every other bolt, then uniformly
remove the last twelve bolts to maintain equal
NOTE: Motors that do not have the SJC sensor (Item preload on the brake cover plate. Install bolts

1) [Figure 30-20-7] will be covered by a plate using the same procedure.
and O-ring. The plate will need to be ordered
separately when ordering a new motor from Assembly: Replace the gasket and end cap.
Bobcat Parts.
Assembly: Tighten the bolts to 35 - 39 N•m (26 - 29 ft-lb)
Figure 30-20-8 torque.
Figure 30-20-10
N-18294
N-18296
NOTE: Mark the motor, brake and motor housings for
proper alignment during assembly [Figure 30-
20-8]. Remove the disk spring (Item 1) [Figure 30-20-10] from
the brake housing.
Drain the fluid from the motor casing.
NOTE: Mark the top side of the disk spring for proper
Inspect for the vendor motor serial number (Item 1) installation.
[Figure 30-20-8], these serial numbers may be needed
when ordering replacement parts. Assembly: Apply multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.

Figure 30-20-11
1
2
N-18299
1
Inspect the piston surface (Item 1) and the bushing
surface (Item 2) [Figure 30-20-13] in the brake shaft.
N-18297
NOTE: The bushing (Item 2) [Figure 30-20-13] can be
replaced in the brake shaft. When the bushing
Remove the piston from the brake housing [Figure 30- is replaced, install the bushing flush with the

20-11]. top of the brake shaft.
NOTE: The use of air pressure through the brake line

connection (Item 1) [Figure 30-20-11] will aid
in piston removal.
Figure 30-20-12
N-18298
Inspect the brake piston (Item 1) [Figure 30-20-12] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-20-12].
Assembly: Apply oil to the seal (Item 2) [Figure 30-20-

12] for added protection when installing the brake piston.

Figure 30-20-14
2 1
3 N-18347
1 Assembly: Clamp the disc pack in a vise and measure

1 the disc pack height [Figure 30-20-15].
N-18300
Assembly: The correct disc pack specifications is 37,7 +
0,05 mm (1.48 + 0.002 in).
Remove the eight mounting bolts (Item 1) [Figure 30-20-

14] and washers from the brake housing. Assembly: Extra outer disc's (Item 2) [Figure 30-20-17]
are used to reduce the number of required shims to make
Remove the brake housing (Item 2) [Figure 30-20-14] up the required thickness for the brake pack.
from the rear housing.
NOTE: Brake pack height is for reference only.
Remove the snap ring and the inner piston seal (Item 3)
[Figure 30-20-14]. Figure 30-20-16
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake 1

housing on the rear housing.
Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-20-14].
Assembly: Apply Loctite® 243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
N-18350
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)
torque.
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-20-16]. Outer discs can also be used as
shims.

HYDROSTATIC DRIVE MOTOR (SIX TRACK NOTE: The 20 kN (4500 lbf) is NOT the amount of
SPROCKET NUTS) (CONT’D) pressure required by the press. It is the
amount of downward force applied by the
Disassembly And Assembly (Cont'd) press.
Figure 30-20-17 Figure 30-20-19
3
2
1
P100805
N-18301
Assembly: Assemble the brake discs into a pack making Disassembly: Remove the brake discs (Item 1) [Figure
sure the inner discs (Item 1), alternate with the outer disc

30-20-19] and shims from the brake shaft.
(Item 2) and an outer disc is placed at each end of the
disc pack with the shims (Item 3) [Figure 30-20-17] and Figure 30-20-20
base of the pack.
Figure 30-20-18
1 2
N-18302
3
P100800 Remove the brake shaft (Item 1) [Figure 30-20-20] from
the rear housing.
Assembly: Assemble the brake piston into the brake NOTE: Be sure shaft seats fully into the cylinder
housing without the inner brake piston seal (Item 3) block.
[Figure 30-20-14] and brake piston outer seal (Item 2)
[Figure 30-20-12]. Apply 20 kN (4500 lbf) to set the Assembly: Install new O-ring (Item 2) [Figure 30-20-20]
brake pack. Using a depth gauge (Item 1), measure from on the rear housing.
the gasket mating surface (Item 2) to the inner machined
groove (Item 3) on the brake piston [Figure 30-20-18].
The dimensional measurement must be 8,7 ± 0,1 mm

(0.343 ± 0.003), if not adjust brake pack discs to the
required measurement.

1
Figure 30-20-21
1 2
1 1
P-48686
1 1
Remove and replace with a new O-ring (Item 1) [Figure
30-20-23].
P-48684
Remove the distributor (Item 2) [Figure 30-20-23] from
the rear housing.
Remove the eight mounting bolts (Item 1) [Figure 30-20-

21] from the rear housing. Assembly: Install the distributor (Item 2) [Figure 30-20-
23] by using the alignment pin.
Assembly: Use Loctite® 243 on the threads and install
the eight mounting bolts (Item 1) [Figure 30-20-21]. Figure 30-20-24
Assembly: Tighten the bolts to 282 - 300 N•m (208 - 221

ft-lb) torque.
Figure 30-20-22
1
1
N-18318
Remove the two seals and back-up O-rings (Item 1)

[Figure 30-20-24] under the seals, from the rear
P-48685 housing.
Assembly: Apply a slight amount of oil to the O-rings

Remove the rear housing assembly (Item 1) [Figure 30- and seals (Item 1) [Figure 30-20-24].
20-22] from the rotating group / front housing assembly.
Remove and inspect the stop pin (Item 2) [Figure 30-20-
24].

HYDROSTATIC DRIVE MOTOR (SIX TRACK When the distributor is aligned correctly, the distributor
SPROCKET NUTS) (CONT’D) can be depressed slightly by hand and will return to its
original position.
Figure 30-20-27
Figure 30-20-25
N-18308
P-48713
Remove the twelve springs from the distributor (Item 1) Remove the plug (Item 1) [Figure 30-20-27] from the
[Figure 30-20-25]. rear housing assembly.

Remove and replace the two seals and back-up O-rings Remove the spring (Item 1), spool (Item 2), and washer
(Item 2) [Figure 30-20-25] under the seals, from the (Item 3) and rear spring (Item 4) [Figure 30-20-29].
distributor.
Figure 30-20-28
Inspect the distributor surfaces for scratches.
Assembly: Apply a small amount of grease to the

springs to hold them in place during installation.
Figure 30-20-26
2
1 1
N-18309
1 Remove the plugs (Item 1) [Figure 30-20-28] from the

rear housing assembly to inspect alignment of springs,
washer and spool when reassembling.
N-18323
Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor marked L
(Item 2) [Figure 30-20-26].


1
Figure 30-20-29
4
3
N-18311
1
Replace the O-ring on the plug (Item 1) [Figure 30-20-
31].
N-18315
Assembly: Apply Loctite® activator 7649 to the plug
threads and allow 10 seconds for the activator to dry.
Inspect all parts and replace as needed [Figure 30-20- Apply Loctite® 243 to the plug threads. Install the plug

29]. (Item 1) and tighten to 85 N•m (63 ft-lb) torque.
Figure 30-20-30 Figure 30-20-32
1 1
N-18310
N-18312
Remove the plug (Item 1) [Figure 30-20-30]. Remove the plug (Item 1) [Figure 30-20-32].
Assembly: Apply Loctite® activator 7649 to the plug

threads and allow 10 seconds for the activator to dry.
Apply Loctite® 243 to the plug threads. Install the plug
and tighten to 60 N•m (44 ft-lb) torque.

Figure 30-20-33
1
2
1
P-48687
Remove the cam ring (Item 1) [Figure 30-20-35] from the

front housing assembly.
N-18313
Inspect the cam ring inside surface for wear and
scratches.

Assembly: Align the marks (Item 2) [Figure 30-20-35]
Figure 30-20-34 on the cam rings to the front housing.
4 Figure 30-20-36
1
3
2 2
1
N-18314
P-48688
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-20-34].
Remove and replace the O-ring (Item 1) [Figure 30-20-
Inspect all parts and replace as needed. 36] from the front housing assembly.
Install a new O-ring (Item 4) [Figure 30-20-34] on the Assembly: Slightly smear the O-ring (Item 1) [Figure
plug before installation. 30-20-36] with grease to hold in place.
Remove the rotating group (Item 2) [Figure 30-20-36]

from the front housing assembly.

Figure 30-20-37
1
P-48689
Remove the snap ring (Item 1) [Figure 30-20-39] from

1 the top side of the rotating group.
P-48690
Figure 30-20-40

the bottom side of the rotating group.
Figure 30-20-38
P-48694
The retainer ring (Item 1) [Figure 30-20-40] cannot be

1
removed from the top side of the rotating group, because
P-48691 the rpm target disk is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-20-38] from


HYDROSTATIC DRIVE MOTOR (SIX TRACK If the rpm target disk needs to be changed, remove the
SPROCKET NUTS) (CONT’D) heads of the five roll pins (Item 2) [Figure 30-20-42] and
remove the disk. Replace the target disk and use new roll
Disassembly And Assembly (Cont'd) pins. Using a small hammer, tap the new roll pins through
the new target disk into the cylinder block.
Figure 30-20-41
Figure 30-20-43
2 1
P-48695
P100802
Lift the retaining ring (Item 1) [Figure 30-20-41].

Disassembly: Remove the fluid fill plug (Item 1) [Figure
Use low air pressure and remove the roller / piston 30-20-43] from the housing to drain the fluid from the
assembly (Item 2) [Figure 30-20-41] from the cylinder bearing and face seal area.
block.
Assembly: Install fluid plug using Loctite® 243, tighten
NOTE: Soak the roller / piston assembles (Item 2) flush with the face of the hub.
[Figure 30-20-41] in oil and put all roller /
piston assembles back in the original bore. Figure 30-20-44
NOTE: The roller / piston assembly (Item 2) [Figure

30-20-41] is not a serviceable part.
Figure 30-20-42
1
1
2
N-18343
Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split
P-48693 ring (Item 1) [Figure 30-20-44].
Inspect the rpm target disk (Item 1) [Figure 30-20-42] for

wear and replace as needed.

Disassembly And Assembly (Cont'd) 2

1
Figure 30-20-45
1
2
3
P0020
Disassembly: Install the bearing puller (Item 1) [Figure

30-20-46] under the front housing and support the puller
N-18345 and housing with blocks.
Disassembly: Press the shaft (Item 2) [Figure 30-20-46]

Assembly: Install the front housing (Item 1) and bearing
from the housing.
over the shaft. Install the special tool (MEL1562) (Item 2)

[Figure 30-20-45] over the bearing and press the
bearing onto the shaft. Apply 40034 N (9000 lbf) to set
the bearing. Rotate the housing to check for free travel.
NOTE: The 40034 N (9000 lbf), is NOT the amount of

pressure required by the press. It is the
press.
Assembly: Install the split ring (Item 3) [Figure 30-20-

45] and with a feeler gauge measure the distance
between the split ring and the top of the bearing inner
race.
Assembly: Add the necessary washer to get closest to

the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

remove the tool.

Disassembly And Assembly (Cont’d)

2
1
Figure 30-20-47
P0123
Remove and replace the face seal (Item 1) [Figure 30-

20-49] on the front housing.
P0682
NOTE: When installing face seals, apply a layer of
good quality lithium grease to the mating
Disassembly: Use a bearing puller to remove the surfaces of the face seal.
bearing from the shaft [Figure 30-20-47].

Remove and replace the bearing cup (Item 2) [Figure
NOTE: The bearing will be destroyed during the 30-20-49] on the front housing.
removal procedure. Be sure to have a new
bearing on hand before removing the old NOTE: The bearing cup in the housing may be loose
bearing. after installation. The bearing cup will tighten
in its bore after the motor is completely
Figure 30-20-48 assembled.
Figure 30-20-50
2 1
P13083
P0122
Assembly: Remove and replace the face seal (Item 1)
[Figure 30-20-48] from the shaft.
Remove and inspect the bearing (Item 1) [Figure 30-20-
Assembly: Install a new bearing (Item 2) [Figure 30-20- 50] located in the front housing.
48] onto the shaft.
Replace the bearing if worn or damaged.

HYDROSTATIC DRIVE MOTOR (SIX TRACK
Figure 30-20-51
1
3
P0126
Remove the shaft seal (Item 1) [Figure 30-20-51].

Replace the outer O-ring and inner shaft seal (Item 2)
[Figure 30-20-51].
Remove the bearing cup (Item 3) [Figure 30-20-51] if it

needs replacement.
Figure 30-20-52
3/4
Full
Range
1/2
P-24562
Fill housing with synthetic Mobilgear SHC XMP 150 to

[Figure 30-20-52] 1/2 to 3/4 full.

plug.


HYDROSTATIC DRIVE MOTOR (EIGHT TRACK
SPROCKET NUTS)
Description

pump. Machines equipped with SJC / SCPA are
monitored by a sensor mounted onto the hydrostatic
pump. The sensor is used for detection of motion and for
rate of speed for the SJC / SCPA options.

pressure release braking system. In addition there is a
separate fluid chamber in the motor that is filled with high
performance synthetic fluid for maximum durability, this
fluid has a recommended service interval. (See
SERVICE SCHEDULE on Page 10-70-1.)


HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET Removing And Replacing Fluid
NUTS) (CONT’D)
The loader specifications can be different based on drive Park the loader so that the plug in the hydrostatic drive
motor configurations. Look at the drive motor and motor is at the bottom.
specification section is correct for your model. Remove the plug and let the fluid drain from the
Figure 30-21-1
Figure 30-21-2

P121537A
P100737A
These drive motor and sprocket assemblies have eight

nuts (Item 1) [Figure 30-21-1]. Rotate the hydrostatic drive motor so that the plug (Item
1) [Figure 30-21-2] is at the top. Add high performance
synthetic fluid (P/N 7024981). (See Capacities on Page
SPEC-10-5.)
NOTE: Earlier and later drive motors use different

fluids that are not compatible. The drive
used.

plug.


HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET Remove the track. (See Track Removal And Installation
NUTS) (CONT’D) on Page 40-20-4.)
IMPORTANT 1

clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888

10-10-1.) P100811
Remove the mounting bolts (Item 1) [Figure 30-21-3]

DANGER from the access cover and remove the cover from the
loader.

Installation (Single Speed) on Page 40-20-12.)
P-90328
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598


HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET Figure 30-21-5
NUTS) (CONT’D)
Figure 30-21-4 2 3
5 4 1
3
P100901
1 2
Installation: Install both flanges and tighten the bolts to
half of the required torque in the sequence shown in
4 [Figure 30-21-5]. Retighten all bolts 48 - 54 N•m (35 - 40
P109063
ft-lb) torque in the same sequence.
Disconnect the hydraulic hose (Item 1) [Figure 30-21-4] Figure 30-21-6

that goes to the two-speed port on the two-speed / brake
block.
1
Disconnect the hydraulic hose (Item 2) [Figure 30-21-4] 1
that goes to the drain manifold.
Disconnect the hydraulic hose (Item 3) [Figure 30-21-4]

that goes to the two-speed port on the two-speed / brake
block.
Remove the eight flange bolts (Item 4) from the main

drive hoses. Remove the flanges and drive hoses (Item
5) [Figure 30-21-4].
Installation: Fill the main drive hose ports on the motor P-85991
with new hydraulic fluid before installing the drive hoses.
Remove the ten hydrostatic motor mounting bolts (Item

1) [Figure 30-21-6].
Installation: Tighten the motor mounting bolts to 258

Remove the hydrostatic motor from the loader.

HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET NUTS) (CONT’D)
10
9
8
65 7
6
5
4
3
12
2 23
11 22
65
21
10

1 20
14
40
39
17
18
38
13 36 37
15 41
16
36
19 42
16 29 42
15 35 30
31
43
34 64
24 32 44 36
25 33
26 31
28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56

HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET NUTS) (CONT’D)
Parts Identification (Cont’d)
REF. DESCRIPTION REF. DESCRIPTION

1. Plug 34. Bolt
2. Shaft 35. Bolt
3. Seal 36. Pin
4. Bearing 37. Washer
5. Housing / Front 38. Bolt
6. Seal 39. Disc / Outer
7. Bearing 40. Disc / Inner
8. Washer 41. Bushing
9. Split Rings 42. Shim
10. O-ring 43. Housing / Brake
11. Nut 44. Shaft
12. Stud 45. O-ring
13. Rpm Target Disc 46. Bolt
14. Roll Pin 47. Cover Plate
15. Snap Ring 48. Gasket
16. Retainer 49. Pin

17. Roller 50. Seal
18. Piston 51. Clip
19. Block 52. Spring
20. Cam 53. Spool
21. Distributor 54. Plug
22. Spring 55. Housing / Rear
23. Seal W / O-ring 56. Seal
24. Plug 57. O-ring
25. O-ring 58. Snap Ring
26. Spring 59. Piston
27. Shim 60. Seal
28. Poppet 61. Disc Spring
29. Plug 62. Gasket
30. O-ring 63. Cover Plate
31. Spring 64. Bolt
32. Washer 65. Plug
33. Spool

HYDROSTATIC MOTOR (EIGHT TRACK SPROCKET Assembly: Replace the gasket and torque bolts to 35 -
NUTS) (CONT’D) 39 N•m (26 - 29 ft-lb).
Disassembly And Assembly Figure 30-21-9
Figure 30-21-7
N-18296
P100869
Remove the disc spring (Item 1) [Figure 30-21-9] from
the brake housing.
NOTE: Mark the motor, brake and motor housings for

proper alignment during assembly [Figure 30- NOTE: Mark the top side of the disc spring for proper
21-7]. installation.
Drain the fluid from the motor casing. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Inspect for the vendor motor serial number (Item 1)
when ordering replacement parts.
Figure 30-21-8
P100799
Remove the mounting bolts (Item 1) and the brake cover

plate (Item 2) [Figure 30-21-8].
NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

NUTS) (CONT’D)
Figure 30-21-10
1
2
P100868
1 Inspect the piston surface (Item 1) and the bushing

surface (Item 2) [Figure 30-21-12] in the brake shaft.
P100804
NOTE: The bushing (Item 2) [Figure 30-21-12] can be
replaced in the brake shaft. When the bushing
Remove the piston from the brake housing [Figure 30- is replaced, install the bushing flush with the

21-10]. top of the brake shaft.
NOTE: The use of air pressure through the brake line

connection (Item 1) [Figure 30-21-10] will aid
in piston removal.
Figure 30-21-11
2
P100801
Inspect the brake piston (Item 1) [Figure 30-21-11] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-21-11].
Assembly: Apply oil to the seal (Item 2) [Figure 30-21-

11] for added protection when installing the brake piston.

NUTS) (CONT’D)
Figure 30-21-13
N-18347
3
2
Assembly: Clamp the disc pack in a vise and measure
the disc pack height [Figure 30-21-14].
1 P100866
Assembly: The correct disc pack reference
specifications is 37,7 mm (1.48 in).
Remove the five mounting bolts (Item 1) [Figure 30-21-

13] and washers from the brake housing. Assembly: Extra outer disc's (Item 2) are used to reduce
the number of required shims (Item 3) [Figure 30-21-16]
Remove the brake housing (Item 2) [Figure 30-21-13] to make up the required thickness for the brake pack.
NOTE: Brake pack height is for reference only.
Remove the snap ring and inner piston seal (Item 3)
[Figure 30-21-13]. Figure 30-21-15
NOTE: Install seal with metal case end towards the

brake pack.
Assembly: Use the reference marks to install the brake

housing on the rear housing.
Assembly: Install new washers on the brake housing 1

mount bolts (Item 1) [Figure 30-21-13].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
P100867
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)
torque.
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-21-15]. Outer discs can also be used as
shims.

NUTS) (CONT’D)
Figure 30-21-16
1
2
3
P100858
1 Disassembly: Remove the brake discs (Item 1) [Figure

30-21-18] and shims from the brake shaft.
P100805
Figure 30-21-19
Assembly: Assemble the brake discs into a pack making
sure the inner discs (Item 1), alternate with the outer disc
(Item 2) and an outer disc is placed at each end of the

disc pack with the shims (Item 3) [Figure 30-21-16] and
the base of the pack.
1
Figure 30-21-17
2
2
P100859
Remove the brake shaft (Item 1) [Figure 30-21-19] from

the rear housing.
3
P100800 NOTE: Be sure shaft seats fully into the cylinder
block.
Assembly: Assemble the brake piston into the brake
housing without the inner brake piston seal (Item 3) Assembly: Install new O-ring (Item 2) [Figure 30-21-19]
[Figure 30-21-13] and brake piston outer seal (Item 2) on the rear housing.
[Figure 30-21-11]. Apply 20 kN (4500 lbf) to set the
brake pack. Using a depth gauge (Item 1), measure from
the gasket mating surface (Item 2) to the inner machined
groove (Item 3) on the brake piston [Figure 30-21-17].
The dimensional measurement must be 8,7 ± 0,1 mm
(0.343 ± 0.003 in), if not adjust brake pack discs to the
required measurement.
NOTE: The 20 kN (4500 lbf) is NOT the amount of
press.

NUTS) (CONT’D)
Figure 30-21-20
P100872
Remove the plug (Item 1) [Figure 30-21-22] from the

rear housing.
P100870
Figure 30-21-23
Remove the two-speed spool assembly (Item 1) [Figure

30-21-20] from the rear housing.
Figure 30-21-21
1 2
P100871
2
4
3 Remove the spool (Item 1) [Figure 30-21-23].
N-22501 Assembly: Install new O-ring (Item 2) [Figure 30-21-23]

on the plug and torque to 50 N•m (37 ft-lb)
Inspect the two-speed spool (Item 1), the spring (Item 2),
washer (Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-21].
NOTE: If the two-speed spool (Item 1) [Figure 30-21-

21] is damaged the entire rear housing
assembly has to be replaced.
The two-speed spool (Item 1) [Figure 30-21-

21] has an internal make-up spool, which is
not serviceable. The spool will be damaged if
disassembled.

NUTS) (CONT’D)

1
Figure 30-21-24 1 1
1
2 4 3
1 1
1
2 2
P100861
Remove the ten mounting bolts (Item 1) [Figure 30-21-

25] from the rear housing.
N-22504
Remove the two (8 mm) cam ring mount bolts (Item 2)
[Figure 30-21-25].
Remove the spring (Item 1), washer (Item 2) and rear
spring (Item 3) from the spool (Item 4) [Figure 30-21-24].

Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Inspect all parts and replace as needed.
Assembly: Clean the threads on the bolts and front
housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-25] to 210 - 220 N•m
(154 - 162 ft-lb) torque. Clean the threads on the two (8
mm) bolts (Item 2) [Figure 30-21-25] and the cam ring.
Apply Loctite® #243 and tighten the bolts to 70 - 77 N•m
(52 - 57 ft-lb).

NUTS) (CONT’D)
Figure 30-21-26
1
P100856
Remove the springs from the distributor (Item 1) [Figure

30-21-28].
P100860
Remove and replace with a new O-ring (Item 1) [Figure Assembly: Apply a small amount of grease to the
springs to hold them in place during installation.

30-21-26].
Remove the distributor (Item 2) [Figure 30-21-26] from Figure 30-21-29

the rear housing.
Assembly: Install the distributor (Item 2) [Figure 30-21-

26] by using the alignment pin.
Figure 30-21-27
2 1
P100855
Remove the six seals (Item 1), and six back-up rings
(Item 2) [Figure 30-21-29] from the distributor.
2
N-18318
Remove the seal and back-up ring (Item 1) [Figure 30-

21-27] under the seal, from the rear housing.

and seals (Item 1) [Figure 30-21-27].
Remove and inspect the stop pin (Item 2) [Figure 30-21-

27].

NUTS) (CONT’D)
Figure 30-21-30
P100873
1

plug. Torque to 60 N•m (44 ft-lb).
P100812
Figure 30-21-33
Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor (Item 2)

[Figure 30-21-30].
When the distributor is aligned correctly, the distributor

1
can be depressed slightly by hand and will return to its
original position.
Figure 30-21-31
1
P100875
P100874
Remove the drain plug (Item 1) [Figure 30-21-31].

NUTS) (CONT’D)

1
Figure 30-21-34
4
1
3
2
P100924

36] from the front housing assembly.
N-18314
Assembly: Slightly smear the O-ring (Item 1) [Figure
30-21-36] with grease to hold in place.
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-21-34].

Remove the rotating group (Item 2) [Figure 30-21-36]
from the front housing assembly.
Figure 30-21-37
Install a new O-ring (Item 4) [Figure 30-21-34] on the
plug. Torque to 25 N•m (18 ft-lb)
Figure 30-21-35
2
1
1
P-48690

P100925 the bottom side of the rotating group.
Remove the cam ring (Item 1) [Figure 30-21-35] from the

front housing assembly.
Inspect the cam ring inside surface for wear and

scratches.
Assembly: Align the marks (Item 2) [Figure 30-21-35]

on the cam rings to the front housing.

NUTS) (CONT’D)
Figure 30-21-38
P100927
The retainer ring (Item 1) [Figure 30-21-40] cannot be

1
removed from the top side of the rotating group, because
P-48691 the rpm target disc is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-21-38] from Figure 30-21-41

Figure 30-21-39
2
1
P100928
P100926 Lift the retaining ring (Item 1) [Figure 30-21-41].
Use low air pressure and remove the roller / piston

Remove the snap ring (Item 1) [Figure 30-21-39] from assembly (Item 2) [Figure 30-21-41] from the cylinder
the top side of the rotating group. block.
NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-21-41] in oil and put all roller /
piston assembles back in the original bore.

30-21-41] is not a serviceable part.

NUTS) (CONT’D)

2
Figure 30-21-42
1
P100932
Assembly: Install the front housing (Item 1) and bearing

over the shaft. Install the special tool (MEL1562) (Item 2)
P100929 [Figure 30-21-44] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
bearing. Rotate the housing to inspect for free travel.
Disassembly: Remove the fluid fill plug (Item 1) [Figure
30-21-42] from the housing to drain the fluid from the NOTE: The 40 kN (9000 lbf) is NOT the amount of

bearing and face seal area. pressure required by the press. It is the
Clean the threads of the plug and drain hole. Apply press.
plug.
44] and with a feeler gauge measure the distance
between the split ring and the top of the bearing inner
Figure 30-21-43
race.
Assembly: Add the necessary preload washer to get

closest to the measurement and re install the split ring.
Assembly: Release the pressure from the bearing and

1 remove the tool.
P100931
Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split
ring (Item 1) [Figure 30-21-43].

HYDROSTATIC MOTOR (TWO-SPEED) (EIGHT Figure 30-21-47
TRACK SPROCKET NUTS) (CONT’D)
Figure 30-21-45
2
1
2
P13083

[Figure 30-21-47] from the shaft.
P100934
Assembly: Install a new bearing (Item 2) [Figure 30-21-
47] onto the shaft.
Disassembly: Install the bearing puller (Item 1) [Figure
30-21-45] under the front housing and support the puller

Figure 30-21-48
and housing with blocks.
Disassembly: Press the shaft (Item 2) [Figure 30-21-45] 1

from the housing.
Figure 30-21-46
P100941
Remove and inspect the bearing (Item 1) [Figure 30-21-

48] located in the front housing.
P0682 Replace the bearing and bearing cup if worn or

damaged.
Disassembly: Use a bearing puller to remove the

bearing from the shaft [Figure 30-21-46].
NOTE: The bearing will become unserviceable during

the removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.

HYDROSTATIC MOTOR (TWO-SPEED) (EIGHT Figure 30-21-50
TRACK SPROCKET NUTS) (CONT’D)
Figure 30-21-49 2 1
2
1
P100940
Remove the shaft seal (Item 1) [Figure 30-21-50].
P100939 Remove the bearing cup (Item 2) [Figure 30-21-50] if it

needs replacement.
Remove and replace the face seal (Item 1) [Figure 30- Figure 30-21-51

21-49] on the front housing.
NOTE: When installing face seals, apply a layer of

good quality lithium grease to the mating
surfaces of the face seal. 1
Remove and replace the bearing cup (Item 2) [Figure

30-21-49] on the front housing.
NOTE: The bearing cup in the housing may be loose

after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.
P100930
Rotate the hydrostatic drive motor so that the drain plug

(Item 1) [Figure 30-21-51] is at the top. Fill housing with
180 mL (6.1 U.S. fl oz) high performance synthetic fluid
(P/N 7024981).

plug.


HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK
SPROCKET BOLTS)
Description

pump.

pressure release braking system to stop the loader. In
addition there is a separate fluid chamber in the motor
that is filled with high performance synthetic fluid for
maximum durability, this fluid has a recommended
service interval. (See SERVICE SCHEDULE on Page 10-
70-1.)


HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK Removing And Replacing Fluid
SPROCKET BOLTS) (CONT’D)
The loader specifications can be different based on drive Figure 30-22-2

motor configurations. Look at the drive motor and
specification section is correct for your model.
Figure 30-22-1
P115456A
1 Rotate the hydrostatic drive motor so that the plugs (Item

1) [Figure 30-22-2] are at the top and the bottom. Add
P115456B high performance synthetic fluid (P/N 7270874). (See
Capacities on Page SPEC-10-5.)
This drive motor and sprocket assembly has sixteen bolts NOTE: Earlier and later drive motors use different
(Item 1) [Figure 30-22-1]. fluids that are not compatible. The drive
used.
Remove the plug and let the fluid drain from the

plug.


HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK Remove the track. (See Track Removal And Installation
SPROCKET BOLTS) (CONT’D) on Page 40-22-6.) or (See Track Removal And
Figure 30-22-3
1
IMPORTANT
damage the system.
I-2003-0888 1

10-10-1.)
P131052
DANGER Figure 30-22-4

1
P-90328
AVOID DEATH
P131053
support. Replace if damaged. Remove the mounting bolts (Item 1) [Figure 30-22-3]
D-1009-0409
and (Item 1) [Figure 30-22-4] from the access cover and
remove the cover from the loader.

WARNING Installation (Sixteen Bolt Sprocket) on Page 40-22-14.)
OR (See Sprocket Removal And Installation (Sixteen Bolt
Sprocket) on Page 40-23-15.)
W-2059-0598


HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK Figure 30-22-6
Removal And Installation (Cont'd) 1
Figure 30-22-5
1
1
1
P131056

3
2 Remove the ten motor mounting bolts (Item 1) [Figure
P131054 30-22-6].
Remove the hoses (Item 1) and (Item 2) [Figure 30-22-5] Installation: Tighten the motor mounting bolts to 258

from the motor. N•m (190 ft-lb) torque.
NOTE: The two-speed model will have another hose Remove the hydrostatic motor from the loader.
at the (Item 3) [Figure 30-22-5] location.
Installation: Fill the main drive hose ports (Item 2)

[Figure 30-22-5] on the motor with new hydraulic fluid
before installing the drive hoses.

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK SPROCKET BOLTS) (CONT'D)
Parts Identification (Single Speed)
REF. DESCRIPTION 4
1. Shaft 7
2. Case, Front
3. Washer
4. Bearing 1
5. Plug
17
6. Split Ring
15
7. Seal 5
8. Block, Cyl 23
9. Roller 10
10. Piston 17
19
11. Ring 17
12. Cam*
13. Case, Rear 10
14. Distributor 17
15. Spring 17
16 12

16. C-clip
17. O-ring 21 11
18. Spool 22 17 16
19. Pin 7 9
20. Screw 24 10
21. Spacer 16
22. Brake Pack 11
23. Kantseal 6
24. Retainer 3
7 4
25. Shim
26. Poppet 2 17 8
20
17
19
17
20
5
13 17
15
3
5 15 18
14 17 5
7 26
7 25
7 15
7 17
7 5
15
NA8800S

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK SPROCKET BOLTS) (CONT'D)
Parts Identification (MCR6T) (Two-Speed)
REF. DESCRIPTION 4
1. Shaft 7
2. Case, Front
3. Washer
4. Bearing 1
5. Plug
17
6. Split
5 15
7. Seal
24
8. Block
10
9. Roller 17
10. Piston 20
11. Ring 17
12. Cam*
13. Case, Rear 10
14. Distributor 17 17
15. Spring 16 12

16. Circlip 19 11
17. O-ring 17 16
23 9
18. Spool
7
19. Spacer 10
25 16
20. Pin
11
21. Cap, 2-speed
22. Screw 6
3
23. Brake Pack S/a 4
7
24. Kantseal 8
17
25. Retainer
20 2
26. Shim
27. Poppet 17
22 17 5
7
5
17
13 15
3
5 15 18
17 5
27
16 26
16 21 15
17
3 17 5
14 18 15
7
7
7
7
7
15 7
NA8801S

SPROCKET BOLTS) (CONT'D)
2 1
Figure 30-22-7
1
2
P115628
Check for the vendor motor serial number (Item 1)

when ordering replacement parts.
P115626
Remove the nine rear housing mounting bolts (Item 2)

Remove zero leak plugs (Item 1) [Figure 30-22-7] from [Figure 30-22-9].

the front case.
Assembly: Apply Loctite® 542 to the mounting bolts
Rotate motor with front case face down to drain the fluid (Item 2) [Figure 30-22-9], install and tighten to 257- 267
from the motor casing. N•m (190 - 197 ft-lb) torque.
Assembly: Tighten the plugs to 20 N•m (15 ft-lb) torque. Figure 30-22-10
NOTE: After installing the motor, and before installing 1

the plugs, add hydraulic fluid (See Removing
And Replacing Fluid on Page 30-22-2.).
Figure 30-22-8 2
P115629
Lift the rear housing assembly (Item 1) [Figure 30-22-10]

from the motor and place to the side. (See Rear Housing
Disassembly and Assembly on Page 30-22-14.)
P115627 Lift cam ring and cylinder block assembly (Item 2) from
the front case / shaft assembly (Item 3) [Figure 30-22-
10] and place to the side. (See Cylinder Block
NOTE: Mark the motor (Item 1) [Figure 30-22-8], brake Disassembly and Assembly on Page 30-22-13.)
and motor housings for proper alignment
during assembly. Assembly: Remove and replace the gaskets. Position
the cam ring and cylinder block assembly on the front
housing. Position the rear housing on the cam ring. Align
using the reference marks (Item 1) [Figure 30-22-8].


1
Figure 30-22-11
2
2
P115697

[Figure 30-22-13] on the front shaft housing. (See Face
P115630 Seal Installation on Page 30-22-9.)
Assembly: Remove and install a new bearing (Item 2)

Remove the split ring (Item 1). Using a blunt screw driver, [Figure 30-22-13] onto the shaft, if required.
place in the gap between the two halves of the split ring

and use a hammer to provide impulse. Lift off the Figure 30-22-14
abutment washer (Item 2) [Figure 30-22-11].
Figure 30-22-12 1
2
1
3
2
P121048
2
P115696 Assembly: Install the front housing (Item 1) and bearing
over the shaft. Install the special tool (MEL1612-T550)
(Item 2) [Figure 30-22-14] over the bearing and press
Position the motor, using a crane, with the front shaft/ the bearing onto the shaft. Apply 40 kN (9000 lbf) to set
housing (Item 1) facing up and the front case mounting the bearing. Rotate the housing to check for free travel.
flanges (Item 2) [Figure 30-22-12] resting on the
supports of a mounting jig. NOTE: The 40 kN (9000 lbf) is NOT the amount of
Press the shaft / housing (Item 1) out of the front case amount of downward force applied by the
(Item 2) [Figure 30-22-12] using a hydraulic press. Move press.
the front case and brake pack assembly to the side.
Move both the front shaft housing and the front case back 14] and with a feeler gauge measure the distance
to the bench. (See Front Case Disassembly and between the split ring and the top of the bearing inner
Assembly on Page 30-22-11.) race.

Assembly: Add the necessary washer to get closest to

the measurement and reinstall the split ring. Release the
pressure from the bearing and remove the tool (Item 2)
[Figure 30-22-14].
Face Seal Installation
Figure 30-22-15
B-14493
2
1 Shake off the excess alcohol and install the seal ring
assembly on the motor [Figure 30-22-16].
NOTE: Apply a thin layer of hydraulic fluid to the

mating surface of the face seals.

NOTE: Do not get any hydraulic fluid on the rubber O-
ring.
B-14496 Figure 30-22-17
Install the O-ring (Item 1) on the seal ring (Item 2)

[Figure 30-22-15].
NOTE: Inspect the seal ring and motor housing for

burrs before installing the O-ring. Install the
O-ring making sure it is not twisted. To
remove any twists, gently pull a section of the
O-ring and let it snap back.
The O-ring, seal ring and motor assembly must be clean

and free of any dust, oil film or foreign matter.
NOTE: When installing the face seals, lubricate with

B-14494
alcohol and press down into place evenly to
avoid twisting. A flat surface ring, or a tool,
may be used to pop the O-ring into place. Remove the seal installation tool. Inspect the assembled
height at four places 90 degrees apart. The assembled
heights should be the same [Figure 30-22-17].
If the assembled heights are not the same, check the O-

ring for twists.


2
Brake Pack Disassembly and Assembly
Figure 30-22-18
1
1
P121049
Assembly: Align the outer tabs of the brake pack discs

(Item 1) to fit into the slots in the case (Item 2) [Figure
30-22-20].
P115698 NOTE: The brake pack assembly is to be replaced as

a complete assembly.

Remove the eight mounting bolts (Item 1) [Figure 30-22- NOTE: The thicker shims or any extra inner discs are
18] and washers from the brake pack assembly. to be located against the brake retainer (Item
1) [Figure 30-22-19].
Assembly: Apply a Loctite® 542 to the bolts and install
bolts and washers into the rear housing. Start each bolt
by hand, tighten opposite bolts to maintain squareness.
Assembly: Tighten bolts to 35 - 39 N•m (26 - 29 ft-lb).

torque.
Figure 30-22-19
3 2 1
P115700
Remove the brake retainer (Item 1), brake pack (Item 2)

and brake spacer (Item 3) [Figure 30-22-19] from the
front case.

Front Case Disassembly and Assembly
Disassemble the motor. (See Disassembly And

Assembly on Page 30-22-7.)
3
Figure 30-22-21
1 2
2 1
P115699
Assembly: Remove and replace the O-ring (Item 1) and

outer seal (Item 2) [Figure 30-22-23] on the rear side of
the front case.
Assembly: Remove and replace the bearing cup (Item 3)

[Figure 30-22-23] on the front case, if required.

P115698 Figure 30-22-24
Move the front case assembly (Item 1) to an assembly 1

bench. Remove the brake pack assembly (Item 2) 1
[Figure 30-22-21]. (See Brake Pack Disassembly and
Figure 30-22-22
3
1
1
P115702
Locate the three holes (Item 1) [Figure 30-22-24] in the

bottom of the front case. Remove the piston from the
2 front case using a blunt tool on the inside of the piston.
P115701

[Figure 30-22-22] on the front case assembly. (See Face
Seal Installation on Page 30-22-9.)
Remove the spiral C-clip (Item 2) and shaft seal (Item 3)

[Figure 30-22-22].

3 4
2
Front Case Disassembly and Assembly (Cont’d)
1
Figure 30-22-25
4
3
1
P115703
2
Remove the piston assembly and disk spring (Item 1)

[Figure 30-22-26] from the brake housing.
NOTE: Mark the top side of the disk spring for proper
P121050 installation. The inside edge of the spring is to
face upwards and contact the piston.

Assembly: Install the brake piston assembly (Item 1) Assembly: Check the brake piston for damage, including
with push-pins (Item 2) facing upwards as shown. Apply the inside surface. Replace the inner and outer seals on
hydraulic fluid to the inner and outer seals (Item 3) the piston (Item 2) [Figure 30-22-26].
[Figure 30-22-25] prior to assembly.
Assembly: Replace the inner and outer seals on the
NOTE: Install the new shaft seal (Item 4) [Figure 30- piston seal ring (Item 3) and the seals on the three step
22-25] with the metal case end towards the pins (Item 4) [Figure 30-22-26].
brake pack. Apply grease to the lip of the seal.

Cylinder Block Disassembly and Assembly
Disassemble the motor. (See Disassembly And

Figure 30-22-27
1
1
2
P115705
Remove the snap rings (Item 1) and retainer rings (Item

2) [Figure 30-22-29] from the top and bottom sides of the
rotating group.
Figure 30-22-30

P115627
Move the cylinder block assembly and cam ring (Item 1)

[Figure 30-22-27] to an assembly bench.
Figure 30-22-28
2 1
P115711
3
Use low air pressure and remove the roller / piston

assembly (Item 1) from the cylinder block (Item 2)
[Figure 30-22-30].
NOTE: Soak the roller / piston assembles (Item 1)

2 [Figure 30-22-30] in oil and put all roller /
P115704 piston assembles back in the original bore.

Check the cam ring inside surface (Item 1) for wear and 30-22-30] is not a serviceable part.
scratches.

28] from the cam.
Assembly: Slightly smear the O-ring with grease to hold

in place.
Remove the rotating group (Item 3) [Figure 30-22-28].

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK Place one edge of the rear housing assembly on a solid
SPROCKET BOLTS) (CONT'D) surface to as to expose the distributor on the bottom.
Place a narrow blunt object into the distributor stop pin-
Disassembly And Assembly (Cont'd) hole (Item 1) to remove the distributor (Item 2) [Figure
30-22-32].
Rear Housing Disassembly and Assembly
Remove and replace the seals and back-up rings in the
Disassemble the motor. (See Disassembly And rear housing (Item 3) [Figure 30-22-32].
Move the rear housing (Item 1) [Figure 30-22-31] to an and seals.
assembly bench.
Assembly: Install the distributor (Item 2) using the
Figure 30-22-31 alignment pin to align the hole in the rear housing (Item
1) and the hole in the distributor (Item 4) [Figure 30-22-
2 32].
NOTE: When the distributor is aligned correctly, the

distributor can be depressed slightly by hand
1 and will return to its original position.
Figure 30-22-33

2 3
1 1
P115709
Remove the distributor stop pin (Item 2) [Figure 30-22-

31] from the rear housing and inspect for damage.
Assembly: Replace the stop pin, if needed, and tighten 3

P115708
Figure 30-22-32
Remove the springs (Item 1) from the distributor (Item 2)
[Figure 30-22-33].
2
1 Remove and replace the O-rings (Item 3) [Figure 30-22-
33] on the distributor.
Assembly: Apply a small amount of grease to the

springs and position the rear housing to ensure the
springs stay in place during assembly.
4
3
P115706

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK Flushing Plug Disassembly and Assembly
Figure 30-22-36
Two-Speed Spool (optional) Disassembly and Assembly
Figure 30-22-34 1
P115709
Remove the flushing plug (Item 1) [Figure 30-22-36]

P115707
Assembly: Install the plug (Item 1) [Figure 30-22-36]

and tighten to 40 N•m (30 ft-lb) torque.
Remove the distributor (Item 1) [Figure 30-22-34] from
the rear housing assembly. (See Rear Housing Figure 30-22-37
Disassembly and Assembly on Page 30-22-14.)
Remove the C-clip (Item 2) from the top of the distributor.
Figure 30-22-35
4
3
2
5 1
3 1
2
P115809
Remove the outer spring (Item 1), shim washer (Item 2),
spool (Item 3), and inner spring (Item 4) [Figure 30-22-
P115710 37].
NOTE: Replace the O-ring (Item 5) on the plug, the

Remove the cap (Item 1), spool (Item 2), and rear spring springs (Item 1 and Item 4), and the washer
(Item 3) [Figure 30-22-35]. (Item 2) [Figure 30-22-37].
NOTE: Use a blunt tool to push on the piston and cap Inspect the spool and replace, if damaged.
assembly through a hole in the bottom of the
distributor. Assembly: Sub-assemble the inner spring (Item 4),
spool (Item 3), washer (Item 2), and outer spring (Item 1)
Inspect all parts and replace as needed. [Figure 30-22-37] and install into the rear housing.

HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK
Flushing Plug Disassembly and Assembly (Cont’d)
Figure 30-22-38
P115709

Remove the poppet plug (Item 1) [Figure 30-22-38] from
the rear housing.
Assembly: Install the plug and tighten to 25 N•m (18 ft-

lb) torque.
Figure 30-22-39
2
1
4
P115810
Remove the spring (Item 1), shim washer (Item 2), and
poppet (Item 3) [Figure 30-22-39].
Install a new O-ring (Item 4) [Figure 30-22-39] on the

plug before installation.

CHARGE PRESSURE Testing
Description Figure 30-30-1
Charge pressure is a supply of fluid to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
2 4
hydraulic control valve. 1 3
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to test charge pressure, hydraulic hose
(Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic gauge
6895 kPa (69,0 bar) (1000 psi) (Item 3), adapter fitting (P/
N 93F-5) (Item 4) [Figure 30-30-1] and MEL1563 or

7217666 Remote Start Tool Kit.
Figure 30-30-2
3
2
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-30-2].
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to

the adapter fitting. Tighten all connections.

CHARGE PRESSURE (CONT’D) Figure 30-30-4
Testing (Cont’d)
WARNING
1
to fall and cause injury or death. 2
W-2059-0598 3
P-90301
Raise the loader lift arms and install an approved lift arm
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].
10-10-1.) Install the hose (Item 2) [Figure 30-30-4], that was
disconnected from the motor, to the T fitting.
Install the hose (Item 3) [Figure 30-30-4], that is

Figure 30-30-3 attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings.

7217666 on Page 10-61-1.)
Start the loader and warm the hydraulic fluid to 140° F.
1 On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2688 - 3378 kPa (26,8 - 33,8 bar) (390 - 490 psi) with the
pump in neutral.
P-90302
NOTE: If the machine is equipped with SJC option
the charge pressure should be set at 2930 -
Disconnect the hydraulic hose (Item 1) [Figure 30-30-3]. 3620 kPa (29,3 - 36,2 bar) (425 - 525 psi) at
60°C (140°F) fluid @ High idle.

CHARGE PRESSURE (CONT’D) Sender Removal And Installation (Later Models)
Sender Removal And Installation (Earlier Models) Figure 30-30-6
Figure 30-30-5
2
2 1
P115656
P-90302
Disconnect the wiring harness (Item 1) and remove the
hydraulic charge pressure sender (Item 2) [Figure 30-30-
Disconnect the wire (Item 1) [Figure 30-30-5] from the 6].
sender.

Installation: Tighten the charge pressure sender to 10 -
Remove the sender (Item 2) [Figure 30-30-5] from the 10,9 N•m (7.4 - 8.1 ft-lb) torque.
motor.
NOTE: Replace the O-ring on the sender before
Installation: Tighten the charge pressure sender to 10 - installation.
10,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Replace the O-ring on the sender before

installation.

Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-30-7 Remove the plug, spring and poppet [Figure 30-30-8].
Inspect the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-30-9

P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-7].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item 1)
[Figure 30-30-9] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55,2 kPa

(0,6 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2688 - 3378 kPa (26,8 - 33,8 bar) (390 - 490 psi) with the
pump in neutral.

Adjusting (Cont’d)
SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
P-64435
I-2003-0888
Figure 30-30-10 Inspect the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-30-11] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim (Item 1) [Figure 30-30-11] = 300,0

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2930 - 3620 kPa

(29,3 - 36,2 bar) (425 - 525 psi) at 60°C (140°F) fluid @
P-64431 High idle.
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-10].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.


HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-14.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See Belt Replacement on Page 1

30-50-2.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-40-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-40-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-40-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-40-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two mounting nuts and bolts (Item 1) [Figure
ft-lb) torque 30-40-3].

Remove the hydrostatic pump from drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydraulic Pump
Startup on Page 20-60-8.)

Hydrostatic Pump Startup

1
Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-8.)
Replenishing / High Pressure Relief Valve Removal

And Installation
Figure 30-40-4
P-66670
1
Remove the high pressure relief valve (Item 1) [Figure

30-40-4] and [Figure 30-40-5] from the pump.
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)

torque.

Inspect for damage and replace as needed.
P-43857
There are four replenishing / high pressure relief valves If the high pressure relief valve must be replaced, it must
(Item 1) [Figure 30-40-4] in the hydrostatic pump be replaced as a complete unit.
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function. The pressure setting for a new high pressure relief valve
is 36500 kPa (365 bar) (5294 psi).
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
REF. DESCRIPTION
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)
REF. DESCRIPTION
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

Disassembly
Figure 30-40-6
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-40-8].

P-43858
Remove the large O-ring (Item 2) [Figure 30-40-8].
Remove the four mounting bolts (Item 1) [Figure 30-40- Remove the two small O-rings (Item 3) [Figure 30-40-8].
6].

Figure 30-40-9
Figure 30-40-7
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-40-9] from the

Separate the two hydrostatic pumps [Figure 30-40-7]. pump housing end cap.

2
1
Figure 30-40-10
N-17194
2
Inspect the valve plate locating pin (Item 1) [Figure 30-
N-19551 40-12] for wear and replace if needed.
Inspect the needle bearing (Item 2) [Figure 30-40-12] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
40-10].

Figure 30-40-13
Remove the gasket (Item 2) [Figure 30-40-10].
Figure 30-40-11
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-40-13]

from the pump.
Remove the valve plate (Item 1) [Figure 30-40-11].
Inspect the valve plate for wear. (Both Sides.)

3 3
Figure 30-40-14
1 1
3 2
3
2
N-17200
Inspect the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-40-16] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-40-16] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-40-14] from the cylinder block.

Inspect the cylinder block for wear and replace as
Inspect all the pistons (Item 2) [Figure 30-40-14] for needed.
wear and replace the rotating group as needed.
Inspect pins (Item 3) [Figure 30-40-16] to see if they are
Figure 30-40-15 all the same length.
Figure 30-40-17
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-40-
15] from the cylinder block.
Remove the thrust plate (Item 1) [Figure 30-40-17] from
the pump housing.

Figure 30-40-18
1
1
2
N-17240
3
N-17481 the pump housing and remove the drive shaft and
bearing from the housing.
Remove the drive shaft key (Item 1) the snap ring (Item Figure 30-40-21
2) and the support washer (Item 3) [Figure 30-40-18]

from the drive shaft end of the pump.
Figure 30-40-19
N-17241

N-17239 the drive shaft and remove the bearing.
Inspect the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-40-19] from the pump housing.

Disassembly (Cont’d)
Figure 30-40-22
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-40-24] from the pump housing.
Figure 30-40-25
Inspect the pump shaft (Item 1) [Figure 30-40-22] for
wear and replace if needed.

Figure 30-40-23
N-17245
1 1
Inspect the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-40-25] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-40-23]

from the lower trunnion cover. Remove the cover.

Figure 30-40-26
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-40-28] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-40-29
Inspect the dust seal on the pintle shaft.

Remove the four mount bolts (Item 1) from the pump
housing and remove the linkage bracket (Item 2) [Figure
30-40-26].
Figure 30-40-27
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-29] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-40-

27].

1
Figure 30-40-30
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-40-32] and

N-17249 remove the swash plate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-30] and replace as needed.

Figure 30-40-31
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-40-31] from
the swash plate shaft.

Assembly
Figure 30-40-33
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-35] on

N-17253 the swash plate shaft.
Figure 30-40-36
Install the lower bearing (Item 1) [Figure 30-40-33] on
the swash plate.

Figure 30-40-34
N-17248
Install the bearing race (Item 2) and O-ring (Item 3)

N-17252 [Figure 30-40-35] as shown in [Figure 30-40-36].
Install the swash plate and bearing into the pump

housing [Figure 30-40-34].

Assembly (Cont’d)
Figure 30-40-37
1 N-17245
Figure 30-40-40
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-37]

and cover.

Figure 30-40-38
2
N-17244
1 1 Install the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-39] at the lower trunnion as shown in
[Figure 30-40-40].
N-17246
Install the linkage bracket (Item 2) and the four mounting

bolts (Item 1) [Figure 30-40-38] and tighten to 24 - 30
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-40-41
N-17241
1 1
Install the bearing and snap ring (Item 1) [Figure 30-40-

N-17243 43] on the pump shaft.
Figure 30-40-44
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-41].

Install the four mounting bolts (Item 1) [Figure 30-40-41]
and tighten to 24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-40-42
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-44].
Install the snap ring (Item 1) [Figure 30-40-44].

N-17242
Install the snap ring (Item 1) [Figure 30-40-42] on the

pump shaft.

Assembly (Cont’d)
1
1
Figure 30-40-45
1
1 3
1 2
N-17200
Install the four slipper pins (Item 1) [Figure 30-40-47]

N-17239 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the seal (Item 1) [Figure 30-40-45] into the pump and install into the ball guide retainer (Item 3) [Figure 30-
housing. 40-47].

Figure 30-40-46 Figure 30-40-48
3
2
N-17481 N-17199
Install the washer (Item 1), snap ring (Item 2) and the Install the ball guide retainer and washer (Item 1) [Figure
drive shaft key (Item 3) [Figure 30-40-46]. 30-40-48] onto the slipper holddown pins.

Assembly (Cont’d)
1
2
Figure 30-40-49
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-40-51] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-40-52
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
40-49].
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. 2
1
Figure 30-40-50
N-17196
The bearing cage (Item 1) [Figure 30-40-52] will

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

N-17197 40-52] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-40-50].

Assembly (Cont’d)
1 1
Figure 30-40-53
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-55] to 47 - 61
Coat the backside of the valve plate with petroleum jelly Figure 30-40-56
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-40-53].
The notch (Item 1) [Figure 30-40-53] on the valve plate

must engage the locating pin.
Figure 30-40-54 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-40-56].
Install the large new O-ring (Item 2) [Figure 30-40-56].
N-19551 Install the pump coupler (Item 3) [Figure 30-40-56].
Coat a new end cap gasket (Item 1) [Figure 30-40-54]

with petroleum jelly and install onto the end cap.

Assembly (Cont’d)
Figure 30-40-57
N-19570
Install the two pumps together [Figure 30-40-57].

Figure 30-40-58
1
P-43858
Tighten the four bolts (Item 1) [Figure 30-40-58] to 47 -



HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The end caps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-41-1

P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-41-3] from both sides of the hydrostatic
pump.
Removal:
WARNING

of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-41-2 I-2003-0888
Figure 30-41-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
41-2] on the hydrostatic pumps.
from the hydraulic controller.

HYDROSTATIC PUMP (SJC) (CONT'D) Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
Hydraulic Controller Removal And Installation [Figure 30-41-5].
(Cont'd)
Figure 30-41-7
Figure 30-41-5
1
1 2
3 1
P-90210
P-90210
Alternately tighten bolts (Item 1) [Figure 30-41-7] to 10,4

Remove the controller (Item 1) [Figure 30-41-5] from the N•m (7.7 ft-lb) torque. Ensure bolts are tightened to

pump. specifications.
Remove the controller gaskets (Item 2) [Figure 30-41-5] NOTE: When a hydraulic controller is replaced, the
from the pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Installation: Page 30-41-25.)
1
2 2
P-90209 P-64978
NOTE: Do NOT remove the three screens (Item 2) With the engine running and the loader on jack stands:
[Figure 30-41-6] they will be damaged during Bleed the trapped air in the controller by loosening the
removal and must be replaced. small set screw (Item 1) [Figure 30-41-8] a maximum of
2 turns. Leave the screw loose until fluid comes dripping
Be sure the feedback lever (Item 3) [Figure 30-41-5] is in out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
the center of the servo piston groove (Item 1) [Figure 30- torque.
41-6].
Repeat the bleed procedure for all the solenoids.

HYDROSTATIC PUMP (SJC) (CONT’D) Figure 30-41-10

Page 70-10-14.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See Belt Replacement on Page 1

30-50-2.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-41-10] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-41-9 Remove the pump pulley from the pump drive shaft.
Figure 30-41-11
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-41-9] on the
hydrostatic pump drive shaft.
Remove the two mounting nuts and bolts (Item 1) [Figure
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 30-41-11].
ft-lb) torque
Installation: Tighten the mounting bolts and nuts to 88 -
Remove the hydrostatic pump from the drive belt

housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-41-5.)

HYDROSTATIC PUMP (SJC) (CONT’D)
Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-41-12

1
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-41-12].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic fluid until the hydraulic fluid flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

1. O-ring
2. Bolt 3 1
3. End Housing 4 1
4. Right Rotating Assembly
5. Timing Pin
6. Bearing 6
5
7. Spacer/Coupler 7
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover
13. Hydraulic Controller 9
14. High Pressure Relief 1 8 2
15. Case Housing
16. Plug 1
10
17. Dowel Pin 11
18. Charge Pressure Relief
19. Left Servo 2
20. Right Servo 12
21. Left Rotating Assembly 16 2
22. End Housing 14
2
17

16
15 13
17
13
18 20
14
22 19
5
2 6
21
8
1 1
9
10
11
12
12
2 P-90240

High Pressure Relief And Bypass Valve
Figure 30-41-13
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-41-15]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-15] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-13] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-13].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36500 kPa (365 bar)
Figure 30-41-14 (5294 psi).
4
3
2 1
P-64436
Replace the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-14].
Remove relief valve assembly (Item 3) [Figure 30-41-14]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-41-14] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-41-16 1 4 5
3 6
2
1 P-64435

P-64431
Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-41-17] for damage or foreign material. Ensure
The charge relief valve (Item 1) [Figure 30-41-16] is the poppet moves freely in it’s bore.
located on the back of the hydrostatic pump.

Inspect the sealing ring (Item 4) [Figure 30-41-17] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Assembly: Tighten charge relief valve to 70 N•m (52 ft-
lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-41-17].
NOTE: One shim (Item 6) [Figure 30-41-17] = 296,5

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.

HYDROSTATIC PUMP (SJC) (CONT’D) Note the connectors facing each other.
Disassembly And Assembly Figure 30-41-20

Page 70-10-14.)
1
Remove the hydrostatic pump. (See Removal And
Figure 30-41-18
1
2
P-90228
1 1 Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-41-20].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-41-

18]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.)
Figure 30-41-19
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-41-19].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-41-19] from both sides.
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT’D) Right End Housing
Disassembly And Assembly (Cont'd) Figure 30-41-23
Figure 30-41-21
3
1
1
1
P-64445
P-90217
Left End Housing
Assembly: Note the slotted portion (Item 1) of the Figure 30-41-24

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-41- 3 1
21].
Figure 30-41-22
1
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-41-23] and [Figure 30-41-24].
Assembly: Alternately, tighten mount bolts to 130 N•m

Replace the O-ring (Item 1) [Figure 30-41-22]. (96 ft-lb) torque.

Figure 30-41-25
P-64466
Ensure servo follower (Item 2) [Figure 30-41-26] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-41-27].
Pull the end housings from the case housing [Figure 30- Figure 30-41-28
41-25].

Figure 30-41-26
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-41-28] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-41-26].

Figure 30-41-29
RIGHT SIDE
P-64454
Figure 30-41-30

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-41-29] and

[Figure 30-41-30] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-41-29] and [Figure 30-41-30] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-41-31
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-41-34
P-64455
LEFT SIDE
Figure 30-41-32 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 31] and [Figure 30-41-32] in the case housing with the
notch (Item 1) [Figure 30-41-33] and [Figure 30-41-34]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-41-31] and [Figure 30-41-32] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-33] and [Figure
30-41-34].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

Figure 30-41-35
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-37].

B25012
Figure 30-41-38
Right Side Rotating Group [Figure 30-41-35].

Figure 30-41-36
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-38] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-36].


1
Figure 30-41-39
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 41].
Figure 30-41-42
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-41-39] in the slippers, are not
1

plugged.
Figure 30-41-40
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-42]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-41-40].


3
Figure 30-41-43
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-41-45].
Remove the swash plate from the end cap housing (Item
Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-41-45].
1) [Figure 30-41-43].

Remove the slide ring (Item 3) [Figure 30-41-45], ensure
Figure 30-41-44 it pivots freely.
Figure 30-41-46
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-44] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in end cap housing (Item 2) [Figure 30-41-46].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-41-44] are not bent or damaged.


1 1
Figure 30-41-47
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 49].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-49] on them. The edges face towards
swash plate (Item 1) [Figure 30-41-47]. the outside of the end cap housing

Figure 30-41-48 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-41-49].

2
Figure 30-41-50
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-48].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-41-48] on swash plate.
Replace O-ring (Item 1) [Figure 30-41-50].
Inspect wear surfaces (Item 2) [Figure 30-41-50] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-41-51
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-41-53] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-41-54
Figure 30-41-52
RIGHT SIDE

1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-41-51] and a rubber mallet.
[Figure 30-41-52] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-41-54] and remove
bearing.

Figure 30-41-55
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-57].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-41-58

B25013
Servo Piston Assembly [Figure 30-41-55].

1
The Servo Piston Assembly [Figure 30-41-55] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-41-56
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-58].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-56].

Figure 30-41-59
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-41-61] is parallel to the drive shaft
centerline. Measure with a straight-edge [Figure 30-41-
60].
Slide the servo piston assembly out of the bore. [Figure
30-41-59]. Figure 30-41-62

Figure 30-41-60
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-41-62] from the pump housing.

Figure 30-41-63 1
1
2
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-41-65] from

P-64494 the servo piston.

Each servo has a pair of bushings (Item 1), O-rings (Item cover.
2) and square-cut seals (Item 3) [Figure 30-41-63].

Figure 30-41-66
Figure 30-41-64
1
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-41-66] from the

Remove the locknut (Item 1) [Figure 30-41-64] from the servo piston.
servo piston.
Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT’D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The tools listed will be needed to do the following
procedure:
Figure 30-41-67
The pump mechanical neutral adjustment sets the

position of the servo piston and pump swash plate
1 relative to the hydraulic controller. This procedure should
2 be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.

10-10-1.)
WARNING
P-64498
Remove the piston stop adjustment mechanism (Item 1) Failure to use jackstands can allow the machine to
[Figure 30-41-67] from the servo piston. fall or move and cause injury or death.

W-2017-0286
Inspect mechanism for broken parts.
Raise the lift arms, and install an approved lift arm
Replace O-ring (Item 2) [Figure 30-41-67]. support device. (See Installing on Page 10-20-2.)
Figure 30-41-68 Raise the operator cab. (See Raising on Page 10-30-2.)
Connect remote start too. (See REMOTE START TOOL

KIT - MEL1563 on Page 10-60-1.) or (See REMOTE
START TOOL (SERVICE TOOL) KIT - 7217666 on Page
10-61-1.)
Disconnect the swash plate angle sensors in the

2 electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
1
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
If equipped disconnect the speed sensors located on the

top of the motor carriers. This prevents uncommanded
P-64502
wheel movement error codes from occurring during
adjustments.
Bearings (Item 1) [Figure 30-41-68] in case housing are
replaced by using a press and bearing driver.
Inspect center coupler (Item 2) [Figure 30-41-68].

WARNING
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-69
1
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-71] from the

P-64973 MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-41-69] Figure 30-41-72

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-41-70
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-41-72]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-41-70] from the pump mechanical neutral setting.
MB ports on the front side of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-73
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-41-75]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment locknut (Item 1)
[Figure 30-41-73]. Figure 30-41-76

Start the loader using the Remote Start Tool and run at
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-41-74
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT’D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The Hydraulic Controller Neutral Adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-41-77 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing Hydraulic
Controller Neutral Adjustments.
2 NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the locknut (Item 2) [Figure 30-41-77] to 30 N•m

(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-2.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Connect the Remote Start Tool. (See REMOTE START
25.) TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-78
P-64975
1 Install 3447 kPa (34,5 bar) (500 psi) pressure gauges in

P-90239 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting [Figure 30-41-80].
Disconnect the hydraulic controller connectors (Item 1) Figure 30-41-81

[Figure 30-41-78] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-41-79
1
1
P-90236
Loosen the locking screw (Item 1) [Figure 30-41-81].

P-90226
Start the loader using the Remote Start Tool and run at
an idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-41-79] pertaining to the side of the
hydrostatic pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-82
P-90236

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-41-85

in system pressure. Mark the position of the adjustment
screw.
Figure 30-41-83
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-41-85] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-41-83] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)


DRIVE BELT Figure 30-50-3
Earlier Models
Belt Adjustment
The drive belt does not need adjustment. The belt has a 1
spring loaded idler that constantly maintains the correct
belt tension. The spring loaded idler stop adjustment, 2
detailed below, is critical for long belt life.
Stop Adjustment


P109784A
Figure 30-50-1
Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-50-3].
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-2] to 105 – 115 N•m (78 – 85 ft-lb) torque.
Figure 30-50-4

Later Models
1
P109785
2
The spring loaded idler is located above the battery on

the left side of the engine [Figure 30-50-1].
Figure 30-50-2
P126273
Allow the stop arm (Item 1) to contact the top of the

spring loaded idler (Item 2) [Figure 30-50-4].
1
Tighten the spring loaded idler and pivot adjustment bolt
(Item 1) [Figure 30-50-2] to 105 – 115 N•m (78 – 85 ft-lb)
torque.
P115668
Loosen the spring loaded idler adjustment bolt and pivot

bolt (Item 1) [Figure 30-50-2].

DRIVE BELT (CONT’D) Figure 30-50-7
Belt Replacement
1
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
Figure 30-50-5
2
1
P109783
Loosen the spring loaded idler adjustment bolt and pivot

bolt (Item 1). Insert a breaker bar (Item 2) [Figure 30-50-
7] into the slot provided in the stop arm as shown and
push the breaker bar down to release tension on the
drive belt.

P109781
Tighten the adjustment bolt (Item 1) [Figure 30-50-7] to
hold the spring loaded idler off the drive belt.
Remove the drive belt shield bolt (Item 1) [Figure 30-50- Remove the drive belt from the hydrostatic pump pulley
5]. and flywheel pulley. Inspect the pulleys for wear.
Figure 30-50-6 Install new drive belt.
Loosen the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-7] and allow the idler to contact the drive
1 belt.
Continue the procedure on the next page.

2
P109782
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
[Figure 30-50-6] toward the back of the loader to unseat
the shield from the top and bottom drive belt shield
mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-50-6].

DRIVE BELT (CONT’D) Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
Belt Replacement (Cont’d) of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-50-9].
Figure 30-50-8
Figure 30-50-10
1 1
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
P109781
torque wrench (Item 2) [Figure 30-50-8] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated. Install the drive belt shield bolt (Item 1) [Figure 30-50-

10].
Maintain torque on the stop arm and tighten the spring
loaded idler adjustment bolt and pivot bolt (Item 1) Install the battery. (See Removal And Installation on
[Figure 30-50-8] to 105 – 115 N•m (78 – 85 ft-lb) torque. Page 60-20-1.)
NOTE: This procedure is required to preload a new Close the rear door.
drive belt in order to achieve the correct stop
adjustment after the initial belt break-in NOTE: The stop arm MUST be adjusted after 50 hours
period. operation with the new drive belt. (See Stop
Adjustment on Page 30-50-1.)
Figure 30-50-9
See the SERVICE SCHEDULE for the correct
Top Mounting Bolt service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)
1
P107207A
Bottom Mounting Bolt
P107206

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation (Earlier Figure 30-50-13

Models)
Remove the battery. (See Removal And Installation on 2

Page 60-20-1.) 1
Remove the drive belt. (See Belt Replacement on Page

30-50-2.)
Figure 30-50-11
1 P114387
2 Remove the nut (Item 1) from the tensioner assembly

and remove the wheel (Item 2) [Figure 30-50-13].
3 Figure 30-50-14

P114385
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-50-11].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 – 115 N•m (78 – 85 ft-lb) torque
Figure 30-50-12
1
2
P117155
Disassemble the tensioner assembly as shown [Figure

30-50-14].
Inspect the parts for wear and replace as needed.

1
NOTE: The wheel (Item 1) and the tensioner arm (Item
2) [Figure 30-50-14] are not serviceable and
must be replaced as a complete assembly.
P114384
Remove the tensioner assembly (Item 1) [Figure 30-50-

12].

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation (Later Figure 30-50-17

Models)

1
3
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
2
Remove the drive belt. (See Belt Replacement on Page
30-50-2.)
Figure 30-50-15
1
P126275
2
Remove the nut (Item 1), bolt (Item 2) and tuned weight
3 (Item 3) [Figure 30-50-17] from the tensioner assembly.
Figure 30-50-18

2 1
P126273
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-50-15].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 – 115 N•m (78 – 85 ft-lb) torque
Figure 30-50-16
P126277
Remove the bolt (Item 1) and wheel (Item 2) [Figure 30-

50-18] from the tensioner assembly.
1
P126274
Remove the tensioner assembly (Item 1) [Figure 30-50-

16].

DRIVE BELT (CONT’D)
Tensioner Pulley Disassembly And Assembly 

(Later Models) (Cont’d)
Figure 30-50-19
1 2
P126284
Disassemble the tensioner assembly as shown [Figure

30-50-19].
NOTE: The wheel (Item 1) and the tensioner arm (Item

2) [Figure 30-50-19] are not serviceable and
must be replaced as a complete assembly.

TWO-SPEED / BRAKE VALVE
Description
Figure 30-60-1
P107947
The two-speed / brake valve (Item 1) [Figure 30-60-1] is

located in front of the hydrostatic pump. The high range is

selected by a switch located on the right handle for
manual loaders and on the left joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure fluid to the shift spool in
each motor. The charge pressure hydraulic fluid shifts the
spools allowing the motors to move into high range.
When low range is selected, the solenoid is de-energized
and the shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Removal And Installation

IMPORTANT
DANGER When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)
P-90328 Raise the operator cab. (See OPERATOR CAB on Page

10-30-1.)
AVOID DEATH
• Disconnecting or loosening any hydraulic Mark all hydraulic hoses for proper installation.
can cause lift arms to drop. Figure 30-60-2

D-1009-0409 1
WARNING
P107947
W-2059-0598
Disconnect and plug the two tubelines (Item 1) [Figure

30-60-2] from the two-speed / brake valve.
WARNING
W-2017-0286

TWO-SPEED / BRAKE VALVE (CONT'D) Figure 30-60-5
Valve Block Removal And Installation (Cont’d)
Figure 30-60-3
2
1 1
P107946
Disconnect the wire harness (Item 1) [Figure 30-60-5].

P107948
Remove the two mounting bolts (Item 2) [Figure 30-60-5]
Disconnect and plug the two hydraulic hoses (Item 1)
[Figure 30-60-3] from the two-speed / brake valve. Remove the two-speed / brake valve block from the

loader.
Figure 30-60-4
P107949
Disconnect and plug the two hydraulic hoses (Item 1)

[Figure 30-60-4].

TWO-SPEED / BRAKE VALVE (CONT'D) Figure 30-60-8
Valve Block Disassembly And Assembly
Figure 30-60-6
1
1
P107100
Use a test meter and test the solenoid coil (Item 1)

P107098 [Figure 30-60-8] for resistance.
The resistance value for the solenoid coil can be found on

Mark all hydraulic hoses and fittings for proper the electrical schematic.
installation.

Figure 30-60-9
Remove the hydraulic fittings (Item 1) [Figure 30-60-6]
Figure 30-60-7
1
2
P107101
3
Use a test meter and test the solenoid coil (Item 1)

P107099 [Figure 30-60-9] for resistance.
The resistance value for the solenoid coil can be found on

Remove the two bolts (Item 1) from the two-speed the electrical schematic.
solenoid (Item 2) [Figure 30-60-7].
Remove the electrical solenoid nut (Item 3) from the

brake solenoid (Item 4) [Figure 30-60-7].
Assembly: Tighten the bolts (Item 1) to 2,7 N•m (2 ft-lb)

torque.
Assembly: Tighten the nut (Item 3) to 6 N•m (53 in-lb)

torque.

TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-60-10
P107104
Remove the make-up solenoid (Item 1) [Figure 30-60-

10] from the valve block.

Assembly: Tighten the solenoid valve to 27 N•m (20 ft-
lb) torque.
Figure 30-60-11
1
1
2 2 2
P107103
Remove the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-60-11].


DRAIN MANIFOLD
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic fluid to the reservoir.

DRAIN MANIFOLD (CONT’D) Figure 30-70-2
Drain Manifold Removal And Installation
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-90485
Figure 30-70-1

1
P-90484
Remove and plug all hoses from the drain manifold (Item
1) [Figure 30-70-1].
Disconnect the wiring harness from the fluid temperature

switch (Item 2) [Figure 30-70-1].

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG11001 -

ALJG15999 AND B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) . . . . . . . . . . 40-20-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12

Sprocket Removal And Installation (Two-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG11001 -

ALJG15999 AND B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) . . . . . . . . . . 40-21-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-3
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-9
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-12
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . 40-21-13
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-14

TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG16001 AND
B2KZ12001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-1
Checking (Solid-Mounted Undercarriage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-3
Adjusting (Solid-Mounted Undercarriage) 
(Earlier Models With Two Track Tension Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-4
(Later Models With One Track Tension Fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-5
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-10
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-11
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-14
Sprocket Removal And Installation (Sixteen Bolt Sprocket) . . . . . . . . . . . . . . . . . . 40-22-14
TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG16001 AND

B2KZ12001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-1

Checking (Roller Suspension Undercarriage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-3
Adjusting (Roller Suspension Undercarriage) 
(Earlier Models With Two Track Tension Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-4
(Later Models With One Track Tension Fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-5
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-10
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-11
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-14
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-15
Sprocket Removal And Installation (Sixteen Bolt Sprocket) . . . . . . . . . . . . . . . . . . 40-23-15
TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

BRAKE Block Removal And Installation
Description
Figure 40-10-1
DANGER
P-90328
1
AVOID DEATH
P-85426
The brake is used to hold the machine in place. The support. Replace if damaged.
brake is operated by a switch (Item 1) [Figure 40-10-1] D-1009-0409

located on the left panel.
WARNING
W-2059-0598


BRAKE (CONT’D) Figure 40-10-4
Block Removal And Installation (Cont'd)
Figure 40-10-2
2
1 1
1
1
P-85430
Mark the hydraulic hoses for proper installation.

1 P-85428
Remove and cap the four hydraulic hoses (Item 1)
[Figure 40-10-4].
10-2] located on the side of the transmission. Remove the two mount bolts (Item 2) [Figure 40-10-4].

Figure 40-10-3 Remove the brake block from the loader.
P-85427
Disconnect and cap the tube line (Item 1) [Figure 40-10-

3] from the rear of the brake valve.

BRAKE (CONT'D) Figure 40-10-7
Block Disassembly And Assembly 1

2 1
Figure 40-10-5 2 1
2
2 3
1
2
P-85432
2
Replace the O-rings (Item 1) and back-up rings (Item 2)
P-85431 [Figure 40-10-7] on the solenoid valve.
Inspect the screens (Item 3) [Figure 40-10-7] and clean

Loosen the electrical brake solenoid nut (Item 1) and the with solvent.
three fittings (Item 2)[Figure 40-10-5].

Assembly: Tighten the solenoid valve to 21,7 - 27,1 N•m
Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48 - (16 - 20 ft-lb) torque.
60 in-lb) torque.
Figure 40-10-6
2
1
P-85429
Remove the solenoid nut (Item 1) and solenoid coil (Item

2) [Figure 40-10-6].
Remove the solenoid valve (Item 3) [Figure 40-10-6]

from the block.


BRAKE (TWO-SPEED)
Description
Figure 40-11-1
P-85413F
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-11-1]

located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure fluid
to the brakes. The charge pressure fluid pushes the
spring away from the brake discs allowing the drive motor
to move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure fluid to hold the spring away from the brake
discs.
When the hold signal is interrupted the solenoid will close

the circuit and the charge fluid will be shut off an the
spring will apply the brakes. This will happen if the engine
rpm drops below a set rpm, the seat bar sensor fails or if
there is a break in the wires for the brake block solenoid.
For more information on the brake. (See Description on

Page 30-60-1.)


TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG11001 - ALJG15999 AND B2KZ11001 -
B2KZ11999 AND T1ML11001 & ABOVE)
Description
Figure 40-20-1

MS2786S
The track carriage components consist of front and rear idlers, rollers, the track, track tensioner, the drive sprocket and
the track housing [Figure 40-20-1].

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Figure 40-20-3
MOUNTED) (S/N ALJG11001 - ALJG15999 AND
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE)
(CONT’D)
Checking Tension
Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
1
prematurely.
NOTE: The wear of track rollers vary with the working

conditions and different types of soil
conditions.
Park the loader on a level surface.

P-85869A
Figure 40-20-2
Figure 40-20-4

Track
13 - 16 mm
Roller
(1/2 - 5/8 in)
P-85870A Track
B-18896C
Raise one side of the loader and put jackstands at the

front and rear of the loader frame so that the track is DO NOT put your fingers into the pinch points between
about 76 mm (3 in) off the ground [Figure 40-20-2]. the track and the roller. Use a 13 - 16 mm (1/2 - 5/8 in)
Lower the loader to the jackstands. Be sure the bolt, dowel or block to measure the gap (Item 1) [Figure
jackstands do not touch the tracks. 40-20-3] and [Figure 40-20-4].
Measure the track sag at either middle track roller (Item

1) [Figure 40-20-2]. The correct gap is 13 - 16 mm (1/2 -
5/8 in). WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

(CONT’D)
Adjusting Tension
Figure 40-20-5
2 1
1
2
P109765
Pressure must be released from the grease cylinder to

decrease track tension.
2 1
Install the bleed tool (MEL1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-20-6]
P-76325 to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover

open [Figure 40-20-5]. Figure 40-20-7
NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-20-5] is used to remove grease. 1
Increase Track Tension
Add grease to the grease fitting (Item 1) [Figure 40-20-5]

until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].
P109764
NOTE: Do not remove grease fitting unless pressure
is released using the bleed fitting (Item 2)
[Figure 40-20-6]. Tighten the access cover bolt (Item 1) [Figure 40-20-7]
to secure the tool.
NOTE: If replacement is necessary, always replace
grease fitting (Item 1) [Figure 40-20-5] with Turn the tool 90° counterclockwise and let the grease
genuine Bobcat Parts. The fitting is a special flow into a container. Release pressure [Figure 40-20-7]
fitting designed for high pressure. until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].
Decrease Track Tension
Tighten the bleed fitting. Pivot the access cover closed
and tighten the access cover bolts.
WARNING
Raise the loader. Remove the jackstands.
HIGH PRESSURE GREASE CAN
CAUSE SERIOUS INJURY Repeat the procedure for the other track.
• Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2 Dispose of grease in an environmentally safe manner.
turns.
W-2781-0109

TRACK UNDERCARRIAGE COMPONENTS (SOLID-
(CONT’D) IMPORTANT
Track Removal And Installation
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
DANGER must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
It may be necessary to adjust the MEL1560 tool to loosen

the bleed fitting an additional turn after the pressure is
released from the first 90° turn. This will allow the grease
to flow out faster when lifting the track in the next step.
You MUST pivot the access cover against the MEL1560
P-90328 tool and tighten the mount bolt (Item 1) [Figure 40-20-8]
before continuing.
AVOID DEATH

D-1009-0409

1.) 1

P-85416
WARNING
With a chain hoist, lift on the track moving the front idler
Never work on a machine with the lift arms up unless assembly toward the rear of the track assembly until all
the lift arms are secured by an approved lift arm track tension has been released [Figure 40-20-8].
support device can allow the lift arms or attachment Tighten the bleed fitting using the MEL1560 tool (Item 1)
to fall and cause injury or death. [Figure 40-20-8].
W-2059-0598
Decrease the track tension. (See Adjusting Tension on

Page 40-20-3.)
NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76 mm (3 in).

TRACK UNDERCARRIAGE COMPONENTS (SOLID- To install the rubber track:
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) Completely retract the front idler and track tensioner.
(CONT’D)
Track Removal And Installation (Cont’d) Put the track over the rear drive sprocket lugs.
Figure 40-20-9 Put the track over the rear idler.
Slide the track under the rollers.
Put the track on the front idler wheel.
Adjust the track to the proper tension. (See Adjusting

Tension on Page 40-20-3.)
NOTE: The grease tube must be completely retracted

against the coil spring assembly before
adding grease, to prevent air from being
trapped in the grease tube.
NOTE: Inspect the alignment of the grease tube (Item

1) [Figure 40-20-19] before adjusting the track.
P-85370

With pry bars, pry the track up and over the front idler
[Figure 40-20-9].
Completely remove the track from the front track

assembly.
Figure 40-20-10
P-85417
With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-20-10].

(CONT’D)
Idler (Front) Removal And Installation 1 1

1.)
Remove the track. (See Track Removal And Installation

on Page 40-20-4.)
Figure 40-20-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

[Figure 40-20-13] may be inserted to keep the front idler
wheel in place until the track is installed.
NOTE: The bolts must be removed before completing

track installation. It will not be possible to

1 remove the bolts after track tension has been
set.
P-76843
Slide the front idler wheel out of the track housing

[Figure 40-20-11].
NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-20-11] is toward the top of the
track housing for installation.
Figure 40-20-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-20-

12] on the front idler wheel frame engage the holes in the
track tensioner.

(CONT’D)
Idler (Front) Removal And Installation (Cont’d)
Figure 40-20-14
P-76325
Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-20-16].
1
P-85418

Slide the track tensioner (Item 1) [Figure 40-20-14] out
of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-20-14] before sliding it into the track
housing.
Figure 40-20-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-20-15].

(CONT’D) CORRECT
Idler (Front) Removal And Installation (Cont'd)
Figure 40-20-17
WRONG
2
2
P-85014A
1
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
against the coil spring assembly (Item 2) [Figure 40-20-
19].
P-85371

Figure 40-20-18
WRONG
P-85014
Installation: [Figure 40-20-17] and [Figure 40-20-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-20-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

(CONT’D)
Track Tensioner Disassembly And Assembly
WARNING 4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
(Item 3), and wear ring (Item 4) [Figure 40-20-21] from
the grease tube.
• Spring loaded components under pressure can Installation: Apply oil to new O-ring, back-up ring, seal,
cause serious injury or death. and wear ring before installation.

• Do not disassemble the coil spring assembly
W-2617-1004
Installation: Apply grease to area between seal and O-
ring before installing.
Figure 40-20-20
onto the chrome shaft before replacing the
grease fitting and adding grease, to prevent
2 air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-20-20].

(CONT’D) 8
Track Tensioner Disassembly And Assembly (Cont’d)
WARNING
1 2 3 4 5 6 7
P-85019
Inspect and replace any damaged parts.
The items listed below refer to [Figure 40-20-23].

P-62574
1. Coil Spring Assembly

AVOID INJURY OR DEATH 2. O-ring 
• Spring loaded components under pressure can 3. Chrome Shaft
cause serious injury or death. 4. Seal

• Do not disassemble the coil spring assembly 5. Back-up Ring
W-2617-1004 6. O-ring
7. Wear Ring
Figure 40-20-22 8. Grease Tube
1 NOTE: The O-ring (Item 2) is used to secure the

chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-20-23] during the
installation of the track tensioner into the
track housing.
P-85372
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 284 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

20-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Roller Removal And Installation
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) Remove the track from the loader. (See Track Removal
(CONT’D)
And Installation on Page 40-20-4.)
Idler (Rear) Removal And Installation
Figure 40-20-25
on Page 40-20-4.)
Figure 40-20-24
1
1 1
1
P-85421
2
2
Remove the bolts (Item 1) [Figure 40-20-25] from the

roller shaft. (Both ends of the roller shaft.)
P-76847
Installation: Tighten the bolts or nuts to 410 - 450 N•m

Remove the two mount bolts and washers (Item 1) (300 - 330 ft-lb) torque.
[Figure 40-20-24].
Remove the roller from the track assembly.
Remove the rear idler from the loader.
Installation: Align the square sides of the idler shaft with

the notches in the track housing (Item 2) [Figure 40-20-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 407 - 447


TRACK UNDERCARRIAGE COMPONENTS (SOLID- Sprocket Removal And Installation (Two-Speed)
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) Figure 40-20-27
(CONT’D)
Sprocket Removal And Installation (Single Speed)

1
Figure 40-20-26
1
2
2
P100737A
Remove the eight nuts (Item 1) [Figure 40-20-27] and

remove the drive sprocket from the motor.
P-85407
NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in

Remove the six nuts (Item 1) [Figure 40-20-26] and the sprocket holes (Item 2) [Figure 40-20-27]
remove the drive sprocket from the motor. to aid in the removal of the sprocket.
NOTE: Install three (1/2 in - 13UNC x 3 in) long bolts in Installation: Tighten the nuts to 492 - 544 N•m (363 -
the sprocket holes (Item 2) [Figure 40-20-26] 401 ft-lb) torque.
to aid in the removal of the sprocket.
Installation: Tighten the nuts to 280 - 300 N•m (207 -

222 ft-lb) torque.

(CONT’D)
Track Housing Removal And Installation

1
NOTE: Jackstands used when removing the track
must not interfere with track housing removal.
Remove the track from the loader. (See Track Removal

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-3.)
Support the track housing. P-76864
Figure 40-20-28
At the rear of the loader remove the two mount bolts
(Item 1) [Figure 40-20-29].
1 Installation: Tighten the mount bolts to 410 - 450 N•m


Figure 40-20-30
P-85409

from the bottom track housing mount plate. (At the front
and rear of the loader.)
Installation: Tighten the mount bolts to 410 - 450 N•m P-85408

At the front of the loader remove the two mount bolts
(Item 1) [Figure 40-20-30].
Remove the track housing from the loader.
Installation: Tighten the mount bolts to 410 - 450 N•m



TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG11001 - ALJG15999 AND
Description
Figure 40-21-1

P-85368
The track carriage components consist of front and rear idlers, rollers, leaf springs, the track, track tensioner, the drive
sprocket and the track housing [Figure 40-21-1].

(CONT’D)
Checking Tension

prematurely.

conditions.

P-85540A
Figure 40-21-2
Figure 40-21-4

Track
13 mm
Roller
(1/2 in)
1
P-85354A Track
B-18896C

front and rear of the loader frame so that the track is DO NOT put your fingers into the pinch points between
about 76 mm (3 in) off the ground [Figure 40-21-2]. the track and the roller. Use a 13 mm (1/2 in) bolt, dowel
Lower the loader to the jackstands. Be sure the or block to measure the gap [Figure 40-21-3] and
jackstands do not touch the tracks. [Figure 40-21-4].

1) [Figure 40-21-2]. The correct gap is 13 mm (0.50 in).
WARNING
AVOID INJURY
W-2142-0903

(CONT’D)
Adjusting Tension
Figure 40-21-5
2 1
1
2
P109765

decrease track tension.
2 1
Install the bleed tool (MEL1560) on the bleed fitting (Item
P-76325 to fit behind the edge of the access cover.

Figure 40-21-7
open [Figure 40-21-5].
NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
1
[Figure 40-21-5] is used to remove grease.

[Figure 40-21-4]. P109764

is released using the bleed fitting (Item 2) Tighten the access cover bolt (Item 1) [Figure 40-21-7]
[Figure 40-21-5] to secure the tool.
NOTE: If replacement is necessary, always replace Turn the tool 90° counterclockwise and let the grease
grease fitting (Item 1) [Figure 40-21-5] with flow into a container. Release pressure [Figure 40-21-7]
genuine Bobcat Parts. The fitting is a special until the track adjustment is correct [Figure 40-21-3] and
fitting designed for high pressure. [Figure 40-21-4].
Decrease Track Tension Tighten the bleed fitting. Pivot the access cover closed
WARNING Raise the loader. Remove the jackstands.
Repeat the procedure for the other track.

CAUSE SERIOUS INJURY Dispose of grease in an environmentally safe manner.
• Do not loosen bleed fitting more than 1 - 1/2
turns.
W-2781-0109

TRACK UNDERCARRIAGE COMPONENTS (SOLID-
(CONT’D) IMPORTANT
require that certain spills and leaks on the ground
DANGER must be cleaned in a specific manner. See local, state
I-2067-0499

released from the first 90° turn. This will allow the grease
P-90328 tool and tighten the mount bolt (Item 1) [Figure 40-21-7]
before continuing.
AVOID DEATH

D-1009-0409

1.) 1

P-85380
WARNING
With a chain hoist, lift on the track moving the front idler
Never work on a machine with the lift arms up unless assembly toward the rear of the track housing assembly
the lift arms are secured by an approved lift arm until all track tension has been released [Figure 40-21-
support device. Failure to use an approved lift arm 8].
to fall and cause injury or death. Tighten the bleed fitting using the MEL1560 tool (Item 1)
W-2059-0598 [Figure 40-21-8].
Decrease the track tension. (See Adjusting Tension on

Page 40-21-3.)

76 mm (3 in).

(CONT’D)
Track Removal And Installation (Cont’d)
Figure 40-21-9
P-85369
and remove the track from the loader [Figure 40-21-10].
Installation: Completely retract the front idler / track

P-85370
tensioner.

With pry bars, pry the track up and over the front idler Put the track on the front idler wheel.
[Figure 40-21-9].
Put the track over the rear drive sprocket lugs.
Completely remove the track from the front idler
assembly. Slide the track under the rollers.
Put the track over the rear idler.
NOTE: Inspect the alignment of the grease tube (Item

1) [Figure 40-21-19] before adjusting the track.

Tension on Page 40-21-3.)

(CONT’D)
Idler (Front) Removal And Installation 1 1

on Page 40-21-4.)
Figure 40-21-11
P-73967
Installation: Two short 10 mm (3/8 in) bolts (Item 1)

[Figure 40-21-13] may be inserted to keep the front idler
wheel in place until the track is installed.
1
NOTE: The bolts must be removed before completing
track installation. It will not be possible to

remove the bolts after track tension has been
P-76843
set.
Slide the front idler wheel out of the track housing

[Figure 40-21-11].
NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-21-11] is toward the top of the
track housing for installation.
Figure 40-21-12
P-76051
Installation: Make sure the pins (Item 1) [Figure 40-21-

12] on the front idler wheel frame engage the holes in the
track tensioner.

(CONT’D)
Idler (Front) Removal And Installation (Cont’d)
Figure 40-21-14
P-76325
Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-21-16].

P-76844
Slide the track tensioner (Item 1) [Figure 40-21-14] out

of the track housing.
Installation: Track tensioner must be oriented as shown

in [Figure 40-21-14] before sliding it into the track
housing.
Figure 40-21-15
1 2
P-76850
Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-21-15].

(CONT’D) CORRECT
Idler (Front) Removal And Installation (Cont'd)
Figure 40-21-17
WRONG
2
2
P-85014A
1
Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
against the coil spring assembly (Item 2) [Figure 40-21-
19].
P-85371

Figure 40-21-18
WRONG
P-85014
Installation: [Figure 40-21-17] and [Figure 40-21-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-21-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

(CONT’D)
WARNING 4
3
2
P-85018
P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
(Item 3), and wear ring (Item 4) [Figure 40-21-21] from
the grease tube.
• Spring loaded components under pressure can Installation: Apply oil to new O-ring, back-up ring, seal,
cause serious injury or death. and wear ring before installation.

W-2617-1004
Installation: Apply grease to area between seal and O-
ring before installing.
Figure 40-21-20
onto the chrome shaft before replacing the
grease fitting and adding grease, to prevent
2 air from being trapped in the grease tube.
P-85036
Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-21-20].

(CONT’D) 8
WARNING
1 2 3 4 5 6 7
P-85019

P-62574
1. Coil Spring Assembly

AVOID INJURY OR DEATH 2. O-ring 
• Spring loaded components under pressure can 3. Chrome Shaft
cause serious injury or death. 4. Seal

• Do not disassemble the coil spring assembly 5. Back-up Ring
W-2617-1004 6. O-ring
7. Wear Ring
Figure 40-21-22 8. Grease Tube
1 NOTE: The O-ring (Item 2) is used to secure the

chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-21-23] during the
installation of the track tensioner into the
track housing.
P-85372

THE SPRING EXCEEDS 284 kg (10,000 lb).
NOTE: The coil spring assembly (Item 1) [Figure 40-

21-22] is only sold as a complete assembly
from Bobcat Parts.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Roller Removal And Installation
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) Remove the track from the loader. (See Track Removal
(CONT’D)
Figure 40-21-25
on Page 40-21-4.)
Figure 40-21-24
1
1
1
P-85374
2
2
Remove the bolt and washer (Item 1) [Figure 40-21-25]

from the roller shaft. (Both ends of the roller shaft.)
P-76847
Remove the roller from the track assembly.

Remove the two mount bolts and washers (Item 1)
[Figure 40-21-24]. Installation: Support the roller from underneath with a
hydraulic floor jack and tighten the bolts to 712 N•m (525
Remove the rear idler from the loader. ft-lb) torque.
Installation: Align the square sides of the idler shaft with

the notches in the track housing (Item 2) [Figure 40-21-
24].
Align the holes in the housing with the holes in the shaft.
Install the bolts and washers and tighten to 712 N•m (525
ft-lb) torque.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Installation: Tighten the leaf spring bolts (Item 2)
MOUNTED) (S/N ALJG11001 - ALJG15999 AND [Figure 40-21-26] and (Item 1) [Figure 40-21-27] to 237
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) N•m (175 ft-lb) torque.
(CONT’D)
Leaf Spring Removal And Installation Figure 40-21-28

Figure 40-21-26
1
P-76930
3
Remove the leaf spring assembly [Figure 40-21-28] from

the track housing.

P-85375
NOTE: The leaf spring assembly [Figure 40-21-28] is
only sold as a complete left-hand or right
Remove the roller bolt and washer (Item 1) [Figure 40- hand assembly from Bobcat Parts.
21-26] from the roller shaft. (Both ends of the roller
shaft.) Figure 40-21-29
Remove the roller from the track housing.
Installation: Support the roller from underneath with a

hydraulic floor jack and tighten the bolts to 712 N•m (525
ft-lb) torque.
Remove the leaf spring bolts (Item 2) [Figure 40-21-26]

1
from the leaf spring mounts. (Both sides of the track
housing.)
Figure 40-21-27
P-76027
The upper and lower leaf spring mounts are wider on one
side to prevent the leafs from rubbing on the track
housing during operation.
1
Installation: The leaf springs are installed correctly when
there is a slight gap (Item 1) [Figure 40-21-29] between
the leafs and the track housing. (Cutaway view shown for
clarity.) The gap is easily seen at the roller end of the leaf
P-85377 spring (Item 3) [Figure 40-21-26].
Access the front, inside leaf spring assembly bolts (Item

1) [Figure 40-21-27] from underneath the loader through
an access hole in the track housing.

TRACK UNDERCARRIAGE COMPONENTS (SOLID- Sprocket Removal And Installation (Two-Speed)
B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE) Figure 40-21-31
(CONT’D)

1
Figure 40-21-30
1
2
2
P100737A
Remove the eight nuts (Item 1) [Figure 40-21-31] and

P-85407
NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in

Remove the six nuts (Item 1) [Figure 40-21-30] and the sprocket holes (Item 2) [Figure 40-21-31]
remove the drive sprocket from the motor. to aid in the removal of the sprocket.
NOTE: Install three (1/2 in - 13UNC x 3 in) long bolts in Installation: Tighten the nuts to 492 - 544 N•m (363 -
the sprocket holes (Item 2) [Figure 40-21-30] 401 ft-lb) torque.

222 ft-lb) torque.

(CONT’D)
Track Housing Removal And Installation

1
NOTE: Jackstands used when removing the track
must not interfere with track housing removal.

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-3.)
Support the track housing. P-76864
Figure 40-21-32
At the rear of the loader remove the two mount bolts
(Item 1) [Figure 40-21-33].

1 (300 - 330 ft-lb) torque.

Figure 40-21-34
P-85422

from the bottom track housing mount plate. (At the front
and rear of the loader.)
Installation: Tighten the mount bolts to 410 - 450 N•m P-85408

At the front of the loader remove the two mount bolts
(Item 1) [Figure 40-21-34].
Remove the track housing from the loader.


TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG16001 AND B2KZ12001 & ABOVE)
Description
Figure 40-22-1
NA10327S
The track carriage components consist of the front and rear idlers, rollers, the track, track tensioner, drive motor and the
drive sprocket. [Figure 40-22-1].

MOUNTED) (S/N ALJG16001 AND B2KZ12001 &
ABOVE) (CONT'D)
Description (Cont’d)
Figure 40-22-2
SOLID-MOUNTED UNDERCARRIAGE
P115667D
Figure 40-22-4
P107800
A bleed tool [Figure 40-22-2] is available and

recommended to decrease track tension. The bleed tool
will direct the flow of grease to aid in cleanup.
The bleed tools are sized differently:
Part number 6675936 – Used for machines with two

track tension fittings.
ROLLER SUSPENSION UNDERCARRIAGE
Part number 7277225 – Used for machines with one
track tension fitting. P121536B
NOTE: This model may be equipped with one of two

types of undercarriage systems. Identification
of the type used on your machine is
necessary to select the correct procedure
[Figure 40-22-3] and [Figure 40-22-4].

TRACK UNDERCARRIAGE COMPONENTS  Figure 40-22-6
(SOLID- MOUNTED) (S/N ALJG16001 AND
Checking (Solid-Mounted Undercarriage)

prematurely.

conditions.
Figure 40-22-5 P115666
Figure 40-22-7

Track
19 – 22 mm Roller
(3/4 – 7/8 in)
P115667D
Track
B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-22-5]. DO NOT put your fingers into the pinch points between
Lower the loader to the jackstands. Be sure the the track and the roller. Use a 19 – 22 mm (3/4 – 7/8 in)
jackstands do not touch the tracks. bolt, dowel or block to check the gap [Figure 40-22-6]
Measure the track sag at the either middle track roller
(Item 1) [Figure 40-22-5]. The correct gap is 19 – 22
mm (3/4 – 7/8 in).
WARNING
AVOID INJURY
W-2142-0903


(Earlier Models With Two Track Tension Fittings) 1
Figure 40-22-8
2
P115662

1 2 decrease track tension.
Install the bleed tool (6675936) on the bleed fitting (Item

P115664
to fit behind the edge of the access cover.

Loosen the access cover bolts and pivot the access cover Figure 40-22-10
NOTE: You MUST select the correct fitting for the

task required. The grease fitting (Item 2) is
1

[Figure 40-22-7].
NOTE: Do not remove grease fitting unless pressure P115661

is released using the bleed fitting [Figure 40-
22-9].
Tighten the access cover bolt (Item 1) [Figure 40-22-10]
NOTE: If replacement is necessary, always replace to secure the tool.
grease fitting (Item 2) [Figure 40-22-8] with
genuine Bobcat Parts. The fitting is a special Turn the tool 90° counterclockwise and let the grease
fitting designed for high pressure. flow into a container. Release pressure [Figure 40-22-
10] until the track adjustment is correct [Figure 40-22-6]
WARNING Raise the loader. Remove the jackstands. Repeat the
procedure for the other track. Dispose of grease in an
HIGH PRESSURE GREASE CAN environmentally safe manner.
CAUSE SERIOUS INJURY
turns.
W-2781-0109

TRACK UNDERCARRIAGE COMPONENTS  Pressure must be released from the grease cylinder to
(SOLID- MOUNTED) (S/N ALJG16001 AND decrease track tension.
Figure 40-22-12
(Later Models With One Track Tension Fitting)
Figure 40-22-11
1
2
P115662A
1
Install the bleed tool (7277225) on the track tension fitting

(Item 1), adjust and tighten the collar (Item 2) [Figure 40-
P115664A
22-12] to fit behind the edge of the access cover.

Loosen the access cover bolts and pivot the access cover Figure 40-22-13
Add grease to the track tension fitting (Item 1) [Figure

40-22-11] until the track adjustment is correct [Figure 40-
22-6] and [Figure 40-22-7]. 1
NOTE: Take care if using a pneumatic grease gun

because high pressure can damage the
grease fitting. Connect the pneumatic grease
gun to a regulated air supply set at the lowest
setting and slowly increase the air pressure
until the grease fitting starts taking grease. P115661A
NOTE: Do not remove track tension fitting unless

pressure is released [Figure 40-22-12].
to secure the tool.
NOTE: If replacement is necessary, always replace
Turn the tool 90° counterclockwise and let the grease
track tension fitting (Item 1) [Figure 40-22-11]
flow into a container. Release pressure [Figure 40-22-
with genuine Bobcat Parts. The fitting is a
13] until the track adjustment is correct [Figure 40-22-6]
special fitting designed for high pressure.
Tighten the track tension fitting to 24 – 30 N•m (18 – 22
ft-lb) torque. Pivot the access cover closed and tighten
WARNING the access cover bolts.
Raise the loader. Remove the jackstands. Repeat the

HIGH PRESSURE GREASE CAN procedure for the other track. Dispose of grease in an
CAUSE SERIOUS INJURY environmentally safe manner.
• Do not loosen the track tension fitting more than
1 - 1/2 turns.
W-2994-0515

TRACK UNDERCARRIAGE COMPONENTS 

IMPORTANT
DANGER require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
I-2067-0499

released from the first 1/4 turn. This will allow the grease
P-90328
tool and tighten the bolt (Item 1) [Figure 40-22-10]
AVOID DEATH before continuing.
tubeline, hose, fitting, component or a part failure Figure 40-22-14

D-1009-0409


WARNING P115667D
Never work on a machine with the lift arms up unless With a chain hoist, lift on the track moving the front idler
the lift arms are secured by an approved lift arm assembly toward the rear of the machine until all track
support device. Failure to use an approved lift arm tension has been released [Figure 40-22-14].
to fall and cause injury or death. Tighten the bleed fitting using the MEL1560 tool (Item 1)
W-2059-0598 [Figure 40-22-10] and lower the track.
Decrease the track tension. (See Adjusting (Solid-

Mounted Undercarriage) (Earlier Models With Two Track
Tension Fittings) on Page 40-22-4.) or (See Adjusting
(Solid-Mounted Undercarriage) (Later Models With One
Track Tension Fitting) on Page 40-22-5.)

76 mm (3 in).

Figure 40-22-15
P120890
Slowly rotate track in reverse until the tubing is centered

on the front idler [Figure 40-22-17].
P120888 Figure 40-22-18
Install five pieces of 38,1 N•m (1.5 in) round steel tubing

in the lugs before the front idler [Figure 40-22-15].
Figure 40-22-16
P120876
1
With a pry bar, pry the track over the front idler [Figure
40-22-18].
P122263 Completely remove the track from the front idler

assembly.
NOTE: Front idler is shown removed for photo clarity.
NOTE: Verify that tubing does not extend past the

inside edge of the front idler (Item 1) [Figure
40-22-16].

Figure 40-22-19
P120877

and rear idler. Remove the track from the loader [Figure
40-22-19].
To install the rubber track:
Completely retract the front idler and track tensioner.
Put the track under the rear idler.
Put the track on the front idler wheel using the same
procedure as removing the track.

(Solid-Mounted Undercarriage) (Earlier Models With Two
Track Tension Fittings) on Page 40-22-4.) or (See
Adjusting (Solid-Mounted Undercarriage) (Later Models
With One Track Tension Fitting) on Page 40-22-5.)


Idler (Front) Removal And Installation

on Page 40-22-6.)
Figure 40-22-20

P120892
Slide the front idler (Item 1) [Figure 40-22-20] out of the

track housing.
Figure 40-22-21
1 1
P122303
Remove the six bolts (Item 1) and remove the machined

guide (Item 2) [Figure 40-22-21] from the front idler.
Installation: Tighten the bolts to 162 - 169 N•m (120 -

125 ft-lb) torque.

Track Tensioner Removal And Installation

1
on Page 40-22-6.)
Remove the front idler. (See Idler (Front) Removal And

Figure 40-22-22
P120895
1
Figure 40-22-25

P120893
Figure 40-22-23 1
P120899
1
Figure 40-22-26
P120894
1
Slide the track tensioner assembly (Item 1) [Figure 40-
22-22] and [Figure 40-22-23] out of the track housing.
P120900
Installation: Before installing grease cylinder, orientate

base end (Item 1) [Figure 40-22-24] so when installed,
base end of cylinder is seated firmly against stop [Figure
40-22-25] and [Figure 40-22-26] with the grease / bleed
fittings orientated towards access hole of carriage.

WARNING
P120897
P-62574
AVOID INJURY OR DEATH Figure 40-22-29

• Spring loaded components under pressure can
cause serious injury or death.

W-2617-1004
Figure 40-22-27
2 1
2
1
P106695
Remove the shaft (Item 1) from the tube (Item 2) [Figure

40-22-29].
P120896
Remove the cylinder (Item 1) from the coil spring

assembly (Item 2) [Figure 40-22-27].

SPRING ASSEMBLY (Item 2) [Figure 40-22-27].

B2KZ12001 & ABOVE) (CONT'D) 1
Figure 40-22-30
1
2
3
4
P120897
The coil spring assembly (Item 1) [Figure 40-22-31] is

only sold as a complete assembly from Bobcat Parts.

P-98308 THE SPRING EXCEEDS 10,000 lb.
Remove the wiper seal (Item 1), wear ring (Item 2), back-

up ring (Item 3) and O-ring (Item 4) [Figure 40-22-30].
WARNING
P-62574

W-2617-1004

TRACK UNDERCARRIAGE COMPONENTS  Roller Removal And Installation
B2KZ12001 & ABOVE) (CONT'D) Remove the track. (See Track Removal And Installation
on Page 40-22-6.)
Figure 40-22-33
on Page 40-22-6.)
Figure 40-22-32
P120902
1

P120901 roller shaft. (Both ends of the roller shaft.)

Remove the two bolts (Item 1) [Figure 40-22-32]. (Both
ends of the idler shaft.)
Remove the roller from the track frame.
Remove the rear idler from the track frame.

330 ft-lb) torque.

TRACK UNDERCARRIAGE COMPONENTS  NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in
(SOLID- MOUNTED) (S/N ALJG16001 AND the sprocket holes (Item 2) [Figure 40-22-35]
B2KZ12001 & ABOVE) (CONT'D) to aid in the removal of the sprocket.
401 ft-lb) torque.
Figure 40-22-34
Sprocket Removal And Installation (Sixteen Bolt
Sprocket)
1
Figure 40-22-36
1
2
P-85407
Remove the six nuts (Item 1) [Figure 40-22-34] and

P131055
NOTE: Install three (1/2” - 13UNC x 3 in) long bolts in

the sprocket holes (Item 2) [Figure 40-22-34]
Remove the bolts (Item 1) [Figure 40-22-36], attach a
lifting device and remove the drive sprocket from the
motor.
222 ft-lb) torque.
Figure 40-22-37
Sprocket Removal And Installation (Two-Speed)
1
Figure 40-22-35 16 9
8
2
15
10
1 7
3
14
11
2 6
4
13
5 12
P115456B
Installation: Tighten the bolts to 125 - 135 N•m (90 - 100

P122661 ft-lb) torque.
Use an alternating tightening sequence [Figure 40-22-

Remove the nuts (Item 1) [Figure 40-22-35], attach a
37] and then repeat to tighten the bolts.
motor.

TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG16001 AND B2KZ12001 & ABOVE)
Description
Figure 40-23-1
NA10328S
The track carriage components consist of front and rear idlers, rollers, leaf springs, the track, track tensioner and the drive
sprocket [Figure 40-23-1].

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-23-3
SUSPENSION) (S/N ALJG16001 AND B2KZ12001 &
ABOVE) (CONT'D)
Description (Cont’d)
Figure 40-23-2
SOLID-MOUNTED UNDERCARRIAGE
P121538A
Figure 40-23-4
P107800
A bleed tool [Figure 40-23-2] is available and

recommended to decrease track tension. The bleed tool
will direct the flow of grease to aid in cleanup.
The bleed tools are sized differently:
Part number 6675936 – Used for machines with two

track tension fittings.
ROLLER SUSPENSION UNDERCARRIAGE
Part number 7277225 – Used for machines with one
track tension fitting. P121536A
NOTE: This model may be equipped with one of two

types of undercarriage systems. Identification
of the type used on your machine is
necessary to select the correct procedure

TRACK UNDERCARRIAGE COMPONENTS Figure 40-23-6
(ROLLER SUSPENSION) (S/N ALJG16001 AND
Checking (Roller Suspension Undercarriage)

prematurely.

conditions.
Figure 40-23-5 P121201
Figure 40-23-7

Track
19 – 22 mm Roller
(3/4 – 7/8 in)
P121536A
Track
B-18896C
front and rear of the loader frame so that the track is
about 76 mm (3 in) off the ground [Figure 40-23-5]. DO NOT put your fingers into the pinch points between
Lower the loader to the jackstands. Be sure the the track and the roller. Use a 19 – 22 mm (3/4 – 7/8 in)
jackstands do not touch the tracks. bolt, dowel or block to check the gap [Figure 40-23-6]
1) [Figure 40-23-5]. The correct gap is 19 – 22 mm (3/4
– 7/8 in).
WARNING
AVOID INJURY
W-2142-0903

TRACK UNDERCARRIAGE COMPONENTS Figure 40-23-9

(Earlier Models With Two Track Tension Fittings) 1
Figure 40-23-8
2
P115662

1 2 decrease track tension.
Install the bleed tool (6675936) on the bleed fitting (Item

P115664
to fit behind the edge of the access cover.

Figure 40-23-10
NOTE: You MUST select the correct fitting for the

task required. The grease fitting (Item 2) is
Increase Track Tension 1

[Figure 40-23-7].

is released using the bleed fitting (Item 1) P115661
[Figure 40-23-8].
NOTE: If replacement is necessary, always replace Tighten the access cover bolt (Item 1) [Figure 40-23-10]
grease fitting (Item 2) [Figure 40-23-8] with to secure the tool.
genuine Bobcat Parts. The fitting is a special
fitting designed for high pressure. Turn the tool 90° counterclockwise and let the grease
flow into a container. Release pressure [Figure 40-23-
Decrease Track Tension 10] until the track adjustment is correct [Figure 40-23-6]

WARNING and tighten the access cover bolts.
Raise the loader. Remove the jackstands. Repeat the

procedure for the other track. Dispose of grease in an
CAUSE SERIOUS INJURY
turns.
W-2781-0109

TRACK UNDERCARRIAGE COMPONENTS Pressure must be released from the grease cylinder to
(ROLLER SUSPENSION) (S/N ALJG16001 AND decrease track tension.
Figure 40-23-12
Adjusting (Roller Suspension Undercarriage) (Later
Models With One Track Tension Fitting)
Figure 40-23-11
1
2
P115662A
1
Install the bleed tool (7277225) on the track tension fitting

P115664A
(Item 1), adjust and tighten the collar (Item 2) [Figure 40-
23-12] to fit behind the edge of the access cover.

Figure 40-23-13
Add grease to the track tension fitting (Item 1) [Figure

40-23-11] until the track adjustment is correct [Figure 40-
23-6] and [Figure 40-23-7].
1
NOTE: Take care if using a pneumatic grease gun
because high pressure can damage the
grease fitting. Connect the pneumatic grease
gun to a regulated air supply set at the lowest
setting and slowly increase the air pressure
until the grease fitting starts taking grease.
P115661A
NOTE: Do not remove track tension fitting unless
pressure is released [Figure 40-23-12].
NOTE: If replacement is necessary, always replace to secure the tool.
track tension fitting (Item 1) [Figure 40-23-11]
with genuine Bobcat Parts. The fitting is a Turn the tool 90° counterclockwise and let the grease flow
special fitting designed for high pressure. into a container. Release pressure [Figure 40-23-13]
Decrease Track Tension [Figure 40-23-7].
Tighten the track tension fitting to 24 – 30 N•m (18 – 22 ft-

lb) torque. Pivot the access cover closed and tighten the
WARNING access cover bolts.
HIGH PRESSURE GREASE CAN Raise the loader. Remove the jackstands. Repeat the
CAUSE SERIOUS INJURY procedure for the other track. Dispose of grease in an
• Do not loosen the track tension fitting more than environmentally safe manner.
1 - 1/2 turns.
W-2994-0515


IMPORTANT
DANGER require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
I-2067-0499
It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 1/4 turn. This will allow the grease
P-90328
You MUST pivot the access cover against the MEL tool
and tighten the mount bolt (Item 1) [Figure 40-23-10]
AVOID DEATH before continuing.
tubeline, hose, fitting, component or a part failure NOTE: Removal is shown on a solid undercarriage.
can cause lift arms to drop. Procedure is the same for the roller
• Keep out of this area when lift arms are raised suspension.

support. Replace if damaged. Figure 40-23-14
D-1009-0409


WARNING
the lift arms are secured by an approved lift arm P131051
to fall and cause injury or death. With a chain hoist, lift on the track moving the front idler
W-2059-0598 assembly toward the rear of the machine until all track
tension has been released [Figure 40-23-14].
Decrease the track tension. (See Adjusting (Roller
Suspension Undercarriage) (Earlier Models With Two Tighten the bleed fitting using the MEL1560 tool (Item 1)
Track Tension Fittings) on Page 40-23-4.) or (See [Figure 40-23-2] and lower the track.
Models With One Track Tension Fitting) on Page 40-23-
5.)

76 mm (3 in).

Figure 40-23-15
P120890
Rotate track in reverse until the tubing is centered on the

front idler [Figure 40-23-17].
P120888 Figure 40-23-18
Install five pieces of 38,1 N•m (1.5 in) round steel tubing

in the lugs before the front idler [Figure 40-23-15].
Figure 40-23-16
P120876
1
With a pry bar, pry the track over the front idler [Figure
40-23-18].
P122263 Completely remove the track from the front idler

assembly.
NOTE: Front idler is shown removed for photo clarity.
NOTE: Verify that tubing does not extend past the

inside edge of the front idler (Item 1) [Figure
40-23-16].

Figure 40-23-19
P120877

and rear idler. Remove the track from the loader [Figure
40-23-19].
To install the rubber track:
Completely retract the front idler and track tensioner.
Put the track under the rear idler.
Put the track on the front idler wheel using the same
procedure as removing the track.

(Roller Suspension Undercarriage) (Earlier Models With
Two Track Tension Fittings) on Page 40-23-4.) or (See
Models With One Track Tension Fitting) on Page 40-23-
5.)


Idler (Front) Removal And Installation

on Page 40-23-6.)
Figure 40-23-20

P122300
Slide the front idler (Item 1) [Figure 40-23-20] out of the

track housing.
Figure 40-23-21
1 1
P122303
Remove the six bolts (Item 1) and the machined guide

(Item 2) [Figure 40-23-21] from the front idler.

125 ft-lb) torque.

Track Tensioner Removal And Installation
Remove the track. (See Track Removal And Installation 1

on Page 40-23-6.)
Remove the front idler. (See Idler (Front) Removal And

Figure 40-23-22
P120895
1
Figure 40-23-25

P120893
Figure 40-23-23 1
P120899
1
Figure 40-23-26
P120894
1
Slide the track tensioner assembly (Item 1) [Figure 40-
23-22] and [Figure 40-23-23] out of the track housing.
P120900
Installation: Before installing grease cylinder, orientate

base end (Item 1) [Figure 40-23-24] so when installed,
base end of cylinder is seated firmly against stop [Figure
40-23-25] and [Figure 40-23-26] with grease / bleed
fittings orientated towards access hole of carriage.

WARNING
P120897
P-62574
AVOID INJURY OR DEATH Figure 40-23-29


W-2617-1004
Figure 40-23-27
2 1
2
1
P106695
Remove the shaft (Item 1) from the tube (Item 2) [Figure

40-23-29].
P120896
Remove the cylinder (Item 1) from the coil spring


SPRING ASSEMBLY (Item 2) [Figure 40-23-27].

B2KZ12001 & ABOVE) (CONT'D) 1
Figure 40-23-30
1
2
3
4
P120897
The coil spring assembly (Item 1) [Figure 40-23-31] is

only sold as a complete assembly from Bobcat Parts.

P-98308 THE SPRING EXCEEDS 10,000 lb.
Remove the wiper seal (Item 1), wear ring (Item 2), back-

up ring (Item 3) and O-ring (Item 4) [Figure 40-23-30].
WARNING
P-62574

W-2617-1004

TRACK UNDERCARRIAGE COMPONENTS  Roller Removal And Installation
B2KZ12001 & ABOVE) (CONT'D) Remove the track from the loader. (See Track Removal
Figure 40-23-33
on Page 40-23-6.)
Figure 40-23-32
P122302
1

P120901 roller shaft. (Both ends of the roller shaft.)

Remove the two bolts (Item 1) [Figure 40-23-32] (Both
ends of the idler shaft).
Remove the roller from the leaf spring assembly.
Remove the rear idler from the loader.


Leaf Spring Removal And Installation

Support the roller and leaf spring assembly.
Figure 40-23-34
P122299
Remove the leaf spring assembly [Figure 40-23-36] from

the track housing.

P122301
Figure 40-23-35
P122302
Remove the leaf spring bolts (Item 1) [Figure 40-23-34]

and [Figure 40-23-35] from the leaf spring mounts.

195 ft-lb) torque.

TRACK UNDERCARRIAGE COMPONENTS  NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in
(ROLLER SUSPENSION) (S/N ALJG16001 AND the sprocket holes (Item 2) [Figure 40-23-38]
B2KZ12001 & ABOVE) (CONT'D) to aid in the removal of the sprocket.
401 ft-lb) torque.
Figure 40-23-37
Sprocket Removal And Installation (Sixteen Bolt
Sprocket)
1
Figure 40-23-39
1
2
P-85407
Remove the six nuts (Item 1) [Figure 40-23-37] and

P131055
NOTE: Install three (1/2” - 13UNC x 3 in) long bolts in

the sprocket holes (Item 2) [Figure 40-23-37]
Remove the bolts (Item 1) [Figure 40-23-39], attach a
motor.
222 ft-lb) torque.
Figure 40-23-40
Sprocket Removal And Installation (Two-Speed)
1
Figure 40-23-38 16 9
8
2
15
10
1 7
3
14
11
2 6
4
13
5 12
P115456B
Installation: Tighten the bolts to 125 - 135 N•m (90 - 100

P122661 ft-lb) torque.
Use an alternating tightening sequence [Figure 40-23-

Remove the nuts (Item 1) [Figure 40-23-38], attach a
40] and then repeat to tighten the bolts.
motor.


TRACK MAINTENANCE Driving over sharp objects should be avoided. If this
is impossible, do not make turns while driving over
Track Damage Identification sharp objects.
The following pages show photos and illustrations of Cutting Of Steel Cords
track damage and the probable cause of the damage. It
is intended to be used for identifying the reason for track Figure 40-30-2
damage and how to avoid future track damage.
Track and Sprocket Rotation:
Figure 40-30-1
Move Sprockets to opposite sides of the loader
P-3864
Remove track

Reinstall 180° Figure 40-30-3
P-85440
NOTE: All applications and conditions will cause

wear on the track inbeds and sprocket teeth.
Rotating the tracks and sprockets will extend Steel Cords
their life. The track can be removed and PI-13034
reinstalled 180 degrees. The sprocket can be
removed and installed on the opposite side of
the loader [Figure 40-30-1]. Damage:
Prevention: Embedded steel cords are cut off [Figure 40-30-2]

The following preventions should be taken to minimize
the risk of this damage:
Recommended track tension should be periodically

checked. (See Checking Tension on Page 40-20-2.)
Avoiding quick turns on bumpy and rocky fields.
Drive carefully to avoid having stones and other

articles clog the rubber tracks.

TRACK MAINTENANCE (CONT'D) Causes of the damage:
Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 40-30-4
Rubber tracks are driven with an extraordinary heavy
load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
P-3865 Figure 40-30-6

Damage:
Embedded metals will gradually wear away by friction Minimum Wear

[Figure 40-30-4].
Figure 40-30-5
Excessive Wear
PI-13037A
Track Rotation:
Certain applications or conditions can cause wear on the

track inbeds and sprocket teeth. Rotating the tracks 180
degrees will help extend track life [Figure 40-30-6]. (See
PI-13037 Track Damage Identification on Page 40-30-1.)
Remove the track and rotate it 180 degrees on the same

Replacement: side of the loader. (See Track Removal And Installation
on Page 40-20-4.)
When track embedded metals are worn
approximately 50% or more, replace the track.
Example of excessive wear is shown in [Figure 40-
30-4] and [Figure 40-30-5].

TRACK MAINTENANCE (CONT'D) Figure 40-30-8
Track Damage Identification (Cont'd)
Separation Of Embedded Metals
Figure 40-30-7
Idler
Rubber
track
PI-13039
Causes of the damage:
Embedded metals are adhered between the steel cords

P-4379 and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:

Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded embedded metals, the embedded metals will
metals cause their separation from the rubber track's eventually peel off [Figure 40-30-8].
body [Figure 40-30-7].
Figure 40-30-9
Replacement:
Even a partial separation of embedded metals

requires replacement of the track.
Guide
PI-13040
When a rubber track is detracked, it becomes stuck

between the guide or the undercarriage frame,
causing the separation of embedded metals [Figure
40-30-9].

Figure 40-30-10
Minimum
wear
Excessive
wear
PI-13041A
Sprocket Rotation:
PI-13041
Certain applications or conditions can cause wear on the
sprockets. Rotating the sprockets to the opposite side of
Excessively worn sprockets, example shown [Figure the loader will help extend sprocket life [Figure 40-30-
40-30-10] will pull embedded metals out of the track. 11]. (See Track Damage Identification on Page 40-30-1.)

Prevention: Remove the sprocket. (See TRACK UNDERCARRIAGE
COMPONENTS (SOLID-MOUNTED) (S/N ALJG11001 -
Similar to the prevention against the cutting of the steel ALJG15999 AND B2KZ11001 - B2KZ11999 AND
cords: T1ML11001 & ABOVE) on Page 40-20-1.)
Recommended track tension should be periodically

checked. (See Checking Tension on Page 40-20-2.)
Quick turns on bumpy and rocky fields should be

avoided.

Track Damage Identification (Cont'd) Embedded metal
Separation Of Embedded Metals Due To Corrosion
Figure 40-30-12
Good
Separation of
bonded rubber
cover
PI-13043
Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the

Damage: rubber body [Figure 40-30-13].
Due to corrosion of embedded metals, the adhesion Excessively salty fields, like the sea shore
to the rubber body deteriorates, resulting in complete
separation [Figure 40-30-12]. Strong acidic or alkali soil conditions
Replacement: Compost spread grounds
Even a partial separation of embedded metals On tracks that are out of adjustment, the track rollers,
requires a rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
Prevention:
If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.
When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.

Cuts On The Lug Side Rubber Cuts
Figure 40-30-14
PI-13045
When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 40-30-14]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-30-15].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately Machine operators are requested to drive with great
repaired with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-30-16 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.

Figure 40-30-17 Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-30-16] and [Figure 40-30-
17].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.

Track Damage Identification (Cont'd) Lug abrasion is more or less inevitable. Even if lug
abrasion is proceeding, the rubber track can be used.
Lug Abrasion However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
Figure 40-30-18 abraded tracks with new ones when the lug height
becomes less than 5 mm (0.197 in).
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads
Driving up and down hilly paths with slippage
Making frequent turns on paths covered with rocks

P-4381 and wood

Figure 40-30-19
Lug abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-30-18] and [Figure
40-30-19].
Replacement:
No replacement is required.

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-30-20 embedded metal rubber
PI-13051
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Damage: [Figure 40-30-21].
Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-30-20]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested
Replacement: to avoid driving over stumps and ridges.
Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.

Abrasion Of The Track Roller Side

Track roller
Figure 40-30-22
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Damage: the side of the rubber track to cause the abrasion [Figure
40-30-23].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-30-22]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

Cuts On The Edges Of Track Roller Side
Figure 40-30-24
PI-13056
This damage is caused by objects on the field or by

P-4384 interference with the machine frame.
In case of damage by objects on the operating ground:

Figure 40-30-25
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
Edge Edge easily occurs [Figure 40-30-26].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-30-24] and
[Figure 40-30-25].
Replacement:
In such case, the rubber track does not have to be

replaced.

TRACK MAINTENANCE (CONT'D)
Cuts On The Edges Of Track Roller Side (Cont’d)
Figure 40-30-27
Cut
Tear
PI-13057

In case of damage by interference with the machine
frame
If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-30-27].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.

MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1


Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-6
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-16
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-20
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal And Installation (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
Installation (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1


RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
FAN DUCT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1


SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
Lower the operator cab. (See Lowering on Page 10-30-
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P-90021

2 Remove the seat bar (Item 1) [Figure 50-10-3] from the
operator cab.
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P-85652
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023

4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.


OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without

the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Figure 50-20-1
2
1
1 3
P-85652A
Remove the retaining ring (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D)
Gas Spring Bracket Disassembly And Assembly
Figure 50-20-4
1
1
P-85661
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-

20-4].
Installation: Apply a small amount of thread-locker on

the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4].
WARNING
AVOID INJURY
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987

OPERATOR CAB (CONT’D) Figure 50-20-7
Figure 50-20-5
1
1
1
P103082
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].

P100756
Cap and plug the hoses and expansion valve fitting with
proper A/C caps and plug.
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40- Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)

2.) (torque).
Unhook the four fasteners (Item 1) and remove the cover

(Item 2) [Figure 50-20-5]. (See Removing on Page 80-
150-1.) WARNING
Figure 50-20-6
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
1 spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
1 Remove the operator cab gas spring(s). (See Gas Spring
NOTE: Use the hoist connected to the operator cab

1
grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.
P100879A
Disconnect the heater unit wiring harness connectors

(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve with
plugs to prevent coolant loss from the
system.

OPERATOR CAB (CONT’D) Figure 50-20-10
Figure 50-20-8
P-85662
1
Using a strap and a hoist remove the cab from the loader
P107406 [Figure 50-20-10].
Disconnect the cab harness connectors (Item 1) [Figure

50-20-8].

Figure 50-20-9
P-85658
Remove the two cab mount nuts and bolts (Item 1)

[Figure 50-20-9] from both sides of the cab.
Installation: Tighten the cab mount nuts and bolts to

24,4 - 29,8 N•m (18 - 22 ft-lb) torque.

OPERATOR SEAT Seat Belt Removal And Installation (Retractable)
Figure 50-30-1
P-90355
P-85776
Remove the mounting nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the seat belt.

Remove the four seat mounting nuts (Item 1) [Figure 50- Installation: Tighten the mounting nut to 73 N•m (54 ft-
30-1] and washers from the operator seat mounting lb) torque.
studs.

3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.

OPERATOR SEAT (CONT’D) Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation Figure 50-30-4

(Standard)
Figure 50-30-3
3 1
P101250
P101249 Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the bracket mounting bolts (Item 1) [Figure 50-

Remove the lower mounting nut, washer and bolt (Item 30-4].

1). Remove the upper mounting nut / bolt (Item 2)
[Figure 50-30-3]. Remove the bracket (Item 3) [Figure 50-30-3].
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting bolts to 73 N•m (54 ft-

lb) torque.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure

Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3

3.)
Remove the seat. 2
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-31-6
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.

Figure 50-31-5
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-31-9
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
31-7]. the seat back to the upright position.

Figure 50-31-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-31-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) Remove the mounting nut (Item 1) [Figure 50-31-11].

Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-31-10]. Figure 50-31-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-31-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-31-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-31-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
Remove the two mounting bolts (Item 1) [Figure 50-31-
13].

Figure 50-31-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-31-14].


BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
The Bob-Tach is located on the front of the loader

connected to the loader lift arms.
Figure 50-40-1 P-85649
Figure 50-40-3

P-85554
1
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1]. P-31402
Lower the Bob-Tach onto the blocks.

Remove the snap ring (Item 1) [Figure 50-40-3] from the
Remove the retainer nut and bolt (Item 1) [Figure 50-40- Bob-Tach pivot pin grease plug (both sides).


BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Figure 50-40-7
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].
Figure 50-40-5
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin.
P-31405
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330
Replace the O-ring (Item 1) [Figure 50-40-5] on the ft-lb) torque.
grease plug.

BOB-TACH (HAND LEVER) (CONT’D) Lever And Wedge Disassembly And Assembly
Removal And Installation (Cont’d) Figure 50-40-9
Figure 50-40-8
1 P-85664
P-31407
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-40-8]
and a hammer, drive the pivot pin out of the lift arm and Figure 50-40-10

Bob-Tach.
35,3 mm
NOTE: Use tapered ream MEL1685 to clean the (1.39 in)
tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
P127544
Installation: Tighten the lever mounting nut until the

spring is compressed to 35,3 mm (1.39 in) [Figure 50-
40-10].

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd)
Figure 50-40-11
P-85667
Remove the wedge (Item 1) [Figure 50-40-13] out the

2 bottom of the Bob-Tach.
P-85665
Always replace bent or broken wedges.
Remove the washer and spring, (Item 1) and the lever

Figure 50-40-12
P-85666
Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-40-12] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

40-12].

BOB-TACH (HAND LEVER) (CONT’D) Later Design
Lever And Wedge Disassembly And Assembly Figure 50-40-15

(Cont'd)
4
Earlier Design
Figure 50-40-14
1
1 2
P121303
2
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
P19287 vise. Remove the bolt (Item 1) [Figure 50-40-15] and
replace the damaged parts as needed.

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), Assembly: Clean the threads and apply Loctite® 242 to
or clevis (Item 4) are damaged, put the assembly in a the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54
vise. Remove the bolt (Item 1) [Figure 50-40-14] and N•m (35 - 40 ft-lb) torque.
Assembly: Clean the threads and apply Loctite® 242 to

the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135

BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-16
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Use a seal pick to remove seal (Item 1) [Figure 50-40-
16] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-16]

with a driver tool and hammer.
Figure 50-40-17
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-40-17].

BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and 1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. 2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].

Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649

Figure 50-41-6
P-31406
1
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Replace the O-ring (Item 1) [Figure 50-41-6] on the [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
grease plug. ft-lb) torque.

1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.
NOTE: Use tapered ream MEL1685 to clean the

tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.

Lever And Wedge Disassembly And Assembly

35,3 mm
(1.39 in)
Figure 50-41-10
1 1
P127544
Installation: Tighten the lever mounting nut until the

P-85570 spring is compressed to 35,3 mm (1.39 in) [Figure 50-
41-12].
Remove the washers and bolts (Item 1) [Figure 50-41- Figure 50-41-13
10] from the cylinder (both ends).

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.
Remove the cylinder from the lever pivots.
Figure 50-41-11
1
2
P-85665
1
Remove the washer and spring, (Item 1) and the lever
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

11].

BOB-TACH (POWER) (CONT’D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
vise. Remove the bolt (Item 1) [Figure 50-41-16] and
Use a punch and hammer to remove the roll pin (Item 1) replace the damaged parts as needed.

[Figure 50-41-14] from the Bob-Tach wedge and spring
clevis. Assembly: Clean the threads and apply Loctite® 242 to
Remove the spring clevis assembly (Item 2) [Figure 50- N•m (90 - 100 ft-lb) torque.
41-14].
Later Design
Figure 50-41-15
Figure 50-41-17
3
P-85667 2
P121303
Remove the wedge (Item 1) [Figure 50-41-15] out the

bottom of the Bob-Tach. If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Always replace bent or broken wedges. vise. Remove the bolt (Item 1) [Figure 50-41-17] and
Assembly: Clean the threads and apply Loctite® 242 to


BOB-TACH (POWER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-41-18
2 1
P-85669
Remove the Power Bob-Tach. (See Removal And


Use a seal pick to remove seal (Item 1) [Figure 50-41-
18] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-18]

with a driver tool and hammer.
Figure 50-41-19
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-41-19].

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4

P-90592A

1] from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

the stabilizer bar rear pivot pin at the lift arm.
Installation: Tighten the retainer bolt and nut to 48 - 54


LIFT ARMS (CONT’D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].

Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer nut and bolt (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT’D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).

P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
P-90611

P114629 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)

Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.
Remove the retaining bolt and nut (Item 1) [Figure 50-

50-13] from the pin on the rod end of the lift cylinder (both
sides).
Installation: Tighten the retainer bolt and nut to 48 - 54


Figure 50-50-16
1
2
P-90609
2
Remove the retaining nut and bolt (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being

removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.


REAR GRILLE
Removing
Figure 50-60-1
P109933

Lift and pull the rear grille backward to remove from the
loader [Figure 50-60-1].
Figure 50-60-2
P109932
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].

REAR GRILLE (CONT’D) Figure 50-60-5
Installing
Figure 50-60-3
P109722
Insert the edge of the rear grille under the loader frame
P109931
and slide rear grille in while lowering [Figure 50-60-5].
Figure 50-60-6
Insert the front tab of the two side covers into the slots in
the loader frame and lower [Figure 50-60-3]. (Left side

shown.)
Figure 50-60-4
P109721
Insert the tabs of the rear grille into the slots in the two
side covers [Figure 50-60-6]. (Left side shown.)
P109718
Insert the rear tab of the two side covers into the slots in
the loader frame and lower [Figure 50-60-4]. (Left side
shown.)

REAR GRILLE (CONT’D)
Shield Removal And Installation
Figure 50-60-7
1 1
2
P114171
Remove the two bolts (Item 1) and remove the shield

(Item 2) [Figure 50-60-7].


REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
3
2
P-85695
1
Remove the top and bottom door hinge mounting nuts

P-85697 and bolts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
2
1 1
P-90584
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation

1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-85698A
Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].

Remove the striker assembly from the loader.
Striker Disassembly And Assembly P-85698A
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320A
Tighten both striker mount bolts (Item 1) [Figure 50-70-
6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the locknut (Item 1) [Figure 50-70-5].
Remove the rollers (Item 2) and the spacer (Item 3) from
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.
Check the parts for wear and replace as needed.

Disconnect the spring (Item 1) [Figure 50-70-7] from the
rear door.

Remove the nut (Item 2) and bolt (Item 3) [Figure 50-70-
7] from the latch.
Installation: Tighten the nut (Item 2) and bolt (Item 3) to

34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.


FUEL TANK Figure 50-80-3
Lift and block the loader. (See Procedure on Page 10-10- 2

1.)
1
Remove the engine / hydrostatic pump assembly from
Page 70-10-14.)
Figure 50-80-1 3
P114312
1
Disconnect the fuel vent hose (Item 1) and remove the
two bolts (Item 2) [Figure 50-80-3].
Drain the fuel tank.
Figure 50-80-4

4
P114311
Remove the fuel vent hose (Item 1) [Figure 50-80-1].

2 3
Figure 50-80-2
1
P-85708
4
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].
3 Disconnect the wire harness connector (Item 2) [Figure

50-80-4] from the fuel level sender.
2 Remove the two mounting bolts (Item 3) and remove the

P114272
bracket (Item 4) [Figure 50-80-4].
Remove the fuel lines (Item 1). Disconnect the harness

(Item 2) from the bottom of the filter. Remove the bolts
(Item 3) and the filter assembly (Item 4) [Figure 50-80-2].
NOTE: Cap and plug all fuel lines and components

after disconnecting the fuel lines.

FUEL TANK (CONT’D) Figure 50-80-7
Figure 50-80-5
1
1
1 1
P-85711
At the right side of the loader, remove the two main frame
P-85710 mount nuts and bolts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount nuts and

Remove the bolts (Item 1) [Figure 50-80-5] from the bolts to 542 - 583 N•m (400 - 430 ft-lb) torque.
battery hold down plate.

Figure 50-80-8
Remove the hold down plate from the loader.
Figure 50-80-6
1 1 1
P-85712
2
P-85709 At the left side of the loader, remove the two main frame
mount nuts and bolts (Item 1) [Figure 50-80-8].
Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount nuts and
(Item 2) [Figure 50-80-6]. bolts to 542 - 583 N•m (400 - 430 ft-lb) torque.
Lift the fuel tank and remove it from the loader frame.
NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
damage.

FUEL TANK (CONT’D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-11
Figure 50-80-9
1
P114271
P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
Disconnect the wire harness connector (Item 1) [Figure
50-80-9] from the fuel level sender. Figure 50-80-12

Remove the fuel level sender.
Figure 50-80-10
P114273
Remove the fuel fill screen (Item 1) [Figure 50-80-12].

P-85716
Inspect and replace as needed.
Inspect the fuel level sender (Item 1) [Figure 50-80-10]

and replace if worn or damaged.


CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING P-85675
Never work on a machine with the lift arms up unless Remove the nut and bolt (Item 1) [Figure 50-90-1] from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598

Figure 50-90-2
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar (Item 2) [Figure 50-90-5] from the

Remove the nut and bolt (Item 1) [Figure 50-90-3] to pivot.
disconnect the lift pedal linkage from the crossbar.

Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-7 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2
Figure 50-90-9
P-85675
Remove the nut and bolt (Item 1) [Figure 50-90-7] from

the pedal linkage.

Remove the linkage (Item 2) [Figure 50-90-7].
P-85676
Figure 50-90-8
Loosen the two mounting nuts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
1
Figure 50-90-10
2
2
P-85675A
Remove the nut and bolt (Item 1) [Figure 50-90-8] from

the pedal linkage. P-85675
Remove the linkage (Item 2) [Figure 50-90-8]. Loosen the nut and bolt (Item 1) [Figure 50-90-10] on
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-90-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11

1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
P-85675
WARNING Remove the nut and bolt (Item 1) [Figure 50-91-1] from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.

to fall and cause injury or death. Figure 50-91-2
W-2059-0598

DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.

Figure 50-91-4 P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]

from the pedal mounting bracket.
Figure 50-91-6
1
1
P-90981 2
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot.
P-85675
Repeat for other side.
Loosen the nut and bolt (Item 1) [Figure 50-91-6] on the
pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7

1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].


CONTROL PANEL
Description
Figure 50-100-1

NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT’D) Figure 50-100-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-100-3

• Keep out of this area when lift arms are raised 2

D-1009-0409
1
WARNING
P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598
the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Two Piece Shaft
Figure 50-100-4 Remove Control Panel. (See Removal And Installation on

Page 50-100-2.)
Figure 50-100-6
2
1 1
2
2
2
P-90612
Scribe a mark across the top of the steering linkage bars 1 1

P-85864
(Item 1) [Figure 50-100-4] which are connected to the

steering shaft on the control panel.
Remove the nuts (Item 1) and the steering stabilizers
Remove the four steering linkage mounting bolts, nuts (Item 2) [Figure 50-100-6].
and rubber isolators (Item 2) [Figure 50-100-4].
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-100-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Two Piece Shaft (Cont’d) 2
Figure 50-100-7
1
2 2
P-85867
1
3 1 3 3
3 Remove the four bolts (Item 1) [Figure 50-100-9] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-9].

Figure 50-100-8 Figure 50-100-10
4
3
1
1
P-85861 P-85868
Remove the nut and bolt (Item 1), steering link, (Item 2), Remove the tie straps (Item 1), the four nuts (Item 2), and
and washers (Item 3) [Figure 50-100-7] and [Figure 50- the plate (Item 3) [Figure 50-100-10].
100-8].
Remove the control handle (Item 4) [Figure 50-100-10].
Installation: Verify correct orientation of components

CONTROL PANEL (CONT’D) One Piece Shaft
Disassembly And Assembly (Cont’d) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Two Piece Shaft (Cont’d)
Figure 50-100-13
Figure 50-100-11
1 1
2
2
1 2 1
1 1
P-85864
P-85872
Remove the nuts (Item 1) and the steering stabilizers

Remove the two bolts (Item 1) from the bellcrank (Item 2) (Item 2) [Figure 50-100-13].
[Figure 50-100-11].
Remove the bellcrank from the bracket [Figure 50-100-

11].
Figure 50-100-12
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-12] for wear and
replace as needed.
Repeat the procedure for the other control handle

assembly.


1 2
One Piece Shaft (Cont’d) 2
Figure 50-100-14
1 1
2 2
1
1
P-85867
1
3 1 3 3
3 Remove the eight bolts (Item 1) [Figure 50-100-16] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-16].

Figure 50-100-15 Figure 50-100-17
4
3
1 1
P-85861 P-85868
Remove the bolts and nuts (Item 1), steering link, (Item Remove the tie straps (Item 1), the four nuts (Item 2), and
2), and washers (Item 3) [Figure 50-100-14] and [Figure the plate (Item 3) [Figure 50-100-17] on both sides.
50-100-15].
Remove the control handles (Item 4) [Figure 50-100-17].
Installation: Verify correct orientation of components


4
One Piece Shaft (Cont’d)
Figure 50-100-18
1
P126303
1 1
2
Inspect the shaft (Item 1), bellcrank (Item 2), four
bushings (Item 3) and the two torsion bushings (Item 4)
[Figure 50-100-20] for wear and replace as needed.
P126302
Linkage Removal And Installation

Figure 50-100-19
WARNING
2
2 Never work on a machine with the lift arms up unless
W-2059-0598
1
1
P126301
WARNING
P126310

Remove the two bolts (Item 1) from the bellcrank (Item 2) of the frame before running the engine for service.
[Figure 50-100-18] and [Figure 50-100-19]. Failure to use jackstands can allow the machine to
Remove the bellcrank assembly (Item 2) [Figure 50-100- W-2017-0286
18] and [Figure 50-100-19] from the bracket.
1.)


Linkage Removal And Installation (Cont’d)

1
Figure 50-100-21
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-100-22].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-21] which are connected to the Installation: Tighten the centering spring bolt and a

steering shaft on the control panel. NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-100-23
and rubber isolators (Item 2) [Figure 50-100-21].

1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-12.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-23] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-100-24
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect the wear on the centering blocks (Item 1) [Figure
P-48630 50-100-25].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-100-25]. Remove the centering
of the following parts: blocks.

ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -
1 Bolt 54,2 N•m (35 - 40 ft-lb) torque.
2 Bushings
NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer
NOTE: If the centering blocks are worn, they can be
5 Spring
removed and rotated 180 degrees and
6 Locknut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-100-26
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-28].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-28].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-29
26] from the pintle.

Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-26].
Figure 50-100-27 2
1 3
1
2 P-48659
4
3 NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-100-29].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-100-29]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the nut and bolt (Item 1) [Figure 50-100-27].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the linkage neutral
steering control lever (Item 4) for damage and replace as adjusting procedure must be performed. (See
needed [Figure 50-100-27]. Linkage Neutral (Adjusting) on Page 50-100-
12.)
NOTE: The washers (Item 2) [Figure 50-100-27] are
hardened, and should only be replaced
through Bobcat Parts.

Pintle Arm Disassembly And Assembly

1
Earlier Model
Figure 50-100-30
4
2 2
4
3
P-54626
2
3 Remove the base pintle (Item 1) [Figure 50-100-32] from

the pump shaft.
1 Remove the retaining bolt (Item 2), adjusting screw (Item

P-54624 3) and neoprene dampener (Item 4) from the base pintle
[Figure 50-100-32].

Remove the nut (Item 1) from the pintle roller cams (Item Inspect parts for wear and damage, replace as needed
2) and inspect the pintle roller cams and washers (Item 3) [Figure 50-100-32].
for damage [Figure 50-100-30].
NOTE: Anti-seize should be used on the adjusting
Inspect the torsion bushing (Item 4) [Figure 50-100-30] screw to prevent corrosion and allow free
for damage and replace as needed. movement while adjusting.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40 Figure 50-100-33
ft-lb) torque.
Later Model
Figure 50-100-31
2 1
1
2
3
P-48619
Using a bushing driver (Item 1) remove the torsion

1 2 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-33].
NA15142
Installation: Install the torsion bushing (Item 2) [Figure

Later models have roller bearings (Item 1) and wear 50-100-33] into the pintle arm using the same procedure
cams (Item 2) [Figure 50-100-31]. as the removal.
NOTE: When the torsion bushing is installed, the

amount of bushing on each side of the pintle
arm should be the same.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
MEL1563 or 7217666 Remote Start Tool Kit. 1
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)

1.) P-85845
Figure 50-100-34
Loosen the nut and bolt (Item 1) [Figure 50-100-35] only
until the tension is released from the torsion bushing.
3
Figure 50-100-36

2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50-

100-34]. P-54613
To make this tool use a locking grip C-clamp and grind

one edge flat (Item 1) and grind the other edge (Item 2) Loosen the nut and bolt (Item 1) only until the tension is
[Figure 50-100-34] to a small rounded edge. released from the torsion bushing (Item 2) [Figure 50-
100-36].
A steering centering block (Item 3) [Figure 50-100-34] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-100-36] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT’D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-37
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.

[Figure 50-100-37] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-38
Tighten bolts (Item 3) [Figure 50-100-38] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-100-37] and
[Figure 50-100-38].
1
P-48451
A modified locking grip C-clamp and steering block

shown in [Figure 50-100-34] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-clamp (Item 2) [Figure 50-100-38]
around both centering blocks.
Lock the C-clamp in place.

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-39
2 1 1
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
P-48632 NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
Loosen the left pump pintle adjustment lock bolts neutral adjustment.
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-39].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-100-40]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
Turn the adjustment screw (Item 1) [Figure 50-100-40] to
NOTE: If the bolts are too loose or too tight, the a point between forward and reverse where there is zero
neutral adjustment may be affected. creep.
Stroke the left steering lever to forward and allow the

lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Verify that
there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-41
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-41] to 47,5 - 54,2 N•m (35 - 40 ft-lb).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-41] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-41] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and reinstall the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with preapplied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-16.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, inspect the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the nut and bolt (Item 1) [Figure 50-100-42] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-43

WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nut and bolt (Item 1) only until the tension is
Raise the operator cab. (See Raising on Page 10-30-2.) released from the torsion bushings (Item 2) [Figure 50-
100-43].
Preload tension in the torsion bushings must be removed
before adjusting the steering linkage. The bolts must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-43] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-44
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-46].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-44] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-45 Figure 50-100-47
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-100-45]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-47].
Verify the cam mounting nuts (Item 4) [Figure 50-100-45]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-48
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-100-50].

P-85844
Figure 50-100-51
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
48] on each steering linkage bar. 2

Figure 50-100-49
P-54613
Tighten the two nut and bolt (Item 1) and (Item 2) to 47,5
- 54,2 N•m (35 - 40 ft-lb) [Figure 50-100-51].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-100-
49]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Verify the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-52 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-53] and [Figure
50-100-54] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.

Drive the loader forward and inspect for drift.
The traditional benchmark for drift is less than 3 m (10 ft)

of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-100-53] and [Figure
50-100-54] in.
Tighten the two bolts and nuts (Item 1) [Figure 50-100- If the drift is excessive to the right, turn the left
52] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-53 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-55
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-100-55]

from the end of the shocks connected to the steering

linkages.
Remove the mounting nuts (Item 2) [Figure 50-100-55]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-101-1]

DANGER

that secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-

101-2].
WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-101-2].
Never work on a machine with the lift arms up unless Remove the control panel (Item 3) [Figure 50-101-2].
W-2059-0598


CONTROL HANDLE / LEVER Boot Removal And Installation
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-110-1
1
2
3
P-85883A
Remove the rubber boot (Item 1) [Figure 50-110-2].

4
Install the new boot and reinstall the steering lever.
1

P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
Remove the control handle / lever. (See Lever Removal



CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-111-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)

functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector [Figure 50-111-3].

Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.

Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, inspect the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 neutral and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2
P-21882 [Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-13] from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the Allen head screws (Item 2) [Figure
P16534 50-111-14] from the handle assembly.
Installation: Tighten the Allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.

Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-111-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A

Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC) Joystick Testing
Description See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to test function.
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.

CONTROL HANDLE / LEVER (SJC) (CONT’D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-2.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890

Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item

2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer (Item [Figure 50-120-2] from the right access panel.
2), and remove the left access panel (Item 3) [Figure 50-
120-1]. Remove the right access panel from the loader.
Remove the left access panel from the loader.


ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
2 1
2
P-90587
P100731
Remove the two mounting nuts (Item 1), and remove the
footrest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
footrest (Item 2) [Figure 50-121-1]. Figure 50-121-4

Figure 50-121-2
2
3 2
2
1
1
1
2
P-90588
P100732
Remove the bolt and engine speed control pedal (Item
1), and remove the mounting screws (Item 2) [Figure 50-
Remove the mounting screws (Item 1), and remove the 121-4].
left inside access panel (Item 2) [Figure 50-121-2].
Remove the right inside access panel (Item 3) [Figure
50-121-4].


WINDOW (REAR) Removal And Installation (Latches)
Rear Window Identification

Latches Rubber Cord
2 • When fluids are under pressure.
1 • Engine is running.
P-85309B P-64994D W-2019-0907
There are two different procedures for removing the rear Figure 50-130-2
window from the machine:
1. This window is equipped with latches (Item 1) [Figure

50-130-1].
2. This window is equipped with a rubber cord and tag

(Item 2) [Figure 50-130-1]. 1 1

P-85706
Remove the rear window assembly by turning the two

latches (Item 1) [Figure 50-130-2] in until they disengage
from the window frame.
Push the rear window out the rear of the operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.
Clean the area before installing the rear window

assembly.
Reverse the procedure to install the rear window.

WINDOW (REAR) (CONT’D) Figure 50-130-4
Disassembly And Assembly (Latches)

8
Figure 50-130-3 7
1
6
1
2
3
4
5
P-85704

P-85705
Remove the screw (Item 1) [Figure 50-130-3] from the 1. Latch

latch.
2. Spacer

Installation: Tighten the screw to 21 - 23 N•m (180 - 200 3. Bushing
in-lb) torque.
4. O-ring
5. Washer
6. Screw
7. Rear Window
8. Seal

WINDOW (REAR) (CONT’D)
Removal (Rubber Cord)
WARNING
• When fluids are under pressure.
• Engine is running.
W-2019-0907
Figure 50-130-5

P-64994
Pull on the tag on the top of the rear window to remove

the rubber cord [Figure 50-130-5].
Push the rear window out of the rear of the operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.

WINDOW (REAR) (CONT’D) Figure 50-130-8
Installation (Rubber Cord)
Figure 50-130-6
1
P109581
Install the rear window assembly from the outside of the

P109560 operator cab into the window frame.
Install a lower corner of the rear window assembly into

Install the rubber molding (Item 1) [Figure 50-130-6] the corner of the window frame (Item 1) [Figure 50-130-
around the edge of the rear window. 8].

Figure 50-130-7 Work the window assembly downward until the window is
fully seated in the lower portion of the window frame.
Figure 50-130-9
2
P-85228
Apply liquid soap to the rubber molding (Item 1) [Figure

P109582
50-130-7] for installation.
NOTE: Install the window assembly with the narrow Apply light pressure to the outside of the window
edge (Item 2) [Figure 50-130-7] towards the assembly holding it tight up against the window frame.
inside of the loader.
Use a multipurpose tool (Item 1) [Figure 50-130-9] under
the molding lip to guide the window assembly into the
window frame.
NOTE: Tapping the window with a rubber hammer will

help seat the window assembly in the window
frame.

WINDOW (REAR) (CONT’D)
Installation (Rubber Cord) (Cont’d)
Figure 50-130-10
P109583A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-

10] with the safety tag into the molding on the outside of
the operator cab.
NOTE: Verify the safety tag is located in the top center

of the window.


WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].

Figure 50-131-4
Figure 50-131-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].

Tighten the nuts to 9 - 10 N•m (80 - 90 in-lb) torque.
NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

1 1
Figure 50-132-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.

Figure 50-132-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.


CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
2

P-85781A 1
2
Open the cab door.
NOTE: Later models route the washer fluid hose

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

hose (Item 1) (if equipped) [Figure 50-140-1].
Figure 50-140-2
2
3
2 1
1 P-85837
Remove the four nuts and bolts (Item 2) [Figure 50-140-

4] from the cab.
P-85588A P-85589A
Remove the hinges (Item 1) [Figure 50-140-4] from the

Rotate and pull the clip (Item 1) out of the gas spring cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. Installation: Install the hinges (Item 1) on the cab and
use the bolts and nuts (Item 2) [Figure 50-140-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].

2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

(270 - 300 in-lb) torque.
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

(270 - 300 in-lb) torque.
Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-140-

4.)
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
1 1
P-90726M
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P-85831
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch inspect the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837

Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Installation on Page 50-31-2.).
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.

P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the nut (Item 3) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8

1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

Disassembly And Assembly (Cont’d) Later Models
Figure 50-150-9
Earlier Models
1
3
2
P100825
1
Figure 50-150-12
P-90842
Later Models
Figure 50-150-10
Earlier Models

7 4
6 3
5 2
3
6 1
5 2 P100824
4 1
Remove the nut (Item 1), washer (Item 2), spring (Item 3)
P-90843 and the spacer (Item 4) [Figure 50-150-11] and [Figure
50-150-12].
Remove the nut (Item 1), washer (Item 2), and the plastic Remove the spacer (Item 4), washer (Item 5), plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150- washer (Item 6) and the bolt (Item 7) [Figure 50-150-12].
10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-
Remove the spacer (Item 4), plastic washer (Item 5), and lb) torque.
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

ARMREST (CONT’D)
Figure 50-150-13
All Models
1 1
2
P-90844
Remove the two nuts and bolts (Item 1) and the slide rail
(Item 2) [Figure 50-150-13] from the armrest mount.

Repeat for the other side.


LEFT SIDE LOWER PANEL Figure 50-160-3
Raise the operator’s cab.
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4

Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1
31-4.)
Lower the operator’s cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].

Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11

1
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
P-90866

remove the speaker from the left side lower panel.

Figure 50-160-13
P-90864
Remove the three screws (Item 1) [Figure 50-160-13]

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operator’s cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4

Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.

NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new lock washer when it has been
side of the cab far enough to access the wire removed.
harness.
Figure 50-170-8
Figure 50-170-6
2 1
1
2 P-90877
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove

Disconnect the wire harnesses (Item 1) and the antenna the radio from the right side lower panel.
(Item 2) [Figure 50-170-6] (if equipped with radio).
Installation: Insert a screwdriver into the slot (Item 2)
NOTE: Install the right side lower panel with the radio [Figure 50-170-8] to lock the tab into place.
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.

Remove the input from the right side lower panel.
Figure 50-170-10
P-90876

remove the speaker from the right side lower panel.


HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if

P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation (Earlier Models) on Page 60-
2) [Figure 50-180-1] (if equipped). 60-2.) or (See Cab Light Removal And Installation (Later

Models) on Page 60-60-3.)
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage. Figure 50-180-4
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
Figure 50-180-2
1
1
1
1
1 2
P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
P-90894
Installation: Route the cab light wire harness in the
groove on the topside of the headliner (if equipped with
Remove the air duct (Item 1) [Figure 50-180-2] (if HVAC).
equipped).
NOTE: Replace the retainers if needed.


FAN DUCT PANELS Figure 50-190-3

1 2
Remove the fan duct. (See Fan Duct Removal And

1
Figure 50-190-1
P114638
Remove the bolts (Item 1) and remove the panel (Item 2)

[Figure 50-190-3].
IMPORTANT

2

P114641
Figure 50-190-2 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P114642
Remove the bolts (Item 1) [Figure 50-190-1] and (Item 1)

[Figure 50-190-2] and remove the panel (Item 2) [Figure
50-190-1].


ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors - Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Mainframe Harness Connectors - SJC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-11
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-11
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-3
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System 
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1


ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-231-1
Foot Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-231-4
CAMSHAFT AND CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . 60-240-1

TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-2


CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C100 FUEL FILTER 2 8 C405 AIR FILTER SWITCH 2 8 FRC1 FUSE RELAY CENTER 112 4,5,8,10,14,15
C103 TAILGATE 8 6,13,14,16 C406 FUEL SENDER 2 8
C105 HYD CHARGE PRESSURE 3 10 C408 CAB-MFR HARN CONN(BLK) 15 4,6,7,11, 12,14,16 J1A GATEWAY CONTROLLER 34 5,8,10,11,13,14,15,16
C108 HYD TEMPERATURE SENDER 2 10 C409 RIGHT HANDLE 10 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,10,11,12,13,16
C110 ALTERNATOR 2 8 C410 LEFT HANDLE 10 13 J2A AUX CONTROLLER 34 10,13,16
C111 MFR-BCT ENG HARN CONN 3 8 C411 LEFT HANDLE 5 WAY 5 16 J2B AUX CONTROLLER 26 4,5,6,7,10,13,16
C112 HYD OIL FILTER SWITCH 2 10 C412 LEFT HANDLE 2 WAY 2 16
C114 HAND THROTTLE 6 8 C415 HIGH FLOW SOLENOID 2 16 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C118 ENG-CROSSOVER 4 8 C418 FRONT ROD 2 10
C126 HORN 2 16 C419 FRONT BASE 2 10
C129 CAB ACCESSORY 3 12 C420 HYD LOCK 2 10 SW1 BRAKE SWITCH 6 11
C130 EXHAUST GAS TEMP SENSOR Doc 2 9 C421 TILT SPOOL LOCK 3 13 SW2 BEACON SWITCH 6 16
C131 EXHAUST GAS TEMP SENSOR TURBO 2 9 C422 LIFT SPOOL LOCK 3 13 SW3 HAZARD SWITCH 6 16
C132 EXHAUST GAS TEMP SENSOR Doc 2 9 C423 BUCKET POSITION 2 16 SW4 HAND/FOOT, H/ISO SWITCH 6 12
C133 EXHAUST GAS TEMP SENSOR Doc 2 9 C425 BRAKE SOLENOID 3 10
C134 EXHAUST GAS PRESS SENSOR 3 9 C426 CAN(Remote Start Tool, ACD) 7 7 SW5 POWER BOBTACH SWITCH 6 16
C135 INTAKE THROTTLE 5 9 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,12,16 SW6 BUCKET POSITION SWITCH 6 16
C136 OIL PRESS & TEMP SENSOR 4 9 C434-1 LEFT WORKLIGHT 1 2 14
C137 O2 SENSOR & HEATER 6 9 C434-2 LEFT WORKLIGHT 2 2 14 SW9 TRAVEL CONTROL SWITCH 6 11
C138 INLET TEMP PRESS SENSOR 5 9 C435-1 RIGHT WORKLIGHT 1 2 14 SW10 BLOWER SWITCH 6 15
C139 INJECTOR 1 2 9 C435-2 RIGHT WORKLIGHT 2 2 14 SW11 AC SWITCH 3 15
C140 INJECTOR 2 2 9 C438 CAB-MFR HARN CONN(DK GRY) 14 12,14,15,16 SW12 DPF SWITCH 10 11
C141 INJECTOR 3 2 9 C441 TWO SPEED 2 16

C142 INJECTOR 4 2 9 C446 HYDRAULIC FAN 2 10 T1 BATT GROUND 1 6
C143 RAIL PRESSURE SENSOR 3 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 T2 BUZZER GROUND 1 11
C144 CAMSHAFT POSITION SENSOR 3 9 C450 RIGHT JOYSTICK(CAB HARN) 4 7 T3 FLASHER 2 16
C145 CRANKSHAFT POSITION SENSOR 3 9 C479 LEFT PANEL(BLACK) 12 7,11 T6 BATT GROUND 1 6
C146 ACCELEROMETER 2 2 9 C480 LEFT PANEL(GRAY) 12 11 T8 BATT GROUND 1 6
C147 ACCELEROMETER 1 2 9 C482 SEATBAR SENSOR 3 12 T10 ENGINE SYSTEM GROUND 1 6
C148 FUEL TEMPERATURE SENSOR 2 9 C483 TEMP CONTROL SWITCH 3 15 T13 BUZZER POWER 1 11
C149 COOLANT TEMPERATUR SENSOR 2 9 C486 AC COMPRESSOR 2 15
T14 PRE HEATER 1 8,9
C150 AMBIENT AIR TEMP SENSOR 2 9 C489 MFR ACCESSORY 2 5,6 T15 RIGHT REAR WORK LIGHT(+) 1 14
C151 EGR VALVE DC MOTOR 6 9 C499 PTOL 4 11 T16 RIGHT REAR WORK LIGHT(-) 1 14
C152 WASTE GATE POSTION 3 9 C500 RH KEY SWITCH 6 11 T17 LEFT REAR WORK LIGHT(+) 1 14
C153 WASTE GATE 2 9 C503 RH DLX PANEL 6 7,11 T18 LEFT REAR WORK LIGHT(-) 1 14
C154 INLET METERING VALVE 2 9 C602 LEFT REAR TAIL LIGHT 2 14 T19 BACKUP ALARM 1 13
C169 ENGINE CAN (Diagnostic) 6 7 C603 RIGHT REAR TAIL LIGHT 2 14 T20 BACKUP ALARM(GND) 1 13
C212 POWER SOCKET 2 12 C606 POWER BOBTACH OPEN 2 16 T32 ECU CASE GROUND 1 6
C252 WASHER 2 12 C607 POWER BOBTACH CLOSE 2 16
C277 AIR RIDE SEAT 6 16 C610 HVAC DUCT FAN 2 15
C278 RIGHT SPEAKER 2 16 C611 BLOWER MOTOR 4 15
C279 LEFT SPEAKER 2 16 C630 THERMOSTAT 3 15
C308 BRAKE SOLENOID 2 10 C635 HEATER VALVE 6 15
C350 AC EVAPORATOR SWITCH 2 15 C667 DOOR 6 12
C355 DLX or STD FUEL HARNESS 6 8,16 C670 EXTERIOR BEACON 6 16
C404 BU ALARM-MFR HARN 2 5,13 C676 RADIO 6 16
WIRING SCHEMATIC Printable Version Click Here
(MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
(S/N T1ML11001 AND ABOVE)
Sheet 1 of 16
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7230752 (A)
659 of 1288
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD
A-5 HORN RELAY B-5 REAR AUX (F)
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK
A-6 B-6 RELIEF SOLENOID
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD
A-7 B-7 REAR AUX (M)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-10 TILT SPOOL LOCK RETURN B-10
A-11 B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 B-12
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL
A-13 B-13 FRONT AUX (F)
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD
A-14 B-14
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2
A-15 B-15 GROUND
A-15 ENGINE SPEED B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17
A-17 REAR LIGHT 2 RELAY B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN B-18
A-18 FAN 2 RETURN B-18
A-19 B-19 FRONT AUX (M)
A-19 PTOL LED B-19 FAN 2 OUTPUT
A-20 B-20
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21

A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED POWER
A-22 STATER RELAY FDBK B-22 RUN/ENTER
A-23 B-23
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25 HYDRAULIC BOOST
A-25 WATER IN FUEL B-25 TWO SPEED MAKEUP
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27 HYDRAULIC BOOST RETURN
A-27 TWO SPEED MAKE-UP RETURN
A-28
A-28 REAR LIGHT 2 RELAY FDBK
A-29
A-29
A-30
A-30 FUEL PULL RELAY FDBK
A-31
A-31 FRONT WORK LIGHT 1 RELAY FDBK
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33
A-34
A-34 HYD OIL FILTER SW1

HARNESS PART NUMBER
MFR MANUAL
FOR 400 MODEL
7226883
FOR 500 MODELS
7223849
FOR 600 MODELS
7221857
WIRING SCHEMATIC
DLX CAB
STD CAB
7235319
7227905
7234736
7227905
7234736
7227905
(MANUAL MACHINE)
STD FUEL 7200449 7149219 7149219 T650 (S/N ALJG11001 - ALJG12302)
DLX FUEL 7200460 7184255 7184255
BCT ENG START 7220812 7220812 7220812 (S/N T1ML11001 AND ABOVE)
ENGINE 7030824 7030824 7030824
TAILGATE DOM 7217484 7217484 7217484
TAILGATE EUR 7217483 7217483 7217483
SUSP JSTK 7163706 7163706 7163706 Sheet 2 of 16
BRAKE ADAPTER 7124853 7165061 7165061 (PRINTED DECEMBER 2016)
WHL 2 SPD ADP 7159366 7159366 7159366
Printed In U.S.A. TRACK 2 SPD 7214626 7230752 (A)
660 of 1288
ENGINE CONTROLLER
CONNECTOR J7
PIN FUNCTION
1 SW POWER
2 GND
3 SW POWER
4 GND
5 SW POWER
6 GND
9 WATER FUEL SENSOR
13 PEDAL POS 2
14 PEDAL POS 2
15 AIR MASS FLOW SENSOR
19 IGN SW INPUT
24 PEDAL POS 1
25 PEDAL POS 1

26 PEDAL POS 1
29 PEDAL POS 2
34 WATER FUEL SENSOR

45 SW POWER SIGNAL
47 CAN 1 LO
48 CAN 1 HI
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 3 of 16
661 of 1288
M SCHEMATIC INDEX LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3 PARTIAL CONNECTOR
UNSWITCHED
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-9
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 10 CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 11
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
BATT POWER
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 14 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 15
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 16
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C408 1240 RED/WHT SHEET 10

(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 10
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 10
C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT 1150 RED/WHT 3
J2B
BATTERY 1180 RED/WHT 2 AUX CTRLR

MEGAFUSE
100.0 Amps
FUSE 15 OPEN
FUSE 17 OPEN
SHEET 8
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 14
FUSE 3 30 A FRC1 HVAC RELAY
1310 RED 1360 RED/WHT SHEET 9
FRC 1 TRACTION LOCK RELAY
FUSE 1 15 A 1320 RED/WHT
SHEET 13
FRC1 REAR LIGHT RELAY
1340 RED SHEET 13
FRC1 FRONT LIGHT RELAY
1330 RED/WHT
FUSE 9 50 A SHEET 13
1060 RED 1065 RED/WHT SHEET 8 FRC1 FRONT LIGHT RELAY
FRC1 PRE HEATER RELAY
FUSE 20 5 A
FRC1 ENGINE ECU RELAY
1325 RED FUSE 16 25 A
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 8
FUSE 18 25 A FRC1 PRE HEATER RELAY
C426 REMOTE RUN, ACD
1460 RED/WHT
FUSE 22 25 A SHEET 15 C412 LH HANDLE HORN Printable Version Click Here
1040 RED 1490 RED/WHT 1410 RED/WHT
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
1290 RED
FUSE 24 25 A
1370 RED/WHT
SHEET 11 WIRING SCHEMATIC
C408 CAB-MFR CONN
1055 RED
(ACCESSORIES) (MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
1030 RED
SHEET 8
Sheet 4 of 16
FRC1 STARTER RELAY (PRINTED DECEMBER 2016)
662 of 1288
SWITCHED
POWER
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 14
HVAC PAGE 15 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 16
FRC1
ENGINE ECU J7A ENGINE ECU
+12V RELAY
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30
87 1504 RNG/WHT 1507 RNG/WHT 3
1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45
FRC1 FUSE RELAY CENTER

1345 RED/WHT

SHEET 4
FUSE 21 15 A
1511 RNG/WHT
SHEET 8 ENG-CROSSOVER
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS SHEET)
FUSE 5 25 A C489
1750 RNG/WHT 1780 RNG/WHT A MFR ACCESSORY
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 10 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION) SHEET 10 C479 LH PANEL
1940 RNG/WHT
1520 RNG/WHT SHEET 10 T13 LH PANEL BUZZER
SHEET 12 C410 LEFT HANDLE 1930 RNG/WHT
SHEET 10 C499 RH PANEL PTOL
1530 RNG/WHT SHEET 12 C409 RIGHT HANDLE 1775 RNG/WHT
SHEET 10 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 10 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 11 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 10 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT 1590 RNG/WHT
SHEET 10 C503 RH DELUXE PANEL
1765 RNG/WHT FUSE 7 25 A
SHEET 7 C426 REMOTE RUN, ACD
1725 RNG/WHT
SHEET 7 C169 ENGINE CAN
FUSE 8 25 A
1580 RNG/WHT
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
FUSE 23 15 A
FRC1
SWITCHED SHEET 8 C110 ALT EXCITATION
POWER RELAY
+12V
PWR 30
WIRING SCHEMATIC
1050 RED 21
SHEET 4
87 3450 LBL
J1A
GWY CTRLR
C428
(LT GRAY)
(MANUAL MACHINE)
GND 85 86
2055 BLK 3380 LBL 4 CAB-MFR HARN CONN 2
SHEET 6
1920 RNG/WHT 9 1920 RNG/WHT 1840 RNG/WHT SHEET 7 T650 (S/N ALJG11001 - ALJG12302)
C449 LH JOYSTICK
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 16
Printed
663 of 1288 In U.S.A. 7230752 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-9 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 10
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
MANUAL CONTROLS PAGE 13 2320 BRN
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS SHEET 9
LIGHTS PAGE 14 C112 HYD OIL FILTER SWITCH
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 15 2370 BRN J1B
SHEET # SHEET 11 GWY CTRLR
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 16 C408 CAB-MFR CONN (SEATBAR SENSOR)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 2220 BRN 2230 BRN 17
SHEET 9
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 9
C105 HYD CHG PRESSURE SENDER
4 2002 BLK 2810 BLK 2180 BRN
J7A SHEET 8
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 8
C405 AIR FILTER SWITCH
T32 2004 BLK
ECU CASE GND SHEET 8 2690 BRN
C408 CAB-MFR CONN (HAND THRTL)
2080 BLK
SHEET 7
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408

C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 10 2765 BLK
C479 LH PANEL SHEET 13
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745 BLK
SHEET 14
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 10 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
GWY CTRLR 15 2500 BLK SHEET 11 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 10
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 15
SHEET 10 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 11
SHEET 10 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2830 BLK 2900 BLK 1 2900 BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 10 SHEET 15
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 15 SHEET 9
C126 HORN C425 BRAKE
2620 BLK
SHEET 13 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
2650 BLK
SHEET 12
T20 BU ALARM 2600 BLK B 2600 BLK 2390 BLK T1 2015 BLK T10
2640 BLK BATT GND SHEET 8 ENGINE
SHEET 13 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT 2455 BLK
SHEET 15
2610 BLK C423 BKT POSITION SOLENOID
C603 RH REAR LIGHT SHEET 7
2630 BLK C426 REMOTE RUN, ACD Printable Version Click Here
SHEET 13 2715 BLK
T18 LH REAR LIGHT SHEET 7
C169 ENGINE CAN
SHEET 13 2045 BLK SHEET 14

2290 BLK
D4 COMPRESSOR DIODE
WIRING SCHEMATIC
SHEET 9
FRC1 TRACTION LOCK RELAY
2035 BLK (MANUAL MACHINE)
2115 BLK 2105 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY T650 (S/N ALJG11001 - ALJG12302)
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY (S/N T1ML11001 AND ABOVE)
SHEET 14 2030 BLK
FRC1 HVAC RELAY
SHEET 8 2005 BLK
FRC1 STARTER RELAY
2120 BLK
Sheet 6 of 16
SHEET 13
FRC1 FRONT LIGHT RELAY (PRINTED DECEMBER 2016)
664 of 1288
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
PARTIAL CONNECTOR
CAN BUS
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 10
LIGHTS 6000 THROUGH 6999 PINK PNK
MANUAL CONTROLS
LIGHTS
PAGE 13
PAGE 14 (TWO WIRE BREAKS * DLX CAB HARN 7234736 AND
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 15 JOIN ONE WIRE)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 16 SHEET # 7235319(SF) ONLY
(NOT IN STD CAB HARN 7207731)
J7A J1B
ECU CNTRLR GWY CTRLR
47 9200 PUR 9215 PUR 9210 PUR 9205 PUR 20

CAN LO
48 9100 PUR/WHT 9115 PUR/WHT 9110 PUR/WHT 9105 PUR/WHT 14
CAN HI
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6

C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1
8 9260 PUR 9230 PUR 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
J2B
1830 RNG/WHT 1
AUX CTRLR SHEET 5
2070 BLK 2 C450
SHEET 6 RIGHT JOYSTICK
9280 PUR 8 9320 PUR/WHT 3 SHEET 11
9180 PUR/WHT 9 9420 PUR 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9300 PUR/WHT 3
SHEET 11
9400 PUR 4
J2B
C426
AUX CTRLR
Remote Run Tool, ACD
14 9500 PUR/WHT A Printable Version Click Here
CAN HI
20 9600 PUR B
CAN LO
WIRING SCHEMATIC
J1B
GWY CTRLR (MANUAL MACHINE)
21 3090 LBL D
C
REMOTE RUN KEY T650 (S/N ALJG11001 - ALJG12302)
1735 RNG/WHT E SWITCHED POWER
SHEET 5
SHEET 4
1165 RED/WHT F UNSWITCHED POWER (S/N T1ML11001 AND ABOVE)
2710 BLK G GROUND
SHEET 6
Sheet 7 of 16
665 of 1288 Printed In U.S.A. 7230752 (A)
LEGEND
ENGINE
PARTIAL CONNECTOR
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 13 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 14 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 16
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
FRC1 C111
+12V STARTER RELAY MFR-BCT HARN CONN
PWR 30 STARTER
1030 RED
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 3560 LBL ALTERNATOR G
L 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6
16 3150 LBL A SIG

SWITCH (NC) ENGINE GROUND TERMINAL
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
SHEET 6
10 3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
CAB-MFR HARN CONN 2 HAND THROTTLE
SHEET 11 5690 YEL 7 5690 YEL C +5V PWR
3690 LBL 6 3690 LBL A
SIG
2690 BRN 8 2690 BRN B GND
J7A
ENG ECU CTRLR SHEET 6 D
E
19 8007 TAN F Printable Version Click Here
9 3865 LBL
C100
1
SIG WATER IN FUEL SENSOR
WIRING SCHEMATIC
34 2865 BRN 2 (FUEL FILTER)
GND
(MANUAL MACHINE)
C118 T650 (S/N ALJG11001 - ALJG12302)
ENG-CROSSOVER
SHEET 5 1511 RNG/WHT 1 (S/N T1ML11001 AND ABOVE)

28 8013 TAN 8013 TAN 2
MAF FREQ
35 8014 TAN 8014 TAN 3
MAF TEMP
+12V
4
SHEET 4
1065 RED/WHT
PWR
30
87 8525 TAN
3420 LBL
8500 TAN
Sheet 8 of 16
56 8510 TAN 85 86 1445 RED/WHT
PREHEATER
SHEET 4 7230752 (A)
RELAY
Printed In U.S.A.
666 of 1288
LEGEND
ENGINE
PARTIAL CONNECTOR
HARNESS
OPTIONS PAGE 16
T14 PRE HEATER 179

PRE HEATER J7B
C153 ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 5V 123 TEMP SENSOR
SENSOR RETURN 2
MAP BEFORE TURBO
2 GND
3 SIG
C151
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 INTAKE
EGR VALVE
3 172 169 MANIFOLD
DC MOTOR POSITION RETURN SENSOR RETURN 4
TEMP SENSOR
6 H BRIDGE POS 192

2 H BRIDGE NEG 193
C149
1 COOLANT TEMP SENSOR 109
COOLANT TEMP
SENSOR 2 COOLANT RETURN 145
C148
1 FUEL TEMP SENSOR 110
FUEL TEMP
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136 SHEET ?
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK
ACCELEROMETER 2 2 SENSOR RETURN 133
SHIELD 129
C145
CRANKSHAFT CRANK SENSOR POS 160
POSITION
CRANK SENSOR NEG 136
SENSOR Printable Version Click Here
C144
C138
147
CAM SHAFT
1
2
SENSOR RETURN
POS SENSOR 159
WIRING SCHEMATIC
SENSOR 112 INTAKE PRESS SENSOR A INLET TEMP
3 VREF1 CAM 140
167 INTAKE PRESS RETURN D PRESSURE
SENSOR
(MANUAL MACHINE)
C143
1 RAIL PRESSURE SENSOR 135 T650 (S/N ALJG11001 - ALJG12302)
RAIL PRESSURE 2 119
SENSOR RETURN
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA
C139 (S/N T1ML11001 AND ABOVE)
C141 126 CYL 1
FUEL INJECTOR LSD1A
FUEL INJECTOR HSDB 151
CYL 3 C140
FUEL INJECTOR LSD1B 175
150 FUEL INJECTOR HSDB Sheet 9 of 16
174 CYL 2
C142
FUEL INJECTOR HSDA 103
FUEL INJECTOR LSD2B (PRINTED DECEMBER 2016)
Printed In U.S.A. CYL 4
FUEL INJECTOR LSD2A 125 C154 7230752 (A)
177 PWM 2
INLET METERING
1 VALVE
667 of 1288
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
CONTROLLER GROUND/RETURN
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
CONNECTOR
WIRE BREAK
HYDRAULICS
OPTIONS PAGE 16 SHEET #
FRC1
TRACTION LOCK C425
+12V RELAY
4100 LGN B C308
PWR 30 BRAKE
SHEET 4 1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035 BLK OPTIONS SHEET)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061, 7124853(SF)
8 4110 LGN
13 3430 LBL
C108
2220 BRN B HYDRAULIC
GND

SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
3.3 OHM PWM
C419 (MANUAL MACHINE)
1 2340 BRN 2 GND
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) T650 (S/N ALJG11001 - ALJG12302)
3.3 OHM PWM
19 13
J2B
AUX CTRLR Sheet 10 of 16
668 of 1288
LEGEND
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
CONNECTOR CAB DISPLAY
MANUAL CONTROLS PAGE 13 WIRE BREAK
LIGHTS PAGE 14 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
T13
BUZZER (+)
1940 RNG/WHT
SHEET 5
LEFT PANEL C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408 2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5

TRAVEL CONTROL 19 2380 BRN 12 2380 BRN 4
3400 LBL 11 PTOL LED
SWITCH (OPTIONAL) LEFT BLINKER INPUT J1A
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 14
SHEET 6 LEFT PANEL (GRAY) 3040 LBL 3040 LBL 4
GWY CTRLR RUN/ENTER SWITCH
3620 LBL 12
SHEET 11 DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DIESEL PARTICULATE 7 C503
FILTER SWITCH 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DPF INHIBIT LAMP 1240 RED/WHT 1
1 SHEET 4 UNSWITCHED POWER
2065 BLK 2 3 8060 TAN
SHEET 6 DPF OVERRIDE 2250 BLK 3
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED

(MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Printed In U.S.A.
Sheet 11 of 16
669 of 1288
7230752 (A)
LEGEND
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB
GROUND PAGE 6
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8-9 CONNECTOR
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
* DLX CAB HARN 7234736 AND
HVAC PAGE 15
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 16 SHEET # 7235319(SF) ONLY
*SW4
HAND/FOOT (NOT IN STD CAB HARN 7227905)
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
2060 BLK 5 6
C438 SHEET 11
(DK GRAY) 4
CAB-MFR HARN CONN 3
7 4235 LGN
8 4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR

C408
(BLACK)
CAB-MFR HARN CONN 1 * T37
DOME LIGHT (+)
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT
SHEET 4
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
1885 RNG/WHT SHEET 15
2210 BLK SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS SHEET)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG

+5V
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR
WIRING SCHEMATIC
* C252
SHEET 8 5690 YEL L SIG
WASHER (MANUAL MACHINE)
2845 BLK X MOTOR
GND
T650 (S/N ALJG11001 - ALJG12302)
Sheet 12 of 16
670 of 1288
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLS
HVAC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
K
AUX CTRLR G
C404 A
C103 SHEET 5 1530 RNG/WHT
BU ALARM-MFR HARN
TAILGATE HARN 30 4940 LGN H
T19 TERMINAL (+)
(SEE ADDITIONAL 31 4930 LGN J SKI CTRL
A 7100 WHT C 7100 WHT
4920 LGN E

OPTIONS SHEET) BACK UP DETENT FLOW
2650 BLK ALARM 13 4910 LGN F
SHEET 6 TWO SPD
4310 LGN C
T20 TERMINAL (-) 4320 LGN D
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 TILT SPOOL LOCK 20 4640 LGN D
SIG
2 17.8 OHM 12V 28 4840 LGN C
22 4830 LGN B SKI CTRL
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG 17.8 OHM 12V SHEET 5
2 J
H
E
7 5
J1B
GWY CTRLR
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 13 of 16
671 of 1288
LEGEND
PARTIAL CONNECTOR
LIGHTS
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 14
HVAC PAGE 15
OPTIONS PAGE 16
C434-1
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
6000 PNK 8 6000 PNK 6120 PNK A SIG RIGHT FRONT
FRC1 WORK LIGHT
2760 BLK B GND
FRONT WORK 37.00 Watts
LIGHTS RELAY
C438 C435-2
(DK GRAY) 6130 PNK A SIG
1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
SHEET 4 87 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK
2120 BLK 85 86

SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
6210 PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
+12V RELAY
PWR 30 T17 TERMINAL (+)
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SIG LEFT REAR
GND 85 2630 BLK GND WORK LIGHT
86 SHEET 6
2045 BLK
SHEET 6 T18 TERMINAL (-)

WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 14 of 16
672 of 1288 Printed In U.S.A. 7230752 (A)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RNG/WHT
BLK
BRN
LBL
LGN
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
CONNECTOR
HVAC
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 13
PAGE 14
WIRE BREAK
(TWO WIRE BREAKS
HVAC
OPTIONS
PAGE 15
PAGE 16
JOIN ONE WIRE)
SHEET #
7235319(SF) ONLY
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT (NOT IN STD CAB HARN 7227905)
2440 BLK * C610
2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK
* C483
C BLK
7420 WHT A DBL POTENTIOMETER
7425 WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130 BLK C GND HEATER

7430 WHT A +12V PWR VALVE
B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT
7510 WHT 3 5.00 Amps Low MOTOR
SW11
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
AC SWITCH 2580 BLK 4
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT 7020 WHT 12
C630
* 3
THERMOSTAT
AC EVAPORATOR C350 2570 BLK 2 Printable Version Click Here

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT
WIRING SCHEMATIC
C486
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH
(MANUAL MACHINE)
(COMPRESSOR)
SHEET 6
2290 BLK
D4
2280 BLK
T650 (S/N ALJG11001 - ALJG12302)
Sheet 15 of 16
673 of 1288
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1-3
OPTIONS
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL #
MANUAL CONTROLS PAGE 13 WIRE BREAK DLX FUEL HARN 7184255, 7200460(SF) ONLY
HVAC PAGE 15 JOIN ONE WIRE) (NOT IN STD FUEL HARN 7149219, 7200449(SF) )
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C428
#
C355
FUEL HARN
(LT GRAY)
CAB-MFR HARN CONN 2 * DLX CAB HARN 7234736 AND
C607
POWER BOB
SIG 1
2
4470 LGN E
B
4470 LGN 11 4470 LGN 7235319(SF) ONLY
GND 2470 BLK 2770 BLK 2770 BLK 4480 LGN
CLOSE SHEET 6
SW5 (NOT IN STD CAB HARN 7227905)
*POWER 2 1
# C606 BOBTACH 3
SWITCH 5 4
GND 2 2480 BLK 6
POWER BOB 1 4480 LGN
SIG 4480 LGN F 10
OPEN
6010 PNK 13 6010 PNK
1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5
C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT

C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 10 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS SHEET) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 10 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY
6
D
(SEE ADDITIONAL
OPTIONS SHEET)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS SHEET)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
6.13 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS SHEET) SHEET 4 2 AIR RIDE
RIGHT
*-
C278
2 7810 WHT 6 3 SEAT
SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
SHEET 11
+ 1885 RNG/WHT 1 2210 BLK 5 GND
SHEET 11 SHEET 11
2 6
SHEET 11 2885 BLK
C415
J2A 26 2460 BRN B GND HIGH FLOW
AUX CTRLR SOLENOID NOT AVAILABLE ON Printable Version Click Here
4460 LGN A SIG 400 LOADERS
7.5 OHM 12 V
J2B
AUX CTRLR
26
WIRING SCHEMATIC
C441
TRACK 2 SPEED
(MANUAL MACHINE)
J1A 26 2350 BRN 2 GND TWO SPEED
ADAPTER
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V (SEE ADDITIONAL T650 (S/N ALJG11001 - ALJG12302)
OPTIONS SHEET)
J1B
GWY CTRLR
26
Sheet 16 of 16
674 of 1288
CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C434-1 LEFT FRONT WORKLIGHT (37W) 2 13 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C434-2 LEFT FRONT WORKLIGHT (50W) 2 13
C105 HYD CHARGE PRESSURE SENSOR 3 9 C435-1 RIGHT FRONT WORKLIGHT (37W) 2 13 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C435-2 RIGHT FRONT WORKLIGHT (50W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 J2A AUX CONTROLLER 34 9,12,15

C110 ALTERNATOR 2 8 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C441 TWO SPEED SOLENOID 2 15
C112 HYD OIL FILTER SWITCH 2 9 C446 HYDRAULIC FAN 2 9 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C449 LEFT JOYSTICK(CAB HARN) 4 7
C114 HAND THROTTLE 6 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7
C479 LEFT PANEL(BLACK) 12 7,10 SW1 BRAKE SWITCH 6 10
C480 LEFT PANEL(GRAY) 12 10 SW2 BEACON SWITCH 6 15
C482 SEATBAR SENSOR 3 11 SW3 HAZARD SWITCH 6 15
C118 ENG-CROSSOVER 4 8 C483 TEMP CONTROL SWITCH 3 14 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C126 HORN 2 15 C486 AC COMPRESSOR 2 14
C129 CAB ACCESSORY 3 11 C489 MFR ACCESSORY 2 5,6 SW5 POWER BOBTACH SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 SW6 BUCKET POSITION SWITCH 6 15
C212 POWER SOCKET 2 11 SW9 TRAVEL CONTROL SWITCH 6 10

C252 WASHER ADAPTER INTMD 2 11 SW10 BLOWER SWITCH 6 14
C253 WASHER PUMP 2 11 C499 PTOL 4 10 SW11 AC SWITCH 3 14
C277 AIR RIDE SEAT 6 15 C500 RH KEY SWITCH 6 10 SW12 DPF SWITCH 10 10

C278 RIGHT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10
C279 LEFT SPEAKER 2 15 C602 LEFT REAR TAIL LIGHT 2 13 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 9 C603 RIGHT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10
C350 AC EVAPORATOR SWITCH 2 14 C606 POWER BOBTACH OPEN 2 15 T3 FLASHER 2 15
C355 FUEL HARNESS 6 8,15 C607 POWER BOBTACH CLOSE 2 15 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,12 C610 HVAC DUCT FAN 2 14 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C611 BLOWER MOTOR 4 14 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C630 THERMOSTAT 3 14 T13 BUZZER POWER 1 10
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C635 HEATER VALVE 6 14
T14 PRE HEATER 1 8
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T15 RIGHT REAR WORK LIGHT(+) 1 13
C410 LEFT HANDLE (MAN/ACS) 10 12 C670 EXTERIOR BEACON HARNESS 6 15 T16 RIGHT REAR WORK LIGHT(-) 1 13
C411 LEFT HANDLE 5 WAY 5 15 C676 RADIO 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T19 BACKUP ALARM 1 12
C418 FRONT ROD 2 9 T20 BACKUP ALARM(GND) 1 12
C419 FRONT BASE 2 9 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 9
C421 TILT SPOOL LOCK 3 12
C422 LIFT SPOOL LOCK 3 12
C423 BUCKET POSITION SOLENOID 2 15
C425 BRAKE SOLENOID 3 9
C426 CAN(Remote Start Tool, ACD) 7 7
C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15

WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 1 of 16
(PRINTED NOVEMBER 2016)

Printed In U.S.A. 7254941 (0)
675 of 1288
PIN FUNCTION PIN FUNCTION A-1 FRONT BASE RETURN B-1
A-2 B-2 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR RELAY - A B-4 RUN SIG ENG ECU
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 LH PADDLE RIGHT B-11
A-12 LH PADDLE LEFT B-12
A-13 RH RIGHT ROCKER UP B-13 FRONT BASE SOLENOID
A-13 TRACTION LOCK FDBK RELAY - D B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-17 B-17 RH PWM LOW
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT ROD RETURN B-18 RH PWM SIGNAL
A-18 HYD FAN RETURN B-18
A-19 B-19 FRONT ROD
A-19 PTOL LED B-19 HYD FAN
A-20 LH SW-FLOAT (ACS) B-20 CAN LOW 2
A-21 B-21 RH TRIGGER
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED POWER

A-22 STARTER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HIGH
A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-28 LH RIGHT ROCKER UP
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30 RH LEFT ROCKER UP
A-30 HVAC FDBK RELAY - B
A-31 RH LEFT ROCKER DOWN
A-31 LIGHT FDBK RELAY - K
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR MAN 7223849
EXMF MFR MAN 7265268
DLX CAB 7253375
STD CAB 7227905 Printable Version Click Here
STD FUEL 7149219
DLX FUEL
BCT ENG START
7266824
7220812
WIRING SCHEMATIC
TAILGATE DOM
TAILGATE EUR
7217484
7217483
(MANUAL MACHINE)
SUSP JSTK 7163706 T650 (S/N ALJG12303 - ALJG17414)
BRAKE ADAPTER 7165061
WHL 2 SPD ADP 7159366 (S/N B2KZ11001 - B2KZ12035)
TRK 2 SPD 7214626
Sheet 2 of 16
676 of 1288 Printed In U.S.A. 7254941 (0)
LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
CONNECTOR J7
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8 CONNECTOR
3 SW POWER HYDRAULICS PAGE 9
4 GND CAB DISPLAY PAGE 10
CAB PAGE 11
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK
9 WATER FUEL SENSOR HVAC PAGE 14
13 OPTIONS PAGE 15 SHEET #
14 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
15
19 IGN SW INPUT
21
24
25
A B C D
26
28 MAF FREQ

29 PEDAL POS 2
35 MAF TEMP
34 WATER FUEL SENSOR GND E F G H

45 ECU RELAY GND
47 CAN 1 LO
48 CAN 1 HI
J K L M
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 3 of 16

677 of 1288
UNSWITCHED BATT POWER C408 1240 RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
SP7
SHEET 10
FUSE 11 25 A SP2 J1B
SHEET 10
C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 OPEN
T4 1
FUSE 17 OPEN
SHEET 8
STARTER
FUSE 4 25 A
SHEET 14

SHEET 13
1340 RED SHEET 13
SP26 FRC1 FRONT LIGHT RELAY
1330 RED/WHT
1335 RED FUSE 20 5 A
1345 RED/WHT SHEET 5
1325 RED FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT SHEET 5
1445 RED/WHT
SHEET 8
1460 RED/WHT
FUSE 22 25 A SP24 SHEET 15 C412 LH HANDLE HORN
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60
WIRING SCHEMATIC
1050 RED
SHEET 5
(MANUAL MACHINE)
1030 RED
SHEET 8
FRC1 STARTER RELAY
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 4 of 16

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FRC1
ENGINE ECU
+12V RELAY - G
PWR
SWITCHED POWER 1506 RNG/WHT
J7A ENGINE ECU
1
87 1504 RNG/WHT SP54 1507 RNG/WHT 3

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT SHEET 8 ENG-CROSSOVER
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489

SP50
FUSE 6 25 A 1850 RNG/WHT
1760 RNG/WHT
1700 RNG/WHT SHEET 10 SW12 DPF SWITCH (UNUSED)
FUSE 12 15 A
SHEET 15 C408 CAB-MFR CONN (BKT POSITION) SHEET 10 C479 LH PANEL (BLACK)
1940 RNG/WHT
C428 1960 RNG/WHT
SP11 1950 RNG/WHT
1765 RNG/WHT FUSE 7 25 A SP65 SP42
SP25
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1 FUSE 23 15 A Printable Version Click Here
POWER RELAY - A
+12V
PWR
30
WIRING SCHEMATIC
SHEET 4 1050 RED 21
3450 LBL
GND 85
87
86
J1A
GWY CTRLR
C428
(LT GRAY) (MANUAL MACHINE)
SHEET 6
SP37
C449 LH JOYSTICK
T650 (S/N ALJG12303 - ALJG17414)
1830 RNG/WHT
SHEET 7 (S/N B2KZ11001 - B2KZ12035)
C450 RH JOYSTICK
Sheet 5 of 16
7254941 (0)
Printed In U.S.A.
679 of 1288
GROUND
2320 BRN
SHEET 9
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 11 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN 2230 BRN 17
SHEET 9
C108 HYD TEMP SENDER SP12
2190 BRN
2 SHEET 9
2001 BLK C105 HYD CHG PRESSURE SENDER
4 SP53 2810 BLK 2180 BRN
J7A 2002 BLK
SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
2080 BLK
SHEET 7
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
SHEET 10 2765 BLK
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
2745 BLK
C499 PTOL SHEET 14
C500 RH PANEL KEY SWITCH J1B SP3 2790 BLK T8

SHEET 10
(LT GRAY) 2540 BLK
SP47 SP28
2830 BLK 2900 BLK 1 2900 BLK
SHEET 15
2700 BLK 2770 BLK
SHEET 10 SHEET 15
2785 BLK 2200 BLK
SHEET 15 SHEET 9
2620 BLK
SHEET 13 C103 C489
SHEET 12 2650 BLK
SP51 2600 BLK B 2390 BLK T1 T10
T20 BU ALARM 2600 BLK 2015 BLK
2640 BLK SP6 BATT GND SHEET 8 ENGINE
SHEET 15
C426 REMOTE RUN, ACD SP27
2630 BLK
SHEET 13 2715 BLK
C169 ENGINE CAN
2290 BLK
SHEET 13 2045 BLK SHEET 14 Printable Version Click Here
D4 COMPRESSOR DIODE
2035 BLK
SHEET 9
2115 BLK SP55 2105 BLK
WIRING SCHEMATIC
SHEET 13
2055 BLK
(MANUAL MACHINE)
SHEET 5
FRC1 SWITCHED POWER RELAY
SHEET 14 2030 BLK T650 (S/N ALJG12303 - ALJG17414)
FRC1 HVAC RELAY
SHEET 8
2005 BLK (S/N B2KZ11001 - B2KZ12035)
FRC1 STARTER RELAY
SHEET 13
2120 BLK Sheet 6 of 16

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* DLX CAB HARN 7253375 ONLY
CAN BUS
J7A
ECU CNTRLR (NOT IN STD CAB HARN 7207731) J1B
GWY CTRLR
47 9200 PUR 9215 PUR SP90 9210 PUR 9205 PUR 20

CAN LO
CAN HI
SP91 RE021
RE018
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)

8 9260 PUR 9230 PUR SP31 9220 PUR 4 9220 PUR SP18 9410 PUR
SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
C479
RE014 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
J2B
1830 RNG/WHT 1
AUX CTRLR SHEET 5
9280 PUR 8
SHEET 6
9320 PUR/WHT
2070 BLK 2
3
*
C450
RIGHT JOYSTICK
9180 PUR/WHT 9 9420 PUR 4
1840 RNG/WHT 1
SHEET 5
9300 PUR/WHT
SHEET 6
2080 BLK 2
3
*
C449
LEFT JOYSTICK
9400 PUR 4
J2B
C426
AUX CTRLR
14 9500 PUR/WHT A
CAN HI Printable Version Click Here
20 9600 PUR B
CAN LO
J1B
WIRING SCHEMATIC
GWY CTRLR
(MANUAL MACHINE)
21 3090 LBL D
C
E
REMOTE RUN KEY
T650 (S/N ALJG12303 - ALJG17414)
1735 RNG/WHT SWITCHED POWER
SHEET 5
SHEET 4
1165 RED/WHT
2710 BLK
F
G
UNSWITCHED POWER
GROUND
(S/N B2KZ11001 - B2KZ12035)
SHEET 6
Sheet 7 of 16

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SHEET 4
1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M
87
ENGINE 8200 TAN
C111
HARN ENG START CONN
A
B
8220 TAN
STARTER
S M
B SHEET 4
GND 85 86
3560 LBL 3560 LBL R
2005 BLK 8210 TAN 1800 RNG/WHT C 1015 RED
SHEET 6 SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
L 1800 RNG/WHT
J1A C405 EXCITATION
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
J1B C355

GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND
SHEET 6 (30 - 270 OHM)
10 3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
9 3865 LBL 1 WATER IN FUEL SENDER
SIG
34 2865 BRN 2 GND (FUEL FILTER)
C118
ENG-CROSSOVER
To C154 - PIN1 and Printable Version Click Here
1511 RNG/WHT 1
SHEET 5 C155 - PIN 3
28 8013 TAN 8013 TAN 2
MAF FREQ
MAF TEMP
35 8014 TAN 8014 TAN 3
MAF Sensor - PIN 1
MAF Sensor - PIN 4
WIRING SCHEMATIC
+12V
1065 RED/WHT
PWR
30
87 8525 TAN
3420 LBL
8500 TAN
4
TO J7B - PIN 79 (MANUAL MACHINE)
SHEET 4 PRE-HEATER Sheet 16 of 16
56 8510 TAN 85 86
SP93
1445 RED/WHT T650 (S/N ALJG12303 - ALJG17414)
SHEET 4
PREHEATER
RELAY - C
(S/N B2KZ11001 - B2KZ12035)
Sheet 8 of 16
Printed In U.S.A. (PRINTED NOVEMBER 2016)
7254941 (0)
682 of 1288
1360 RED/WHT PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
4200 LGN
C425
B
A 4200 LGN
C308
A
BRAKE
TRACK 2 SPEED
SHEET 4 87 SOLENOID
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
7165061
8 4110 LGN
13 3430 LBL
C108
GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
4010 LGN 1 SIG

FAN SOLENOID
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
2190 BRN B GND
SHEET 6
3190 LBL C SIG HYDRAULIC CHARGE
5190 YEL A +8V PWR PRESSURE SENSOR
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A 18 2330 BRN 2 GND FRONT ROD
AUX CTRLR
4330 LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
WIRING SCHEMATIC
1 2340 BRN
C419
2 GND
(MANUAL MACHINE)
FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
19 13
J2B
Sheet 9 of 16
AUX CTRLR

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SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
CAB DISPLAY C499
Press To Operate Loader
C479 (PTOL)
T2
10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1

3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 3 8060 TAN
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Printed In U.S.A. Sheet 10 of 16

7254941 (0)
684 of 1288
*
SW4
CAB
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3
C438
(DK GRAY)
SHEET 11 2060 BLK 5 6
4
CAB-MFR HARN CONN 3
7 4235 LGN
8 4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SP45
* T37
DOME LIGHT (+)
SHEET 4
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY SP41
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5

2800 BLK C GND
1510 RNG/WHT
SHEET 15
SP44 2210 BLK SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL SP13 5370 YEL 5370 YEL C

3 +5V PWR
+5V
5690 YEL
SHEET 8
WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378 (MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
* C252 C253
PWR (S/N B2KZ11001 - B2KZ12035)
A 7310 WHT 1 WASHER
2845 BLK B 2845 BLK 2 GND

MOTOR Sheet 11 of 16

685 of 1288
MANUAL CONTROLS C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
K
AUX CTRLR G
C404 A
C103 1530 RNG/WHT
BU ALARM-MFR HARN SHEET 5
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
OPTIONS Sheet) 4920 LGN E DETENT FLOW
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23

LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK 20 4640 LGN D
2 17.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 J
H
E
7 5
J1B Printable Version Click Here
GWY CTRLR
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 12 of 16

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C434-1
LIGHTS
C408
(BLACK)
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
FRC1 2760 BLK B GND WORK LIGHT
37.00 Watts
FRONT WORK
LIGHTS RELAY - J C438 C435-2
50.00 Watts
13 6610 PNK SP64
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
PWR 2610 BLK 2 GND
SHEET 4 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
87 TAIL LIGHT

SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1 6210 PNK SIG WORK LIGHT
RELAY - E
+12V
1320 RED/WHT SP5
SHEET 4 87 6200 PNK H 6200 PNK 6200 PNK SIG LEFT REAR
2045 BLK 86 SHEET 6
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 13 of 16

Printed In U.S.A.
7254941 (0)
687 of 1288
2440 BLK * C610
2 GND HVAC DUCT
HVAC
7440 WHT 1 SIG FAN
2560 BLK
* C483
C BLK
(TEMP CONTROL
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT SWITCH)
(NOT IN STD CAB HARN 7227905) * C635

D SIG
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT

1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT
AC EVAPORATOR C350 2570 BLK 2

A 7024 WHT
C486
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH WIRING SCHEMATIC
(COMPRESSOR)
2290 BLK 2280 BLK
SHEET 6
D4
(MANUAL MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 14 of 16
Printed In U.S.A.
7254941 (0)
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C428 #
OPTIONS
C355 (LT GRAY) DLX FUEL HARN 7266824 ONLY
FUEL HARN CAB-MFR HARN CONN 2
# C607 (NOT IN STD FUEL HARN 7149219 )
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB 2 B
GND 2470 BLK 2770 BLK 2770 BLK 4480 LGN
CLOSE SHEET 6
SW5
*POWER 2 1 * DLX CAB HARN 7253375 ONLY
# BOBTACH 3
GND
C606
2 2480 BLK SWITCH 5 4
6
POWER BOB 1 F 4480 LGN 10
OPEN
SIG 4480 LGN
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
LEFT HANDLE FLASHER PWR

C411
B
SHEET 4
L
* FLASHER
T3
CONN
(FLASHER) 5 WAY C SHEET 10 3500 LBL
D1
(SEE ADDITIONAL
RIGHT A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
E
OPTIONS DWG) SWITCH

D 6415 PNK 6400 PNK 3 D2 6430 PNK
LEFT 6400 PNK
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
(SEE ADDITIONAL INTERNALLY 6
D
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
4
2 * SW6
OPTIONS DWG)
SHEET 6 6
6.13 OHM
C408
(BLACK) * C676
C412
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
LEFT HANDLE
(HORN) 2 WAY
HORN SIGNAL
PWR
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
SHEET 4 2 AIR RIDE
(SEE ADDITIONAL
OPTIONS DWG)
RIGHT
*- C278
2 7810 WHT 6 3 SEAT
SHEET 11
+ 1885 RNG/WHT 1 2210 BLK 5 GND
SHEET 11 SHEET 11
2 6
SHEET 11 2885 BLK
C415
J2A 26 2460 BRN B GND HIGH FLOW
AUX CTRLR A SIG SOLENOID
4460 LGN Printable Version Click Here
7.5 OHM 12 V
J2B
26
AUX CTRLR
WIRING SCHEMATIC
J1A 26 2350 BRN
C441
2 GND TWO SPEED TRACK 2 SPEED (MANUAL MACHINE)
GWY CTRLR SOLENOID ADAPTER
4350 LGN 1 SIG
5.1 OHM 12 V (SEE ADDITIONAL
OPTIONS DWG)
T650 (S/N ALJG12303 - ALJG17414)
J1B 26
GWY CTRLR (S/N B2KZ11001 - B2KZ12035)
Sheet 15 of 16

689 of 1288
LEGEND
ENGINE
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
See Sheet 8 of 16 ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 2 EXHAUST GAS
123 1 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151 C136
TO C113 PIN 3
1 EGR VREF3 164 4
See Sheet 5 of 14
5 POSITION SIGNAL 116 120 SENSOR GROUND 3
EGR VALVE
3 172 137 5V 2 MAF
DC MOTOR POSITION RETURN
SENSOR
6 H BRIDGE POS 192 TO C113 PIN 2 1
2 H BRIDGE NEG 193 See Sheet 5 of 14

C149
COOLANT TEMP
C148 165 VREF3 OIL PRESSURE 3

OIL PRESSURE &
1 FUEL TEMP SENSOR 110 111 OIL PRESSURE SENSOR 4
FUEL TEMP TEMPERATURE
SENSOR 2 FUEL RETURN 146 148 RETURN GND 1 SENSOR
C147 104 OIL TEMPERATURE SENSOR 2

2 SENSOR SIGNAL 131
ENGINE BLOCK
SHIELD 128
169 RETURN 1 INTAKE
C146 194 SENSOR 2 MANIFOLD
132 TEMPERATURE
2 SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
CRANKSHAFT 1 CRANK SENSOR POS 160
POSITION
2 CRANK SENSOR NEG 136
SENSOR NOTE: ON EARLY MODELS, WIRE
C144 TO PIN 161 WAS TO PIN 141
C138
3 SENSOR RETURN 147 . 161 INTAKE PRESS SENSOR B 1
CAM SHAFT
2 POS SENSOR 159
SENSOR 112 INTAKE PRESS SENSOR A 3 INTAKE MANIFOLD
1 VREF1 CAM PRESSURE
TO C118 - PIN 1| 167 INTAKE PRESS RETURN D 2
SENSOR
C143 See Sheet 8 of 16
1 RAIL PRESSURE SENSOR 135
RAIL
PRESSURE
2 SENSOR RETURN 119 Printable Version Click Here
SENSOR 3 VREF1 SENSOR 138 C139
127 FUEL INJECTOR HSDA 1
151
126 FUEL INJECTOR LSD1A 2 CYL 1 WIRING SCHEMATIC
FUEL INJECTOR HSDB
CYL 3
150 FUEL INJECTOR HSDB
C140
2 (MANUAL MACHINE)
174 1 CYL 2
FUEL INJECTOR LSD2B
T650 (S/N ALJG12303 - ALJG17414)
CYL 4 C154
FUEL INJECTOR LSD2A 125
177 PWM 2
INLET METERING (S/N B2KZ11001 - B2KZ12035)
TO C118 - PIN 1 1 VALVE
SEE Sheet 8 of 16 Sheet 16 of 16
7254941 (0)
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CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C434-1 LEFT FRONT WORKLIGHT (37W) 2 13 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C434-2 LEFT FRONT WORKLIGHT (50W) 2 13
C105 HYD CHARGE PRESSURE SENSOR 3 9 C435-1 RIGHT FRONT WORKLIGHT (37W) 2 13 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C108 HYD TEMPERATURE SENDER 2 9 C435-2 RIGHT FRONT WORKLIGHT (50W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C110 ALTERNATOR 2 8 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J2A AUX CONTROLLER 34 9,12,15
C111 HARNESS ENGINE START CONN 3 8 C441 TWO SPEED SOLENOID 2 15 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C112 HYD OIL FILTER SWITCH 2 9 C446 HYDRAULIC FAN 2 9
C114 HAND THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C118 ENG-CROSSOVER 4 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C126 HORN 2 15 C479 LEFT PANEL(BLACK) 12 7,10 SW2 BEACON SWITCH 6 15
C129 CAB ACCESSORY 3 11 C480 LEFT PANEL(GRAY) 12 10 SW3 HAZARD SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 C482 SEATBAR SENSOR 3 11 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C212 POWER SOCKET 2 11 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C252 WASHER ADAPTER INTMD 2 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C253 WASHER PUMP 2 11 C489 MFR ACCESSORY 2 5,6 SW9 TRAVEL CONTROL SWITCH 6 10
C277 AIR RIDE SEAT 6 15 C499 PTOL 4 10 SW10 BLOWER SWITCH 6 14
C278 RIGHT SPEAKER 2 15 C500 RH KEY SWITCH 6 10 SW11 AC SWITCH 3 14
C279 LEFT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10 SW12 DPF SWITCH 10 10
C308 BRAKE SOLENOID 2 9 C602 LEFT REAR TAIL LIGHT 2 13 T1 BATT GROUND 1 6
C350 AC EVAPORATOR SWITCH 2 14 C603 RIGHT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10

C355 FUEL HARNESS 6 8,15 C606 POWER BOBTACH OPEN 2 15 T3 FLASHER 2 15
C404 BU ALARM-MFR HARN 2 5,12 C607 POWER BOBTACH CLOSE 2 15 T4 MEGAFUSE LOAD SIDE 1 4
C405 AIR FILTER SWITCH 2 8 C610 HVAC DUCT FAN 2 14 T6 BATT GROUND 1 6
C406 FUEL SENDER 2 8 C611 BLOWER MOTOR 4 14 T8 BATT GROUND 1 6
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C630 THERMOSTAT 3 14
T10 ENGINE SYSTEM GROUND 1 6
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C635 HEATER VALVE 6 14 T13 BUZZER POWER 1 10
C410 LEFT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T14 PRE HEATER 1 8
C411 LEFT HANDLE 5 WAY 5 15 C670 EXTERIOR BEACON HARNESS 6 15 T15 RIGHT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C676 RADIO 6 15 T16 RIGHT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C418 FRONT ROD 2 9 T18 LEFT REAR WORK LIGHT(-) 1 13
C419 FRONT BASE 2 9 T19 BACKUP ALARM 1 12

C420 HYD LOCK 2 9 T20 BACKUP ALARM(GND) 1 12
C421 TILT SPOOL LOCK 3 12 T32 ECU CASE GROUND 1 6
C422 LIFT SPOOL LOCK 3 12 T37 DOMELIGHT (+) 1 11
C423 BUCKET POSITION SOLENOID 2 15 T38 DOMELIGHT (-) 1 11
C425 BRAKE SOLENOID 3 9
C426 CAN(Remote Start Tool, ACD) 7 7
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 1 of 16
691 of 1288 7279776 (A)
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD

A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR MAN 7276760
EXMF MFR MAN 7276758
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824
BCT ENG START 7220812
TAILGATE DOM 7217484
TAILGATE EUR 7217483
SUSP JSTK 7266829
BRAKE ADAPTER 7165061 Printable Version Click Here
WHL 2 SPD ADP 7159366
TRK 2 SPD 7214626 WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 2 of 16
692 of 1288
LEGEND
CONNECTOR J7
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK
19 IGN SW INPUT OPTIONS PAGE 15 SHEET #
28 MAF FREQ COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
34 WATER IN FUEL SENSOR

GND
35 MAF TEMP
45 ECU RELAY GND

47 CAN 1 LO A B C D
48 CAN 1 HI
56 GLOW PLUG SIGNAL

E F G H
J K L M
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 3 of 16
7279776 (A)
Printed In U.S.A.
693 of 1288
UNSWITCHED BATT POWER
C408 1240 RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
SP7
SHEET 10
SHEET 10
+12V 1025 RED
FUSE 13 25 A
J2B
100.0 Amps
FUSE 15 OPEN
1 1
FUSE 17 OPEN
SHEET 8
STARTER
FUSE 4 25 A

SHEET 14
SHEET 13
1350 RED/WHT FRC1 REAR LIGHT RELAY
1340 RED
SP26 FRC1 FRONT LIGHT RELAY
1330 RED/WHT
FUSE 20 5 A
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
1055 RED
(ACCESSORIES) WIRING SCHEMATIC Printable Version Click Here
SP60
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
1050 RED
SHEET 5
(S/N B2KZ12036 - B2KZ12105)
1030 RED
SHEET 8
Sheet 4 of 16
FRC1 STARTER RELAY

694 of 1288
FRC1
ENGINE ECU
+12V RELAY - G
SWITCHED POWER J7A ENGINE ECU
PWR 1506 RNG/WHT 1

87 1504 RNG/WHT SP54 1507 RNG/WHT 3

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT
C404
(SEE ADDITIONAL
OPTIONS DWG)

FUSE 5 25 A C489
SP50
1760 RNG/WHT SHEET 11 C438 CAB-MFR CONN (FR WIPER)
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
SP11 1950 RNG/WHT
1765 RNG/WHT FUSE 7 25 A SP65 SP42
SP25
1725 RNG/WHT
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) Printable Version Click Here
FRC1 FUSE 23 15 A
SWITCHED
POWER RELAY - A
SHEET 8 C110 ALT EXCITATION
WIRING SCHEMATIC
+12V
SHEET 4 1050 RED

PWR 30
3450 LBL 21
C428
(MANUAL MACHINE)
87 J1A
SHEET 6 2055 BLK GND 85 86 3380 LBL 4

GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2 T650 (S/N ALJG17415 - ALJG19316)
SP37 SHEET 7
C449 LH JOYSTICK (S/N B2KZ12036 - B2KZ12105)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK Sheet 5 of 16
Printed In U.S.A.
7279776 (A)
695 of 1288
2320 BRN
SHEET 9
GROUND
2370 BRN J1B
SHEET 11 GWY CTRLR
2220 BRN 2230 BRN 17
SHEET 9
C108 HYD TEMP SENDER SP12
2190 BRN
2 SHEET 9
4 SP53 2810 BLK 2180 BRN
J7A 2002 BLK
SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
2080 BLK
SHEET 7
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
SHEET 10 2765 BLK
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745 BLK
SHEET 14

SP3 SHEET 11
2250 BLK GWY CTRLR 15 2500 BLK BATT GND
SHEET 10 C408 CAB-MFR CONN (ACCESSORIES)
(LT GRAY) 2540 BLK
SP47 SP28
2830 BLK 2900 BLK 1 2900 BLK
SHEET 15
2700 BLK 2770 BLK
SHEET 10 SHEET 15
2785 BLK 2200 BLK
SHEET 15 SHEET 9
2620 BLK
SHEET 13 C103 C489
SHEET 12 2650 BLK
SP51 2600 BLK B 2390 BLK T1 T10
2640 BLK SP6 BATT GND SHEET 8 ENGINE
C602 LH REAR LIGHT SHEET 15 2455 BLK
2630 BLK
SHEET 13 2715 BLK Printable Version Click Here
C169 ENGINE CAN

2290 BLK
D4 COMPRESSOR DIODE
WIRING SCHEMATIC
SHEET 9
2035 BLK
(MANUAL MACHINE)
2115 BLK SP55 2105 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY T650 (S/N ALJG17415 - ALJG19316)
2055 BLK
SHEET 5
2030 BLK
(S/N B2KZ12036 - B2KZ12105)
SHEET 14
FRC1 HVAC RELAY
SHEET 8 2005 BLK Sheet 6 of 16
FRC1 STARTER RELAY
2120 BLK
SHEET 13
Printed In U.S.A. FRC1 FRONT LIGHT RELAY 7279776 (A)
696 of 1288
CAN BUS
J7A (NOT IN STD CAB HARN 7227905) J1B
47 9200 PUR 9215 PUR SP90 9210 PUR 9205 PUR 20

CAN LO
CAN HI
SP91 RE021
RE018
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)

8 9260 PUR 9230 PUR SP31 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
C479
RE014 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
J2B
1830 RNG/WHT 1
AUX CTRLR SHEET 5
9280 PUR 8
SHEET 6
9320 PUR/WHT
2070 BLK 2
3
* C450
RIGHT JOYSTICK
9180 PUR/WHT 9 9420 PUR 4
J2B
C426
AUX CTRLR 1840 RNG/WHT 1
Remote Run Tool, ACD SHEET 5
CAN HI
14 9500 PUR/WHT A
9300 PUR/WHT
SHEET 6
2080 BLK 2
3
* C449
LEFT JOYSTICK
20 9600 PUR B
CAN LO 9400 PUR 4
J1B
GWY CTRLR
21 3090 LBL D
C
REMOTE RUN KEY
(MANUAL MACHINE)
SHEET 5
SHEET 4
1165 RED/WHT
2710 BLK
F
G
UNSWITCHED POWER
GROUND
T650 (S/N ALJG17415 - ALJG19316)
SHEET 6
(S/N B2KZ12036 - B2KZ12105)
7279776 (A)
697 of 1288
FRC1
STARTER RELAY - M
+12V
ENGINE
C111
HARN ENG START CONN
STARTER
PWR 30
1030 RED
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
L 1800 RNG/WHT
J1A C405 EXCITATION
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6

J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 SHEET 6
3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
SIG

C118
1511 RNG/WHT
ENG-CROSSOVER
1
To C154 - PIN 1, & WIRING SCHEMATIC
SHEET 5 To C114, Pin 3, Sheet 16 of 16
MAF FREQ
28 8013 TAN 8013 TAN 2
MAF Sensor - PIN 1, Sheet 16 of 16 (MANUAL MACHINE)
35 8014 TAN 8014 TAN 3
MAF TEMP MAF Sensor - PIN 4, Sheet 16 of 16
+12V
PWR
30
3420 LBL 4
TO GLOW PLUG, J7B - PIN 79,
T650 (S/N ALJG17415 - ALJG19316)
1065 RED/WHT 87 8525 TAN 8500 TAN Sheet 16 of 16
56
SHEET 4
8510 TAN 85 86
SP93
1445 RED/WHT
PRE-HEATER
(S/N B2KZ12036 - B2KZ12105)
PREHEATER
SHEET 4
Sheet 8 of 16
RELAY - C
7279776 (A)
698 of 1288
FRC1
TRACTION LOCK
HYDRAULICS C425
+12V RELAY - D B C308
4100 LGN BRAKE
1360 RED/WHT PWR 30
SHEET 4 4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035 BLK OPTIONS DWG)
7165061
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6

C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
2190 BRN B GND
SHEET 6
3190 LBL C SIG HYDRAULIC CHARGE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
WIRING SCHEMATIC
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE) (MANUAL MACHINE)
3.3 OHM PWM
C419 T650 (S/N ALJG17415 - ALJG19316)
1 2340 BRN 2 GND FRONT BASE
3.3 OHM PWM
(S/N B2KZ12036 - B2KZ12105)
Sheet 9 of 16
19 13
J2B
Printed In U.S.A. AUX CTRLR 7279776 (A)
699 of 1288
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
CAB DISPLAY C499
(PTOL)
C479
T2
10 C408 2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6

3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 14
SHEET 6 LEFT PANEL (GRAY) 3040 LBL 3040 LBL 4
GWY CTRLR RUN/ENTER SWITCH
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5 Printable Version Click Here
2065 BLK 2 3 8060 TAN
4
1
8070 TAN 9
DPF INHIBIT REGEN
WIRING SCHEMATIC SHEET 6 6
GROUND
NOT USED
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Printed In U.S.A.
Sheet 10 of 16
7279776 (A)
700 of 1288
*
SW4
HAND/FOOT
(ACS)
CAB
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
SHEET 11
(DK GRAY) 4
CAB-MFR HARN CONN 3 * DLX CAB HARN 7253375 ONLY
7
8
4235 LGN
4275 LGN
9
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SP45
* T37
DOME LIGHT (+)
SHEET 4
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY SP41
1210 RED/WHT A * T38

+12V BATT PWR DOME LIGHT (-)
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL SP13 5370 YEL 5370 YEL C

3 +5V PWR Printable Version Click Here
+5V
SHEET 8 5690 YEL

WIRING SCHEMATIC
(MANUAL MACHINE)
HARNESS WASHER PUMP
7253378 T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
* C252 C253
PWR Sheet 11 of 16
Printed In U.S.A. A 7310 WHT 1 WASHER
MOTOR
2845 BLK B 2845 BLK 2 GND
7279776 (A)
701 of 1288
MANUAL
CONTROLS
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
K
AUX CTRLR G
C404 A
BU ALARM-MFR HARN
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
OPTIONS Sheet) 4920 LGN E DETENT FLOW
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B

C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 TILT SPOOL LOCK 20 4640 LGN D
SIG
2 17.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 2990 BRN 3 11 4810 LGN F SIDE SHIFT
GND
2 J
H
E
7 5
J1B WIRING SCHEMATIC
GWY CTRLR
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 12 of 16
702 of 1288
C434-1
LIGHTS
C408
(BLACK)
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
RC1 2760 BLK B GND WORK LIGHT
37.00 Watts
FRONT WORK
LIGHTS RELAY 1 C438 C435-2
SHEET 4 87 6620 PNK 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
2120 BLK 85 86
SHEET 6
6630 PNK
6000 PNK
RC1
FRONT WORK
LIGHTS RELAY 2 C103
PWR 2610 BLK 2 GND

TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK 2 LEFT REAR
GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1 6210 PNK SIG WORK LIGHT
RELAY - E
+12V
1320 RED/WHT SP5
86 SHEET 6
2045 BLK
WIRING SCHEMATIC
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 13 of 16
Printed In U.S.A.
7279776 (A)
703 of 1288
* C610
HVAC
2440 BLK 2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483

C BLK
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT
(TEMP CONTROL
SWITCH)
(NOT IN STD CAB HARN 7227905) C635
* D SIG
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT

1
GND 85 86 4
2030 BLK
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

A 7024 WHT
C486 Printable Version Click Here

7025 WHT 1 SIG
MAGNET CLUTCH
2290 BLK 2280 BLK
2 GND
(COMPRESSOR) WIRING SCHEMATIC
SHEET 6
D4
(MANUAL MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Printed In U.S.A.
Sheet 14 of 16
7279776 (A)
704 of 1288
# C607
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2 #
OPTIONS
DLX FUEL HARN 7266824 ONLY
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB
GND 2 2470 BLK 2770 BLK B 2770 BLK 4480 LGN
(NOT IN STD FUEL HARN 7149219 )
CLOSE SHEET 6
SW5
*POWER 2 1
# C606 BOBTACH
SWITCH 5
3
4
GND 2 2480 BLK 6
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10 (NOT IN STD CAB HARN 7227905)
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
LEFT HANDLE FLASHER PWR

C411
B
SHEET 4
L
* T3
FLASHER
CONN
(FLASHER) 5 WAY C SHEET 10 3500 LBL
D1
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG)

LEFT D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
(SEE ADDITIONAL INTERNALLY 6
D
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
C423 SHEET 6 2420 BLK BEACON/FLASHER
4
2 *BUCKET
SW6
6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
SHEET 6 6
6.13 OHM
C408
(BLACK) * C676
C412
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
LEFT HANDLE
(HORN) 2 WAY
HORN SIGNAL
PWR
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
(SEE ADDITIONAL SHEET 4 2 AIR RIDE
OPTIONS DWG)
RIGHT
*-
C278
2 7810 WHT 6 3 SEAT
SHEET 11
+ 1885 RNG/WHT 1 2210 BLK 5 GND
SHEET 11 SHEET 11
2885 BLK 2 6
SHEET 11
C415
J2A B HIGH FLOW Printable Version Click Here
26 2460 BRN GND
AUX CTRLR A SIG
SOLENOID
4460 LGN
7.5 OHM 12 V
J2B
26
WIRING SCHEMATIC
AUX CTRLR
(MANUAL MACHINE)
C441
J1A
GWY CTRLR
26 2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER T650 (S/N ALJG17415 - ALJG19316)
J1B 26
OPTIONS DWG) (S/N B2KZ12036 - B2KZ12105)
GWY CTRLR
Printed In U.S.A.
Sheet 15 of 16
7279776 (A)
705 of 1288
LEGEND
ENGINE
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 2 EXHAUST GAS
123 1 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
TO C118 PIN 3 TEMP
1 EGR VREF3 164 See Sheet 7 of 16
4
116 120 SENSOR GROUND 3 MAF
5 POSITION SIGNAL
EGR VALVE SENSOR
DC MOTOR 3 POSITION RETURN 172 137 5V 2
6 H BRIDGE POS 192 TO C118 PIN 2 FREQ 1
2 H BRIDGE NEG 193 See Sheet 7 of 16

C149
COOLANT TEMP
SENSOR 1 COOLANT RETURN 145 C136
C148 165 VREF3 OIL PRESSURE 3

OIL PRESSURE &
1 FUEL TEMP SENSOR 110 111 OIL PRESSURE SENSOR 4
FUEL TEMP TEMPERATURE
SENSOR 2 FUEL RETURN 146 148 RETURN GND 1 SENSOR
C147 104 OIL TEMPERATURE SENSOR 2

2 SENSOR SIGNAL 131
ENGINE BLOCK
C133
SHIELD 128
169 RETURN 1 INTAKE
132 TEMPERATURE
2 SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR
C144
C138
3 SENSOR RETURN 147 VREF INTAKE PRESS SENSOR
CAM SHAFT B 1 INTAKE
SENSOR 2 POS SENSOR 159 PRESSURE
112 INTAKE PRESS SENSOR A 3
1 VREF1 CAM SENSOR
187 INTAKE PRESS RETURN D 2
TO C118 - PIN 1,
RAIL
2 SENSOR RETURN 119
PRESSURE Printable Version Click Here
SENSOR 3 VREF1 SENSOR 138 C139

126 FUEL INJECTOR LSD1A 2 CYL 1
WIRING SCHEMATIC
CYL 3 C140
150 FUEL INJECTOR HSDB 2
CYL 2
(MANUAL MACHINE)
174 FUEL INJECTOR LSD2B 1
CYL 4
125 C154
T650 (S/N ALJG17415 - ALJG19316)
FUEL INJECTOR LSD2A
2
177 PWM
TO C118 - PIN 1 1
INLET METERING
VALVE
(S/N B2KZ12036 - B2KZ12105)
SEE Sheet 7 of 16 Sheet 16 of 16
7279776 (A)
706 of 1288
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND
5 SH05 - CAN BUS
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
6 SH06 - ENGINE
7 SH07 - ENGINE CONTROL UNIT
RED LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED
8 SH08 - HYDRAULICS
9 SH09 - CAB DISPLAY
BATT FEED, FUSED RED/WHITE RED/WHT CONNECTOR
1000 THROUGH 1499
10 SH10 - CAB
11 SH11 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
12 SH12 - LIGHTS
13 SH13 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
14 SH14 - OPTIONS 1
15 SH15 - OPTIONS 2 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
1 1
MONITORING LIGHT BLUE LBL
HARNESS PART NUMBER 3000 THROUGH 3999

MF MFR MAN 7300817 1 1
EXMF MFR MAN 7300650 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7301237 * LIGHTS PINK PNK
6000 THROUGH 6999
7303755 *
WIRE BREAK
STD CAB SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
STD FUEL 7149219 SHT1/F2 SHT1/F2

DLX FUEL 7266824
BCT ENG 7220812 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
TAILGATE DOM 7267103 COMMUNICATION PURPLE/WHITE PUR/WHT

9000 THROUGH 9999

SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALJG19317-ALJG23962, ALJG23985

B2KZ12106-B2KZ13525
Wiring Schematic S630

S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
PROPRIETARY NOTICE TOLERANCES: ECN 101943 Printed On August 2018
csf
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
Standard Machine S/N B2KZ12106
B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC MAN
Sheet 1 of 15
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
B2 MOVED "GND" TEXT FROM A5 TO A2
Click Here For Interactive PDF 104399 AEW 3 COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B1
REV
9205 SWAPPED SIZE AND MATERIAL VALUES
DESCRIPTION
104399 AEW
CHG NOTICE DWN
5
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 15
7300816
707 of 1288
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
C408 1400 RED/WHT
MFR HARN CONN 1 (BLACK) SHT10/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT SHT9/G8
2
FUSE 11 25 A GATEWAY CTRLR
11A 11B 3
SP2
FUSE 13 25 A J1B
1025 RED 1160 RED/WHT SP36 1150 RED/WHT
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
+12V BATTERY MEGAFUSE
100.0 Amps
HW11 1 1
T5 T4
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1

FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/D3
1055 RED
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT6/D3
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

Standard Machine S/N B2LA11412
B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 2 of 15
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 2 / 15
7300816
708 of 1288
FRC1 ENGINE
ECU RELAY - G
1035 RED/WHT +12V PWR 30

1506 RNG/WHT
1 SWITCHED
POWER
SHT2/D1 G1 87 1540 RNG/WHT SP54 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/C7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
1520 RNG/WHT SHT9/C8
SHT11/D2 1705 RNG/WHT

SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT9/D8
SP11 1960 RNG/WHT
J2B SHT9/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT10/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT9/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT SP42 1590 RNG/WHT
2 2 SHT9/E4
1555 RNG/WHT
SHT15/F4
1050 RED +12V PWR 30 FUSE 7 25 A SP65

SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
B2
86 85 GND
BUS BAR
A5 A2 1725 RNG/WHT
SHT5/C2
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
MFR HARN CONN 2 (LT GRAY)
1920 RNG/WHT 1920 RNG/WHT SP37 1840 RNG/WHT
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 3 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 3 / 15
7300816
709 of 1288
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7 GATEWAY CTRLR
6 2370 BRN
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
ECU CASE GND SHT8/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT15/G5 SHT8/D7
2180 BRN
J1B
SHT6/E7
2150 BRN
SHT6/F7
2080 BLK
SHT5/E3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT9/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16

SHT15/D4
AUX CTRLR SHT14/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT15/H5 15
2065 BLK SP28 2730 BLK
SHT9/C8 J2B SHT10/E8
2930 BLK
C428
SHT9/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK
SP47
SHT9/F8
2785 BLK 2770 BLK
SHT14/B7 SHT14/H6 T10
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

SHT12/C4 MFR ACCESSORY B B
2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK BATT GND
SHT12/C4 B B 1
SP51
2610 BLK
SHT12/E4
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK AUX CTRLR

SHT5/B8
2185 BRN
2715 BLK SHT15/E7 SP58 2995 BRN
SHT5/C2 2195 BRN 17 SENSOR GND
SHT11/G2
2505 BLK 2290 BLK
SHT15/G4 SHT13/B8 J2B
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55
2115 BLK 2105 BLK
SHT12/D8
2055 BLK
SHT3/C1
2030 BLK
SHT13/F8
2005 BLK
SHT6/G7
2120 BLK
SHT12/E8

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 4 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
CHG NOTICE DWN SHEET
SHT 4 / 15
7300816
710 of 1288
CAN BUS
DLX CAB HARN 7301237 ONLY
* (NOT IN STD CAB HARN 7303755)
RE016 RE019 C479
C408
GATEWAY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31 TP-16 TP-16 TP-01 TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08 9460 PUR TP-08
9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
CAN HI 9 3 3 3 CAN HI
R3-2 R2
J1B TP-11 TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
AUX CTRLR
9440 PUR TP-06
9280 PUR TP-11 4 CAN LO
8 CAN LO
9340 PUR/WHT
9180 PUR/WHT 2 CAN HI
9 CAN HI
J2B C503
* C450 C460
RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI

3 3 3 3
9420 PUR 9660 PUR CAN LO
4 4 4 4
* C449 C459
THESE SCHEMATICS USED IN S/N ALJG19317-ALJG23962, ALJG23985 LEFT JOYSTICK CONN LEFT JOYSTICK LEFT JOYSTICK
B2KZ12106-B2KZ13525 SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
FOR TELEMATICS SEE CAN BUS6+((7,110 9400 PUR
3 3
9640 PUR
3 3
CAN LO
4 4 4 4
AUX CTRLR C426
SUSP SEAT JOYSTICK HARNESS
TP-12 9500 PUR/WHT TP-12
CAN HI 14 A A CAN HI R18 R21
120 OHM 0.5W RESISTOR 120 OHM 0.5W RESISTOR
ENG ECU CTRLR B1 GATEWAY CTRLR
9600 PUR R1-1 SP90 R2-1
CAN LO 20 B B CAN LO TP-17 TP-17 TP-18 TP-18 TP-20 TP-21 9205 PUR TP-21
9200 PUR 9215 PUR 9210 PUR TP-20
ENG CAN LO 47 20 ENG CAN LO
J2B
3095 LBL
REMOTE RUN 24 9100 PUR/WHT
SP91 9110 PUR/WHT
9115 PUR/WHT 9105 PUR/WHT
ENG CAN HI 48 14 ENG CAN HI
R1-2 TP-19 R2-2
J2A J7A J1B
C169
GATEWAY CTRLR ENGINE CAN
1725 RNG/WHT
3090 LBL 3085 LBL
SHT3/D1 1
REMOTE RUN 21 D D REMOTE RUN KEY
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT TP-19

3 ENG CAN HI
1735 RNG/WHT
SHT3/D1 E E SWITCHED POWER
9255 PUR
4 ENG CAN LO
1165 RED/WHT
SHT2/C1 F F UNSWITCHED POWER
C169
2710 BLK
SHT4/C6 G G GROUND

S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 5 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 5 / 15
7300816
711 of 1288
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
MFR-BCT HARN CONN T21 S
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/E7
SHT3/C1 C C
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
STARTER RELAY SIGNAL 7
3560 LBL
STARTER RELAY FEEDBACK 22
2150 BRN GND
SHT4/G3 B C110 ALTERNATOR
AIR FILTER
1020 RED
3150 LBL SWITCH (NC) S
AIR FILTER SIGNAL 16 A SIG
L
J1A C405
C355 2015 BLK 1
FUEL HARN SHT4/E3
T11
3180 LBL 3180 LBL
FUEL SIGNAL 12 C C A 1

FUEL SENDER
(30 - 270 OHM) T12
2180 BRN 2180 BRN HAND THROTTLE
SHT4/G3 D D B
5690 YEL F
C406 SHT10/C7 E
D
C428
+5V PWR
MFR HARN CONN 2 (LT GRAY) C
3690 LBL 3690 LBL SIG
THROTTLE PRIMARY SIGNAL 10 6 6 A
2690 BRN GND
SHT10/D5 B
8007 TAN
C114
IGN SW ON 4 FRC1
J1B PREHEATER
RELAY - C
ENG ECU CTRLR

1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
IGN SW ON 19 C100 C4
2865 BRN GND C100 T14
WATER IN FUEL RETURN 34 2 1445 RED/WHT
WATER IN FUEL SENSOR SHT2/C1 C5 C2
(FUEL FILTER)
3865 LBL FRC1 FRC1
SIG
WIF SENSOR 9 1
8510 TAN
PRE HEATER RELAY DRIVER 56
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQ SIGNAL 28 2 2 SHT7/G3
8014 TAN
AIR INLET TEMP 35 3 3 SHT7/F3
4 4 SHT7/H7
J7A
ENG-CROSSOVER
3420 LBL

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 6 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 6 / 15
7300816
712 of 1288
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALJG19317-ALJG23809
B2KZ12106-B2KZ13527
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT6/C5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT6/C5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT6/C5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
2 46 FUEL TEMP SENSOR RETURN GND
C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1

KNOCK SENSOR 1 SHIELD-01
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1
ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
3 29 ENGINE BLOCK ACCELEROMETER #2 SHIELD
INJECTOR #1
C146 FUEL INJECTOR #1 HSDA 27 1
CRANKSHAFT POSITION SENSOR SHIELD-03

SHIELD-03
1 36 CRANKSHAFT SENSOR NEG FUEL INJECTOR #1 LSD1A 26 2
2 60 CRANKSHAFT POSITION SENSOR C139
3 87 CRANKSHAFT SENSOR SHIELD
INJECTOR #2
C145 FUEL INJECTOR #2 HSDB 50 1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT6/C5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
RAIL PRESSURE SENSOR

3 38 VREF 1 RAIL PRESSURE SENSOR FUEL INJECTOR #3 LSD1B 75 2
1 35 RAIL PRESSURE SENSOR C141
P
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
2 19
FUEL INJECTOR #4 HSDA 3 1
C143
FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
VREF 1 INLET METERING VALVE
1 SHT6/C5 C142
2 77 INLET METERING VALVE (PWM)
C154
J7B
J7B

S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 7 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 7 / 15
7300816
713 of 1288
HYDRAULICS
FRC1
TRACTION LOCK RELAY - D
C425
4100 LGN
1360 RED/WHT +12V PWR B B
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
86 SHT4/D6 C C B OHM 12 V TRACK 2 SPEED ADAPTER
FRC1 FRC1 (SEE ADDITIONAL OPTIONS DWG)
C308
2035 BLK
SHT4/B8 WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
4110 LGN
TRACTION LOCK SIGNAL 8
3430 LBL
TRACTION LOCK FEEDBACK 13
2220 BRN GND

SHT4/H3 B
HYDRAULIC TEMPERATURE SENDER
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
HYD TEMP SIGNAL 32 A
C108
3320 LBL SIG

HYD FILTER DIFF PRESS 34 A
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1

HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446
2410 BRN GND

HYD LOCK VALVE GROUND 1 2
J1A HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
4200 LGN C105
J1B
19
13
23
6
HYD CHARGE PRESS
SENDER POWER
HYD LOCK
SOLENOID
HYD CHARGE
PRESS SENDER
TRACTION SOLENOID
OUTPUT
HYDRAULIC
FAN
4330 LGN GND

1
AUX CTRLR
FRONT ROD SOLENOID (MALE)
2330 BRN SIG 3.3 OHM PWM
FRONT ROD SOLENOID GROUND 18 2
C418
4340 LGN GND
1
GATEWAY CTRLR
FRONT BASE SOLENOID (FEMALE)
FRONT BASE SOLENOID GROUND 1 2
J2A C419
J2B
19
13
FRONT BASE
SOLENOID
FRONT ROD
SOLENOID
AUX CTRLR

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 8 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 8 / 15
7300816
714 of 1288
1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN
C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/E1 1
2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10 GATEWAY CTRLR
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/E1 5 C499
C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 11
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT14/F4 8 START ENGINE 24 2 2 2
1960 RNG/WHT
J1A
SHT3/E1
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT

SHT4/E8 2 3 7 J1B 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5
1420 RED/WHT UNSWITCHED POWER

5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT

SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
SHT4/E8 2 1 RH DLX PANEL
C479 SHT5/G1
5 6 1590 RNG/WHT SWITCHED POWER

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1
C480 2250 BLK GROUND

1775 RNG/WHT SHT4/F8 3
SHT3/E1 LEFT PANEL CONN (GRAY)
3620 LBL DOOR SIGNAL

SHT10/D3 12
C503 SHT5/F1
3610 LBL PARK BRAKE OUTPUT

2
SW12
DESOX INHIBIT SWITCH(OPT KIT)
2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1700 RNG/WHT 8050 TAN
SHT3/E1 7 9 4 DPF LAMP
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 9 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 9 / 15
7300816
715 of 1288
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT10/D1 5
4
THESE CAB SCHEMATICS USED IN S/N ALJG19317-ALJG23962, ALJG23985
SW4 SW4
B2KZ12106-B2KZ13525
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
7 7
4275 LGN
8 8
4550 LGN
9 9
2795 BLK GND
*
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
1370 RED/WHT 1370 RED/WHT SP45 1390 RED/WHT

SHT2/B1 7 7 1
C129
CAB ACCESSORY
* T37
1210 RED/WHT +12V BATT PWR 2010 BLK
A A 1
* T38
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
2800 BLK

C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B4
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
C428
2790 BLK
2790 BLK
*C667
DOOR HARNESS
SHT4/E3 14 14
(SEE ADDITIONAL
2690 BRN
SHT6/E5 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT9/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/G1 5 5 DOOR UNSW PWR
A
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
SEATBAR/THROTTLE +5V 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5690 YEL
SHT6/E5
HARNESS WASHER PUMP

* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 10 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 10 / 15
7300816
716 of 1288
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR 1530 RNG/WHT
SHT3/E3 A
4930 LGN
RIGHT HANDLE LEFT ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
PWM SIGNAL
GATEWAY CTRLR
2980 BRN GND
TILT SPOOL LOCK GROUND 10 3
LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
HANDLE LOCK (ACS ONLY)

H
2990 BRN GND
LIFT SPOOL LOCK GROUND 2 3 E
J1A LIFT SPOOL LOCK 4640 LGN
FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
7.8 OHM 12V 1520 RNG/WHT
SIG
1 SHT3/E3 A
4830 LGN
C422 LEFT HANDLE RIGHT ROCKER DOWN 22 B RIGHT POSTION SWITCH
4840 LGN
LEFT HANDLE RIGHT ROCKER UP 28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7
LEFT HANDLE PADDEL LEFT 12 G

TILT SPOOL
LOCK SOLENOID
LIFT SPOOL
LOCK SOLENOID
J2A C410
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 11 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 11 / 15
7300816
717 of 1288
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
SP14 GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - RC1
C438
2760 BLK GND
1350 RED/WHT MFR HARN CONN 3 (DK GRAY) B RIGHT FRONT
SHT2/E1 30 6620 PNK SP23 6610 PNK 6610 PNK 6130 PNK WORK LIGHT
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8

6630 PNK
6320 PNK
FRONT WORK LIGHTS 2610 BLK GND

SHT4/D8 2
RELAY-RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
SHT2/E1 TAILGATE HARN
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR SIGNAL 5
C602
3460 LBL
MRKR LIGHT PWR FEEDBACK 31
REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
J1A WORK LIGHT
FRC1
6210 PNK
REAR LIGHT 6210 PNK SIG 1

RELAY - E T15 TERMINAL (+)
1320 RED/WHT T17 TERMINAL (+)

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
FRC1 FRC1 T18 TERMINAL (-)
2045 BLK
SHT4/B8

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 12 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 12 / 15
7300816
718 of 1288
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

M (NOT IN STD CAB HARN 7303755)
7440 WHT SIG
1
C610
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK
C HEATER VALVE
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
HVAC RELAY-B MFR HARN CONN 3
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW

SW10 3
85
B5 B2 3
86
M
7050 WHT
FRC1 FRC1 SW10

7410 WHT
4
C611
GATEWAY CTRLR
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
AC SIGNAL MONITOR 11 12 12 1
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
C350 MAGNET CLUTCH

2290 BLK 2280 BLK (COMPRESSOR)
SHT4/C6
GND
2
C486

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 13 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 13 / 15
7300816
719 of 1288
# C355 C428
FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE SP33
*
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
#
B B SHT4/E6
POWER BOBTACH SWITCH DLX FUEL HARN 7266824 ONLY
#
C607
(NOT IN STD FUEL HARN 7149219)
4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
FLOAT (ACS/AHC ONLY)
3500 LBL
T3
SHT9/F8
SP21 D14
RIGHT POSTION SWITCH 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
2
*
6415 PNK C103 SW3
D
HAZARD SWITCH
6570 PNK
6515 PNK TAILGATE HARN
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 6 2850 BLK
SP46
2725 BLK
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED)

BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND 2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT15/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676 C C
LEFT SPEAKER
* * RADIO CONN A A
HANDLE LOCK (ACS ONLY) 1

7820 WHT
3 LEFT SPEAKER (+) *
7830 WHT
2 4 LEFT SPEAKER (-)
L010
C279
FLOAT (ACS/AHC ONLY) AIR RIDE SEAT
AUX CTRLR RIGHT SPEAKER 1510 RNG/WHT
*
SHT10/E1 4 PWR
2460 BRN PWR
GND
HIGH FLOW SOLENOID GROUND 26 B 7810 WHT
RIGHT POSTION SWITCH HIGH FLOW 2 6 RIGHT SPEAKER (-)
J2A SOLENOID 2210 BLK GND
4460 LGN SIG 7.5 OHM 12 V 7800 WHT SHT10/E1 5
PADDLE HIGH FLOW SOLENOID SIGNAL 26 A 1 5 RIGHT SPEAKER (+) GND
J2B C415 C278 1885 RNG/WHT

SHT10/E1 1 RADIO SWITCHED POWER C277
2885 BLK
SHT10/D1 2 RADIO GROUND
C408 C676
MFR HARN CONN 1 C126 GATEWAY CTRLR
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR
TRIGGER
7210 WHT 7210 WHT SIG 2350 BRN GND
B 13 13 A A _ TWO SPEED GROUND 26 2
TWO SPEED TRACK 2 SPEED
C412 J1A SOLENOID (SEE ADDITIONAL
HORN
4350 LGN OPTIONS DWG)
+ TWO SPEED SIGNAL 26
SIG
1 5.1 OHM 12 V
2785 BLK GND
SHT4/E8 B B
J1B C441

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 14 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 14 / 15
7300816
720 of 1288
SW7 *
OPTIONS 2
C438 RIDE CONTROL
AUX CTRLR MFR HARN CONN 3 (DK GRAY)
3410 LBL 3410 LBL 2890 BLK
RIDE CONTROL SW AUTO 23 14 14 1 2 SHT4/E8

SW7 SW7 RIDE CONTROL (NOT IN STD CAB HARN 7303755)
3480 LBL RELAY - L
RIDE CONTROL RELAY SIGNAL 7 FUSE RELAY CENTER
SP9 1575 RNG/WHT

3415 LBL 3425 LBL L1 SHT3/F1
RIDE CONTROL COIL SIGNAL 21 L4
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL

COIL COIL FRC1 FRC1
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK
SHT4/G8
C428 SW13
3475 LBL 3475 LBL
REVERSING FAN *
REVERSING FAN MANUAL SIGNAL 16 7 7 3
2905 BLK 2970 BLK

SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIGNAL 29 8 8 6
1555 RNG/WHT
5 SHT3/D1
4
SW13
C443 SW13
2175 BRN
REVERSING FAN RETURN SIGNAL 27 2
J2A REVERSING
FAN COIL
3485 LBL
REVERSING FAN SIGNAL 25 1

C442
2185 BRN
SHT4/C3 A
3455 LBL
C RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10
5105 YEL
PRESSURE SENSOR
RIDE CONTROL SENSOR +5V PWR 24 B
J2B
* SW8 * C672
SIDELIGHT SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 15 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 15 / 15
7300816
721 of 1288
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
RED LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED
8 SH08 - HYDRAULICS
BATT FEED, FUSED RED/WHITE RED/WHT CONNECTOR
1000 THROUGH 1499
10 SH10 - CAB
11 SH11 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
12 SH12 - LIGHTS
13 SH13 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
14 SH14 - OPTIONS 1
15 SH15 - OPTIONS 2 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
1 1
MONITORING LIGHT BLUE LBL
HARNESS PART NUMBER 3000 THROUGH 3999

MF MFR MAN 7322211 1 1
EXMF MFR MAN 7322212 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7329485 * LIGHTS PINK PNK
6000 THROUGH 6999
WIRE BREAK
STD CAB 7329492 * SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
STD FUEL 7149219 SHT1/F2 SHT1/F2

DLX FUEL 7266824

9000 THROUGH 9999

SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB SCHEMATICS USED IN S/N ALJG23963-ALJG23984, ALJG23986 & ABOVE

B2KZ13526 & ABOVE
FOR S/N ALJG23985, ALJG23962 & BELOW, B2KZ13525 & BELOW SEE PREVIOUS SCHEMATIC
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
Above TOLERANCES: ECN 106368 Printed On August 2018
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
UNLESS OTHERWISE SPECIFIED SCHEM ELEC MAN
Click Here For Interactive PDF COPYRIGHT C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT DWG. NO.
Sheet 1 of 15
7322210
ORIGINALLY CREATED AND REVISED IN THE YEARS AS DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
0 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT, Printable Version Click Here
SHT 1 / 15
REV DESCRIPTION CHG NOTICE DWN SHEET ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
722 of 1288
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
C408 1400 RED/WHT
MFR HARN CONN 1 (BLACK) SHT10/D3
6 6 SHT5/F7
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
1025 RED 1160 RED/WHT SP36 1150 RED/WHT
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
100.0 Amps
HW11 1 1
T5 T4
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1

FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/D3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/D3
1055 RED
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8
1200 RED
SHT3/C8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 2 of 15
7322210
0 SEE SHEET 1 106368 MMM TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
SHT 2 / 15
723 of 1288
FRC1 ENGINE
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
G1 SP54
POWER
SHT2/D1 87 1540 RNG/WHT 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/C7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
SP50
BUS BAR
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT

SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
C428 1785 RNG/WHT
SHT10/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT9/F4
FRC1 SWITCHED 2 2 SHT9/E4
POWER RELAY - A 1555 RNG/WHT
SHT15/F4
1050 RED 30 FUSE 7 25 A SP65

SHT2/B1 A1 87 A4 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
+12V PWR 7A 7B SHT5/B8
1920 RNG/WHT 86 85 2055 BLK

A5 A2 1725 RNG/WHT
GND SHT5/C2
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
3390 LBL
FRC1 SWITCHED
POWER RELAY - F
FRC1 FRC1
1200 RED 30 2055 BLK
SHT2/B1
+12V PWR
F1 87 F4 1585 RNG/WHT SHT4/B8
GATEWAY CTRLR
3385 LBL 86 85 2065 BLK
F5 F2 SHT4/C8 3450 LBL
SP100 GND
FRC1
FRC1
3380 LBL
J1A
C428
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 3 of 15
7322210
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY Printable Version Click Here
REV DESCRIPTION CHG NOTICE DWN SHEET
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT, SHT 3 / 15
724 of 1288
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7 GATEWAY CTRLR
6 2370 BRN
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/G4 SHT8/D7
2180 BRN
J1B
SHT6/E7
2605 BLK 2150 BRN
SHT5/E7 SHT6/F7
2080 BLK
SHT5/E3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16

SHT15/D4
AUX CTRLR SHT14/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT15/H4 15
2065 BLK SP28 2730 BLK
2930 BLK
C428
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK
SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT12/C4 B B
SP51
2610 BLK
SHT12/E4
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK AUX CTRLR

SHT5/B8
2185 BRN
2715 BLK SHT15/E7 SP58 2995 BRN
2065 BLK SHT5/C2 2195 BRN 17 SENSOR GND
SHT3/C6 SHT11/G2
2505 BLK 2290 BLK
SHT15/G4 SHT13/B8 J2B
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55
2115 BLK 2105 BLK
SHT12/D8
2055 BLK
SHT3/C1
2030 BLK
SHT13/F8
2005 BLK
SHT6/G8
2120 BLK
SHT12/E8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 4 of 15
7322210
0 SEE SHEET 1 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE Printable Version Click Here
725 of 1288
CAN BUS
C479
C408 LEFT PANEL
Z3 Z4
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) (BLACK)
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR
SP31 SP39 SP35
9260 PUR 9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR CAN LO
CAN LO 8 4 4 4
SP30 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
J1B
C479
C503
RH DLX PANEL
AUX CTRLR
TELEMATICS USED IN S/N ALJG23963-ALJG23984, 9440 PUR
4 CAN LO
ALJG23986 & ABOVE, B2KZ13526 & ABOVE 9280 PUR
8 CAN LO
9340 PUR/WHT
9180 PUR/WHT 2 CAN HI
9 CAN HI
FOR S/N ALJG23985, ALJG23962 & BELOW,
J2B C503
B2KZ13525 & BELOW SEE PREVIOUS SCHEMATIC
TELEMATICS * C450 C460
RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
1305 RED/WHT SHT3/B1 1 1 1 1
PWR 10 SHT2/G1 2070 BLK 2070 BLK GND
2605 BLK SHT4/G8 2 2 2 2
GND 11 SHT4/G8 9320 PUR/WHT 9560 PUR/WHT CAN HI
3 3

C448 3 3
MFR HARN CONN 4 (BLACK) 9420 PUR 9660 PUR CAN LO
Z5 SP104 4 4 4 4
120 OHM 0.5 W RESISTOR 9500 PUR/WHT
9515 PUR/WHT 9505 PUR/WHT 7 7
CAN HI 3 9510 PUR/WHT
9 9 * C449 C459
LEFT JOYSTICK
9610 PUR LEFT JOYSTICK CONN LEFT JOYSTICK
9615 PUR 9605 PUR 10 10 1840 RNG/WHT 1840 RNG/WHT +12V PWR
CAN LO 4 9600 PUR SHT3/B1 1 1 1 1
8 8 2080 BLK 2080 BLK GND
SP103 SHT4/G8 2 2 2 2
C481 9300 PUR/WHT 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
AUX CTRLR C426
CAN HI 14 A A CAN HI
9600 PUR 9610 PUR ENG ECU CTRLR Z1 Z2 GATEWAY CTRLR

CAN LO 20 B B CAN LO
120 OHM 0.5W RESISTOR SP90 120 OHM 0.5W RESISTOR
J2B 9200 PUR 9215 PUR 9210 PUR 9205 PUR
ENG CAN LO 47 20 ENG CAN LO
3615 LBL C CAN SELECT
CAN SELECT 25 C
SP91 9110 PUR/WHT 9105 PUR/WHT
3095LBL ENG CAN HI 48 14 ENG CAN HI
REMOTE RUN 24
J7A J1B
J2A
C169
GATEWAY CTRLR ENGINE CAN
1725 RNG/WHT
3090 LBL 3085 LBL
SHT3/D1 1
REMOTE RUN 21 D D REMOTE RUN KEY
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT
3 ENG CAN HI
1735 RNG/WHT
9255 PUR
4 ENG CAN LO
1165 RED/WHT
C169
2710 BLK
SHT4/C6 G G GROUND
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
Sheet 5 of 15
7322210
726 of 1288
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/B8 SHT2/E7
SHT3/C1 C C
1015 RED
GATEWAY CTRLR
3560 LBL
STARTER RELAY FEEDBACK 22
2150 BRN GND
SHT4/G3 B C110 ALTERNATOR
AIR FILTER
1020 RED
3150 LBL SWITCH (NC) S
AIR FILTER SIGNAL 16 A SIG
L
J1A C405
C355 2015 BLK 1
FUEL HARN SHT4/E3
T11
3180 LBL 3180 LBL
FUEL SIGNAL 12 C C A 1
FUEL SENDER

HAND
(30 - 270 OHM) T12
2180 BRN 2180 BRN
THROTTLE
SHT4/G3 D D B
C406
C428
5690 YEL +5V PWR
MFR HARN CONN 2 (LT GRAY) SHT10/C8 C
2690 BRN GND
SHT10/D5 B
8007 TAN
C114
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR

1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL SIG FRC1 FRC1
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQ SIGNAL 28 2 2 SHT7/G3
8014 TAN
4 4 SHT7/H7
J7A
ENG-CROSSOVER
3420 LBL
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 6 of 15
7322210
727 of 1288
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALJG23810 & ABOVE
B2KZ13528 & ABOVE
ENG ECU CTRLR
GLOW PLUG FEEDBACK

FOR S/N ALJG23809 & BELOW, B2KZ13527 & BELOW SEE
SHT6/C5 79 GLOW PLUG FEEDBACK
PREVIOUS SCHEMATIC
EGR VALVE DC MOTOR
1 64 VREF 3 EGR
MAF SENSOR
4 OPEN MAF FREQ
SHT6/C5 1
MAF TEMP
C151 SHT6/C5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148

KNOCK SENSOR 1 BOOST PRESSURE AND TEMPERATURE SENSOR
SHIELD-01 SHIELD-01
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN BOOST TEMP SIGNAL 94 2
2 31 ENGINE BLOCK ACCELEROMETER #1 BOOST PRESSURE PWR 61 3
T
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD BOOST PRESSURE SIGNAL 12 4 P
C147 BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 C150

SHIELD-02 SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
1 SHT6/C5 FUEL INJECTOR #2 LSD2B 74 2
INJECTOR #3

P
INJECTOR #4
2 19
C143
INLET METERING VALVE FUEL INJECTOR #4 LSD2A 25 2

1 SHT6/C5 C142
C154
J7B J7B
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
Sheet 7 of 15
7322210
0 SEE SHEET 1 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
SHT 7 / 15
728 of 1288
HYDRAULICS
FRC1
C425
4100 LGN
SHT2/E1 D1 87 4200 LGN 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
TRACTION LOCK SIGNAL 8
3430 LBL
TRACTION LOCK FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1

C446
2410 BRN GND

HYD LOCK VALVE GROUND 1 2
J1A HYDRAULIC LOCK SOLENOID
1
C420
2190 BRN
SHT4/G3 A
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-4.5V
5190 YEL +5 PWR
SHT10/C8 B
4200 LGN C105
J1B
19
13
6
HYD LOCK
SOLENOID
PRESS SENDER
HYD CHARGE
TRACTION SOLENOID
OUTPUT
HYDRAULIC
FAN
4330 LGN GND

1
AUX CTRLR
C418
4340 LGN GND
1
GATEWAY CTRLR
J2A C419
J2B
19
13
FRONT BASE
SOLENOID
SOLENOID
FRONT ROD
AUX CTRLR
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 8 of 15
7322210
SHT 8 / 15
729 of 1288
1940 RNG/WHT T13
SHT3/E1 1
7040 WHT
1 C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10 GATEWAY CTRLR
SHT4/G8 2 PTOL SWITCH 20 1 1 2
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/E1 5 C499
C500
SHT14/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 8 START ENGINE 24 2 2 2
1960 RNG/WHT
J1A
SHT3/E1
SW9
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT

SHT4/E8 2 3 7 J1B 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5

5 4 SHT2/G1 1
9

SW9 SW9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12
2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 9 of 15
7322210
730 of 1288
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6 (NOT IN STD CAB HARN 7329492)
2060 BLK
SHT10/D1 5
4 THESE CAB SCHEMATICS USED IN S/N ALJG23963-ALJG23984,
SW4 SW4 ALJG23986 & ABOVE, B2KZ13526 & ABOVE
C438
MFR HARN CONN 3 (DK GRAY) FOR S/N ALJG23985, ALJG23962 & BELOW, B2KZ13525 & BELOW
7 7
4235 LGN
SEE PREVIOUS SCHEMATIC
4275 LGN
8 8
4550 LGN
9 9
2795 BLK GND
1
*
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408

SHT2/B1 7 7 1
C129
CAB ACCESSORY
* T37
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
SP8 SP41
SHT3/D1
1580 RNG/WHT
5 5
B B +12V SW PWR
* T38
2800 BLK
C C GND

1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B4
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
C428
2790 BLK
2790 BLK
*C667
DOOR HARNESS
SHT4/E3 14 14
(SEE ADDITIONAL
2690 BRN
SHT6/E5 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
SEATBAR/THROTTLE +5V 24 3 3 3 3 WASHER SIGNAL
C482
J1B
SHT8/D7
5190 YEL HARNESS WASHER PUMP
5690 YEL
* C252
7253378
SHT6/E5 2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 10 of 15
DWG. NO.
7322210
731 of 1288
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR 1530 RNG/WHT
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
PWM SIGNAL
GATEWAY CTRLR
2980 BRN GND
TILT SPOOL LOCK GROUND 10 3
LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
HANDLE LOCK (ACS ONLY)

H
2990 BRN GND
LIFT SPOOL LOCK GROUND 2 3 E
J1A LIFT SPOOL LOCK 4640 LGN
FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
SIG
1 SHT3/E3 A
4830 LGN
C422 LEFT HANDLE RIGHT ROCKER DOWN 22 B RIGHT POSTION SWITCH
4840 LGN
4810 LGN
J1B
4820 LGN
7

C410
LOCK SOLENOID
TILT SPOOL
J2A
LOCK SOLENOID
LIFT SPOOL
TRIGGER
GATEWAY CTRLR
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 11 of 15
DWG. NO.
7322210
732 of 1288
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
2765 BLK 2765 BLK 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
SP14 GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8

6630 PNK
6320 PNK
2610 BLK GND

FRONT WORK LIGHTS
SHT4/D8 2
RELAY-RC2 RIGHT REAR
C103
TAIL LIGHT
TAILGATE HARN
SHT2/E1
1330 RED/WHT
30 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
87 A A 1
C603
86 85
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR SIGNAL 5
C602
3460 LBL
MRKR LIGHT PWR FEEDBACK 31
REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
RIGHT REAR
J1A WORK LIGHT
FRC1
6210 PNK


SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 12 of 15
DWG. NO.
7322210
733 of 1288
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK
C HEATER VALVE
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
3

SW10
85
B5 B2 3
86
M
7050 WHT
FRC1 FRC1 SW10

7410 WHT
4
C611
GATEWAY CTRLR
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
7015 WHT
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
C350
D4
MAGNET CLUTCH
SHT4/C6 GND
2
C486
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 13 of 15
DWG. NO.
7322210
734 of 1288
# C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE SP33
*
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
B B
DLX FUEL HARN 7266824 ONLY
#
SHT4/E6
POWER BOBTACH SWITCH
#
C607

1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8
SP21 D1
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D2
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
SW3 2
*
6415 PNK C103
D
TAILGATE HARN HAZARD SWITCH

6515 PNK
A
E E 1
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D SW2 SW2
2780 BLK 2780 BLK 4
SHT4/E3 4 4 6 2850 BLK
SP46
2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 2830 BLK
6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
LEFT HANDLE F F
SHT4/E8
EXTERIOR HARNESS
6540 PNK
LIFT (ACS/AHC ONLY)
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY
GATEWAY CTRLR OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG)
2350 BRN GND

TWO SPEED GROUND 26 2
TWO SPEED TRACK 2 SPEED
HANDLE LOCK (ACS ONLY) J1A SOLENOID (SEE ADDITIONAL
4350 LGN OPTIONS DWG) C676
SIG 5.1 OHM 12 V
TWO SPEED SIGNAL 26
J1B C441
1 LEFT SPEAKER
* * RADIO CONN
FLOAT (ACS/AHC ONLY) 7820 WHT L010

*
1 3 LEFT SPEAKER (+)
AUX CTRLR HEATED SEAT
7830 WHT 1510 RNG/WHT
RIGHT POSTION SWITCH 2460 BRN GND
2 4 LEFT SPEAKER (-) SHT10/E1 4 PWR
HIGH FLOW SOLENOID GROUND 26 B PWR
HIGH FLOW C279
J2A SOLENOID RIGHT SPEAKER
*
PADDLE 4460 LGN 2210 BLK GND
SIG
A 7.5 OHM 12 V 5
HIGH FLOW SOLENOID SIGNAL 26 SHT10/E1
7810 WHT GND
J2B C415 2 6 RIGHT SPEAKER (-)
C277
7800 WHT SEE OPTION PAGES FOR HARNESSES
1 5 RIGHT SPEAKER (+)
C408 C278
MFR HARN CONN 1 C126 1885 RNG/WHT
1460 RED/WHT SHT10/E1 1 RADIO SWITCHED POWER
A SHT2/C1 (BLACK) HORN CONNECTOR
TRIGGER
7210 WHT 7210 WHT SIG 2885 BLK
B 13 13 A A SHT10/D1 2 RADIO GROUND
+
C412 C676
HORN
_
2785 BLK GND
SHT4/E8 B B
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG23700
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
WARNING &&&Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 14 of 15
DWG. NO.
7322210
735 of 1288
SW7 *
OPTIONS 2
C438 RIDE CONTROL
AUX CTRLR MFR HARN CONN 3 (DK GRAY)
3410 LBL 3410 LBL 2890 BLK

SW7 SW7
3480 LBL
FRC1 SWITCHED
RIDE CONTROL RELAY SIGNAL 7 POWER RELAY - L
SP9 1575 RNG/WHT

3415 LBL 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 3480 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL

COIL COIL FRC1 FRC1
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK 2155 BLK
SHT4/G8
C428 SW13
3475 LBL
3475 LBL
REVERSING FAN *
2905 BLK 2970 BLK

SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
SW13
C443 SW13
2175 BRN
J2A REVERSING
FAN COIL
3485 LBL

C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10 C
5105 YEL PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ821600
AHGL13800
AHGM13900
AJDT15600 &
AJZV18500
ALJG23700
WARNING &&&Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 15 of 15
DWG. NO.
7322210
SHT 15 / 15
736 of 1288
PINS PINS PINS
C100 FUEL FILTER 2 8 C434-1 LEFT WORKLIGHT 1 2 14 FRC1 FUSE RELAY CENTER 112 4,5,8,10,14,15
C103 TAILGATE 8 6,13,14,16 C434-2 LEFT WORKLIGHT 2 2 14
C105 HYD CHARGE PRESSURE 3 10 C435-1 RIGHT WORKLIGHT 1 2 14 J1A GATEWAY CONTROLLER 34 5,8,10,11,13,14,15,16
C107 MASS AIR FLOW SENSOR 6 8 C435-2 RIGHT WORKLIGHT 2 2 14 J1B GATEWAY CONTROLLER 26 4,6,7,8,10,11,12,13,16
C108 HYD TEMPERATURE SENDER 2 10 C428 TILT ACTUATOR 8 17,18 J2A AUX CONTROLLER 34 10,13,16
C110 ALTERNATOR 2 8 C429 LIFT ACTUATOR 8 17,18 J2B AUX CONTROLLER 26 4,5,6,7,10,13,16
C111 MFR-BCT ENG HARN CONN 3 8 C438 CAB-MFR HARN CONN(DK GRY) 14 12,15,16
C112 HYD OIL FILTER SWITCH 2 10 C441 TWO SPEED 2 16 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C446 HYDRAULIC FAN 2 10 J7B ENG ECU CONTROLLER(DSN) 96 9
C114 HAND THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7
C115 FOOT THROTTLE 6 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 11
C116 FOOT THROTTLE INTDM 3 8 C467 LIFT PEDAL LOCK 3 17 SW2 BEACON SWITCH 6 16
C117 CAN BUS 2 2 7 C468 TILT PEDAL LOCK 3 17 SW3 HAZARD SWITCH 6 16
C117-1 CAN BUS 2 2 7 C469 TILT HANDLE 3 17 SW4 HAND/FOOT, H/ISO SWITCH 6 12,14
C118 ENG-CROSSOVER 4 5 C470 TILT PEDAL 3 17
C126 HORN 2 16 C471 LIFT PEDAL 3 17 SW5 POWER BOBTACH SWITCH 6 16
C129 CAB ACCESSORY 3 12 C472 LIFT HANDLE 3 17 SW6 BUCKET POSITION SWITCH 6 16
C169 ENGINE CAN (Diagnostic) 8 7 C474 BRAKE LIGHT 1 18
C209 DOME LIGHT 3 12 C479 LEFT PANEL(BLACK) 12 11 SW9 TRAVEL CONTROL SWITCH 6 11
C212 POWER SOCKET 2 12 C480 LEFT PANEL(GRAY) 12 12 SW10 BLOWER SWITCH 5 15
C252 WASHER 2 12 C482 SEATBAR SENSOR 3 15 SW11 AC SWITCH 3 15
C277 AIR RIDE SEAT 6 16 C483 TEMP CONTROL SWITCH 3 15 SW12 DPF SWITCH 10 11
C278 RIGHT SPEAKER 2 16 C486 AC COMPRESSOR 2 5,6

C279 LEFT SPEAKER 2 16 C489 MFR ACCESSORY 2 5,6,7,12 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 10 C492 ACS/SJC/AWS-MFR HARN 8 4,6 T2 BUZZER GROUND 1 11
C350 AC EVAPORATOR SWITCH 2 15 C493 ACS/SJC/AWS-MFR HARN 4 T3 FLASHER 1 16
C355 DLX or STD FUEL HARNESS 6 8,16 C497 SJC HORN/BLINKER 3 16 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,13 C499 PTOL 4 11 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C500 RH KEY SWITCH 6 11 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C501 PUMP HARNESS 8 18 T13 BUZZER POWER 1 11
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,11, C503 RH DLX PANEL 6 7,11
T14 PRE HEATER 1 9
12,14,16
C409 RIGHT HANDLE 10 13 C536 RIGHT SWASH PLATE 4 18 T15 RIGHT REAR WORK LIGHT(+) 1 14
C410 LEFT HANDLE 10 13 C537 LEFT SWASH PLATE 4 18 T16 RIGHT REAR WORK LIGHT(-) 1 14
C411 LEFT HANDLE 5 WAY 5 16 C602 LEFT REAR TAIL LIGHT 2 14 T17 LEFT REAR WORK LIGHT(+) 1 14
C412 LEFT HANDLE 2 WAY 2 16 C603 RIGHT REAR TAIL LIGHT 2 14 T18 LEFT REAR WORK LIGHT(-) 1 14
C415 HIGH FLOW SOLENOID 2 16 C606 POWER BOBTACH OPEN 2 16 T19 BACKUP ALARM 1 13
C418 FRONT ROD 2 10 C607 POWER BOBTACH CLOSE 2 16 T20 BACKUP ALARM(GND) 1 13
C419 FRONT BASE 2 10 C610 HVAC DUCT FAN 2 15 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 10 C611 BLOWER MOTOR 4 15
C421 TILT SPOOL LOCK 3 9 C630 THERMOSTAT 3 15
C422 LIFT SPOOL LOCK 3 13 C635 HEATER VALVE 6 15
C423 BUCKET POSITION 2 16 C667 DOOR 6 12
C425 BRAKE SOLENOID 3 10 C670 EXTERIOR BEACON 6 16
C426 CAN(Remote Start Tool, ACD) 7 7 C676 RADIO 6 16
C404 Back-up Alarm 2 18
(ACS / SJC MACHINE)

T650 (S/N ALJG11001 - ALJG12302)
Sheet 1 of 18
Printed In U.S.A.
7228618 (A)
737 of 1288
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN B-1
A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD
A-5 HORN RELAY B-5 REAR AUX (F)
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK
A-6 B-6 RELIEF SOLENOID
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD
A-7 B-7 REAR AUX (M)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-10 TILT SPOOL LOCK RETURN B-10
A-11 B-11
A-12 B-12
A-13 B-13 FRONT AUX (F)
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD
A-14 B-14
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2
A-15 B-15 GROUND
A-15 ENGINE SPEED B-15 GROUND P1
A-16 B-16 GROUND
A-17 B-17
A-17 REAR LIGHT 2 RELAY B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN B-18
A-18 FAN 2 RETURN B-18
A-19 B-19 FRONT AUX (M)
A-19 PTOL LED B-19 FAN 2 OUTPUT
A-20 B-20
A-21 B-21
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE RUN KEY

A-22 B-22 SWITCHED POWER
A-22 STATER RELAY FDBK B-22 RUN/ENTER
A-23 B-23
A-24 B-24
A-25 B-25 HYDRAULIC BOOST
A-25 WATER IN FUEL B-25 TWO SPEED MAKEUP
A-27 HYDRAULIC BOOST RETURN
A-27 TWO SPEED MAKE-UP RETURN
A-28
A-28 REAR LIGHT 2 RELAY FDBK
A-29
A-29
A-30
A-30 FUEL PULL RELAY FDBK
A-31
A-31 FRONT WORK LIGHT 1 RELAY FDBK
A-32
A-33
A-33
A-34
HARNESS PART NUMBER

FOR 400 MODEL FOR 500 MODELS FOR 600 MODELS
MFR CTRL 7220815 7228632 7228718
DLX CAB 7235319 7234736 7234736 Printable Version Click Here
STD CAB 7227905 7227905 7227905
STD FUEL 7200449 7149219 7149219
WIRING SCHEMATIC
DLX FUEL 7200460 7184255 7184255
BCT ENG START 7220812 7220812 7220812 (ACS / SJC MACHINE)
ENGINE 7030824 7030824 7030824
TAILGATE DOM 7217484 7217484 7217484 T650 (S/N ALJG11001 - ALJG12302)
TAILGATE EUR 7217483 7217483 7217483
SUSP JSTK 7163706 7163706 7163706 (S/N T1ML11001 AND ABOVE)
BRAKE ADAPTER 7124853 7165061 7165061
WHL 2 SPD ADP 7159366 7159366 7159366
TRACK 2 SPD 7214626
ACS 7222766 7190593 7164144 Sheet 2 of 18
SJC 7200463 Wheel 7210505 Wheel 7210503 Wheel
7236542 Track 7210505 Track 7210504 Track
Printed In U.S.A.
738 of 1288 7228618 (A)
ENGINE CONTROLLER
CONNECTOR J7
PIN FUNCTION
1 SW POWER
2 GND
3 SW POWER
4 GND
5 SW POWER
6 GND
9 WATER FUEL SENSOR
13 PEDAL POS 2
14 PEDAL POS 2
19 IGN SW INPUT
24 PEDAL POS 1

25 PEDAL POS 1
26 PEDAL POS 1
29 PEDAL POS 2
34 WATER FUEL SENSOR

45 SW POWER SIGNAL
47 CAN 1 HI
48 CAN 1 LOW
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 3 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7228618 (A)
739 of 1288
UNSWITCHED
BATT POWER
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 14 WIRE BREAK
HVAC PAGE 15
OPTIONS PAGE 16
C408 1240 RED/WHT SHEET 11

(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 12
1420 RED/WHT
SHEET 11
FUSE 11 25 A J1B
SHEET 11
C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT 1150 RED/WHT 3
J2B

100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
C493
ACS/SJC/AWS-MFR HARN
FUSE 17 25 A (4 PIN)
1280 RED 1235 RED/WHT 2
SHEET 8
STARTER
FUSE 4 25 A
SHEET 15
SHEET 10
SHEET 14
FUSE 2 20 A 1350 RED/WHT SHEET 14
1340 RED
1330 RED/WHT
FUSE 20 5 A
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
FUSE 22 25 A SHEET 16 C412 LH HANDLE HORN
1040 RED 1490 RED/WHT 1410 RED/WHT Printable Version Click Here
(OPTIONS)
FUSE 24 15 A
SHEET 12 WIRING SCHEMATIC
C408 CAB-MFR CONN
1055 RED
SP60 (ACCESSORIES)
(ACS / SJC MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
1050 RED
SHEET 5
Printed In U.S.A. 1030 RED

SHEET 8
Sheet 4 of 18
7228618 (A)
740 of 1288
SWITCHED
POWER
MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 14
HVAC PAGE 15
OPTIONS PAGE 16
FRC1 1505 RNG/WHT SHEET ?

8 J7A ENGINE ECU
ENGINE ECU
+12V RELAY MASS AIR FLOW SENSOR
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP54

85 86
8005 TAN 45
C118

FRC1 FUSE RELAY CENTER ENG-CROSSOVER
1345 RED/WHT
SHEET 4
FUSE 21 15 A B
1511 RNG/WHT
C404
(SEE ADDITIONAL
OPTIONS SHEET)
FUSE 5 25 A SP50 C489


1760 RNG/WHT SHEET 12 C408 CAB-MFR CONN (FR WIPER)
FUSE 12 15 A
SHEET 16 C408 CAB-MFR CONN (BKT POSITION) SHEET 11 C479 LH PANEL
1940 RNG/WHT
C428 1960 RNG/WHT
FUSE 14 5 A SP11 J2B (LT GRAY) SHEET 11 SW9 TRAVEL CONTROL SWITCH
1950 RNG/WHT
1765 RNG/WHT FUSE 7 25 A
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1
SWITCHED
1815 RNG/WHT
FUSE 23 15 A
1800 RNG/WHT
SHEET 8 C110 ALT EXCITATION
(ACS / SJC MACHINE)
POWER RELAY
+12V
PWR 30
T650 (S/N ALJG11001 - ALJG12302)
SHEET 4 1050 RED 21
3450 LBL
GND 85
87
86
J1A
GWY CTRLR
C428
(LT GRAY) (S/N T1ML11001 AND ABOVE)
SHEET 6
1920 RNG/WHT 9 1920 RNG/WHT 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK
1740 RNG/WHT 6
C492
1830 RNG/WHT
SHEET 7 Sheet 5 of 18
C450 RH JOYSTICK
(8 PIN) (PRINTED DECEMBER 2016)
7228618 (A)
Printed
741 of 1288 In U.S.A.
LEGEND
GROUND
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
MANUAL CONTROLS PAGE 13 2320 BRN
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS SHEET 10
LIGHTS PAGE 14 C112 HYD OIL FILTER SWITCH
HVAC PAGE 15 2370 BRN J1B
SHEET # SHEET 12 GWY CTRLR
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 16 C408 CAB-MFR CONN (SEATBAR SENSOR)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 2220 BRN 2230 BRN 17
SHEET 10
2190 BRN
2 SHEET 10
4 2002 BLK SP53 2810 BLK 2180 BRN
J7A SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
ECU CASE GND 2690 BRN
SHEET 8
2832 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 8 2695 BRN
C107 MAF SENSOR SHEET 8
C115 FOOT THROTTLE
2080 BLK C493 3 2235 BLK

SHEET 7 ACS/SJC/AWS-MFR HARN
C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 7 C408 BATT GND

SHEET 11 2765 BLK
SHEET 11
C499 PTOL 2745 BLK
SHEET 15
SHEET 11
(LT GRAY) 2540 BLK
2830 BLK 2900 BLK 1 2900 BLK
SHEET 16
2700 BLK 2770 BLK
SHEET 11 SHEET 16
2785 BLK 2200 BLK
SHEET 16 SHEET 10
2620 BLK
SHEET 14 C103 C489
2650 BLK
SHEET 13
T20 BU ALARM 2600 BLK B 2600 BLK 2390 BLK T1 2015 BLK T10
SHEET 16
SHEET 14
T18 LH REAR LIGHT
2630 BLK
SHEET 7
2715 BLK WIRING SCHEMATIC Printable Version Click Here
C169 ENGINE CAN

2290 BLK (ACS / SJC MACHINE)
D4 COMPRESSOR DIODE
SHEET 10
2035 BLK T650 (S/N ALJG11001 - ALJG12302)
SP55 SP5
SHEET 14
2115 BLK 2105 BLK
2520 BLK
2000 BLK
2055 BLK SHEET 13
SHEET 5 C410 LEFT HANDLE
FRC1 SWITCHED POWER RELAY 2530 BLK
SHEET 13
SHEET 15 2030 BLK
C409 RIGHT HANDLE
FRC1 HVAC RELAY
2005 BLK
Sheet 6 of 18
SHEET 8
2120 BLK
SHEET 14 7228618 (A)
Printed In U.S.A. FRC1 FRONT LIGHT RELAY
742 of 1288
LEGEND
PARTIAL CONNECTOR
CAN BUS
HVAC PAGE 15
OPTIONS PAGE 16
J7A J1B
47 9200 PUR 9215 PUR SP90 9210 PUR 9205 PUR 20

CAN LO
48 9100 PUR/WHT 9115 PUR/WHT SP91 9110 PUR/WHT 9105 PUR/WHT 14
CAN HI
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C117
CAN BUS 2 C169
ENGINE CAN
CAN HI 53 9700 PUR/WHT SP83 9705 PUR/WHT 1 1725 RNG/WHT 1
(FOR DEVELOPMENT SHEET 5
54 9800 PUR SP84 9805 PUR 2 DIAGNOSTICS ONLY) 2715 BLK 2
CAN LO SHEET 6
9155 PUR/WHT 3
9255 PUR 4
9710 PUR/WHT 5
9810 PUR 6

7
8
C408
J1B (BLACK)
8 9260 PUR 9230 PUR SP31 9250 PUR SP79 9270 PUR SP19 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
SP30 SP80
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
C492
(8 PIN)
1830 RNG/WHT 1
SHEET 5 C450
9290 PUR 7 2070 BLK 2
9190 PUR/WHT 8 9320 PUR/WHT 3 SHEET 10
9420 PUR 4
9240 PUR 1
9140 PUR/WHT 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
9300 PUR/WHT 3
SHEET 10
9400 PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
14 9500 PUR/WHT A 9280 PUR 8
CAN HI
CAN LO
20 9600 PUR B
9180 PUR/WHT 9 WIRING SCHEMATIC Printable Version Click Here
(ACS / SJC MACHINE)

J1B
GWY CTRLR
T650 (S/N ALJG11001 - ALJG12302)
21 3090 LBL D
C
REMOTE RUN KEY
SHEET 5
1165 RED/WHT F UNSWITCHED POWER
SHEET 4
2710 BLK G GROUND
SHEET 6
Sheet 7 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7228618 (A)
743 of 1288
LEGEND
ENGINE
PARTIAL CONNECTOR
LOADER SIDE
OPTIONS PAGE 16
FRC1 C111
+12V STARTER RELAY MFR-BCT HARN CONN
PWR 30 STARTER
1030 RED
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 ALTERNATOR G
3560 LBL L 1800 RNG/WHT
J1A C405 EXCITATION
SHEET 6 GND 2015 BLK
AIR FILTER SHEET 6
16 3150 LBL A SIG

C116 C115
FOOT THROTTLE INTDM FOOT THROTTLE
5695 YEL C 5695 YEL C +5V PWR
SHEET 12
33 3695 LBL A 3695 LBL A
SIG
2695 BRN B 2695 BRN B GND
SHEET 6
E
FOOT THROTTLE D
ADAPTER HARNESS F
7217683
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 3690 LBL SHEET 6
4 8007 TAN C428
(LT GRAY)
C114
3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
9 3865 LBL 1 WATER IN FUEL SENSOR
SIG
34 2865 BRN 2 (FUEL FILTER)
GND
56
PREHEATER
28 8013 TAN +12V
PWR
RELAY
30
WIRING SCHEMATIC
1065 RED/WHT 87 8500 TAN
35 8014 TAN SHEET 4
8510 TAN 85 86 1445 RED/WHT
(ACS / SJC MACHINE)
SHEET 4
T650 (S/N ALJG11001 - ALJG12302)
C107
MASS AIR FLOW SENSOR (S/N T1ML11001 AND ABOVE)
1505 RNG/WHT 3 +12V SW PWR
SHEET 5
2832 BLK 4 GND
SHEET 6
8013 TAN 5 Sheet 8 of 18
8014 TAN 2
1
6 7228618 (A)
744 of 1288 Printed In U.S.A.
LEGEND
ENGINE
PARTIAL CONNECTOR
HARNESS
OPTIONS PAGE 16
T14 PRE HEATER 179

PRE HEATER J7B
105
ENGINE ECU CONTROLLER
(ENGINE HARNESS) 122
186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 5V 161 123 TEMP SENSOR
SENSOR RETURN 2
MAP BEFORE TURBO
2 GND 167
3 SIG 112 107
C151 124
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 INTAKE
EGR VALVE
3 172 169 MANIFOLD
DC MOTOR POSITION RETURN SENSOR RETURN 4
TEMP SENSOR
6 H BRIDGE POS 192

2 H BRIDGE NEG 193 166
108
114 144
171
C149 184
COOLANT TEMP 183
163
C148 170
1 FUEL TEMP SENSOR 110 115
FUEL TEMP
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136 SHEET ?
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK 156
2 SENSOR RETURN 133
ACCELEROMETER 2
129 157
SHIELD
154
C145 155
CRANKSHAFT CRANK SENSOR POS 160
POSITION 182
CRANK SENSOR NEG 136
SENSOR Printable Version Click Here
C144
C138
1 SENSOR RETURN 147
CAM SHAFT
SENSOR
2 POS SENSOR 159
141
112 INTAKE PRESS SENSOR A
WIRING SCHEMATIC
3 140 INLET TEMP
VREF1 CAM 167
134
INTAKE PRESS RETURN D PRESSURE
SENSOR
(ACS / SJC MACHINE)
C143
RAIL PRESSURE
119
168 T650 (S/N ALJG11001 - ALJG12302)
2 SENSOR RETURN
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA
C139
C141 126 CYL 1
FUEL INJECTOR LSD1A
CYL 3 175 C140
FUEL INJECTOR LSD1B
C142
150
174
FUEL INJECTOR HSDB
CYL 2
Sheet 9 of 18
FUEL INJECTOR LSD2B
Printed In U.S.A. FUEL INJECTOR HSDA 103 (PRINTED DECEMBER 2016)
CYL 4 125 C154
FUEL INJECTOR LSD2A
177 PWM 2
7228618 (A)
INLET METERING
1 VALVE
745 of 1288
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
CONNECTOR
WIRE BREAK
HYDRAULICS
FRC1
TRACTION LOCK C425
+12V RELAY
4100 LGN B C308
PWR 30 BRAKE
SHEET 4 1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
87 SOLENOID
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS SHEET)
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC

2220 BRN B GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR Printable Version Click Here
J2A
C418 WIRING SCHEMATIC
18 2330 BRN 2 GND FRONT ROD
AUX CTRLR
4330 LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
(ACS / SJC MACHINE)
1 2340 BRN
C419
2 GND FRONT BASE
T650 (S/N ALJG11001 - ALJG12302)
3.3 OHM PWM (S/N T1ML11001 AND ABOVE)
19 13
J2B
Sheet 10 of 18
AUX CTRLR (PRINTED DECEMBER 2016)
7228618 (A)
Printed In U.S.A.
746 of 1288
LEGEND
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
CONNECTOR CAB DISPLAY
T13
BUZZER (+)
1940 RNG/WHT
SHEET 5
LEFT PANEL C499
7040 WHT
C479 (PTOL)
T2
10 C408 2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5

TRAVEL CONTROL 19 2380 BRN 12 2380 BRN 4
3400 LBL 11 PTOL LED
SWITCH (OPTIONAL) LEFT BLINKER INPUT J1A
SHEET 16
GWY CTRLR
5 6 SHEET 16
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
SHEET 12 3620 LBL 12
DOOR SIGNAL
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
3 1 SHEET 4 UNSWITCHED POWER
2065 BLK 2 8060 TAN
SHEET 6 DPF FORCE REGEN 2250 BLK 3
1 SHEET 6 GROUND
5 6 9 6
8070 TAN
4 DPF INHIBIT REGEN
(ACS / SJC MACHINE)

T650 (S/N ALJG11001 - ALJG12302)
Sheet 11 of 18
Printed In U.S.A.
7228618 (A)
747 of 1288
LEGEND
CAB
GROUND PAGE 6
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
HVAC PAGE 15
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 16 SHEET # 7208877(SF) ONLY
*SW4
HAND/FOOT (NOT IN STD CAB HARN)
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
C492 SHEET 12
ACS/SJC/AWS-MFR HARN 4230 LGN (DK GRAY) 4
(8 PIN) SHEET 13 CAB-MFR HARN CONN 3
SHEET 13 4240 LGN
5 4220 LGN 4235 LGN 7 4235 LGN
3 4275 LGN 8 4275 LGN
2 4550 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2

+12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK
* C209
B GND
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A +12V PWR DOME
SHEET 4
C LBL
3640 DOOR SIG LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 16
2210 BLK SHEET 16
2730 BLK 11 2730 BLK
2060 BLK SHEET 12
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS SHEET)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 3630 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG
+5V
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR
5690 YEL
* C252
L SIG
(ACS / SJC MACHINE)
SHEET 8
5695 YEL WASHER
SHEET 8
2845 BLK X GND MOTOR T650 (S/N ALJG11001 - ALJG12302)
Sheet 12 of 18
7228618 (A)
LEGEND
MANUAL
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLS
HVAC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 6
AUX CTRLR SHEET 12 4230 LGN G
C404 A
BU ALARM-MFR HARN
T19 TERMINAL (+)
31 4930 LGN J SKI CTRL

(SEE ADDITIONAL A 7100 WHT C 7100 WHT
OPTIONS SHEET) 4920 LGN E DETENT FLOW
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK 20 4640 LGN D
2 7.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 J
4240 LGN H
SHEET 12
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR
(ACS / SJC MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 13 of 18
Printed In U.S.A.
749 of 1288 7228618 (A)
LEGEND
LIGHTS
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 14
HVAC PAGE 15
OPTIONS PAGE 16
C434-1
C408
(BLACK)
C434-2
SHEET 6
50.00 Watts
C435-1
FRC1 WORK LIGHT
2760 BLK B GND
LIGHT RELAY
C438 C435-2
50.00 Watts

13 6610 PNK SP64
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY C103
PWR 2610 BLK 2 GND
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
+12V RELAY
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SIG LEFT REAR
2045 BLK 86 SHEET 6
(ACS / SJC MACHINE)

T650 (S/N ALJG11001 - ALJG12302)

750 of 1288 7228618 (A)
LEGEND
PARTIAL CONNECTOR
HVAC
HYDRAULICS PAGE 10
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB
MANUAL CONTROLS
PAGE 12
PAGE 13 WIRE BREAK
LIGHTS
HVAC
PAGE 14
PAGE 15
(TWO WIRE BREAKS
JOIN ONE WIRE) 7208877(SF) ONLY
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
(NOT IN STD CAB HARN)
2440 BLK * C610

2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483

C BLK
7425 WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG

B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2030 BLK
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT 7020 WHT 12
C630
* 3
THERMOSTAT Printable Version Click Here

SWITCH B 7023 WHT 7020 WHT 1 WIRING SCHEMATIC
A 7024 WHT
C486
(ACS / SJC MACHINE)
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
T650 (S/N ALJG11001 - ALJG12302)
2290 BLK 2280 BLK
SHEET 6
D4 (S/N T1ML11001 AND ABOVE)
Sheet 15 of 18
751 of 1288
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1-3
OPTIONS
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL #
MANUAL CONTROLS PAGE 13 WIRE BREAK DLX FUEL HARN 7184255, 7200460(SF) ONLY
HVAC PAGE 15 JOIN ONE WIRE) (NOT IN STD FUEL HARN 7149219, 7200449(SF) )
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C428
#
C355
FUEL HARN
(LT GRAY)
CAB-MFR HARN CONN 2 * DLX CAB HARN 7207730, 7208877(SF) ONLY
C607
POWER BOB
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN (NOT IN STD CAB HARN)
GND 2 2470 BLK 2770 BLK B 2770 BLK
CLOSE SHEET 6 4480 LGN
SW5
*POWER 2 1
# C606 BOBTACH 3
SWITCH 5 4
GND 2 2480 BLK 6
POWER BOB 1 4480 LGN
SIG 4480 LGN F 10
OPEN
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)

C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 11 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS SHEET) D 6415 PNK 6400 PNK 3 D2 6430 PNK SWITCH
6400 PNK
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS SHEET)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
4
2 * SW6
OPTIONS SHEET)
9.8 OHM SHEET 6 6
C408
(BLACK) * C676
LEFT HANDLE C412

2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
-
2 7830 WHT 4
* 1
OPTIONS SHEET) SHEET 4 2
C497
SJC
RIGHT
*-
C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 12
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 12 1885 RNG/WHT SHEET 12
3 6520 PNK B OPTIONS SHEET) 2 6
J2A 2885 BLK
SHEET 12
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW
SOLENOID
4460 LGN A SIG
7.5 OHM 12 V WIRING SCHEMATIC Printable Version Click Here
J2B
26
AUX CTRLR
(ACS / SJC MACHINE)
J1A 26 2350 BRN
C441
2 GND TWO SPEED TRACK 2 SPEED T650 (S/N ALJG11001 - ALJG12302)
SOLENOID ADAPTER
GWY CTRLR 4350 GRN 1 SIG
OPTIONS SHEET)
J1B 26
GWY CTRLR
Sheet 16 of 18
7228618 (A)
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS
K TILT PEDAL K TILT MOTOR 2
(500 Models - Track & Wheel) 7169053
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 FLOW

H 2270 BLK 2510 BLK 3 F
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 3 SIG K 4645 LGN 8
4660 LGN LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 SIG 5990 YEL 3 +5V PWR
TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL Printable Version Click Here
WIRING SCHEMATIC
H
E
3980 LBL
3990 LBL
(ACS / SJC MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
Sheet 17 of 18
Printed In U.S.A.
7228618 (A)
753 of 1288
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN
SJC A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 6 ISO LITE
7 L SWASH PLATE ANGLE
CONTROLS
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
SJC SEE SHEET 1 LIFT 14 RF ANGLE
C429 ACTUATOR
A22 PUMP 7188448 15 LR ANGLE
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
2980 BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
C428 23 R QUAD A DRIVE
34 TILT ACTUATOR
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL 4 25 TWO SPEED 1
+5V
5970 YEL
3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
6 27 GROUND
23 2990 BRN 1 GND
24 28 GROUND
4640 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN BRN 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3 32 CAN SHIELD

3810 LBL SIG
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
+5V
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN OR BLK BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4280 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A
C474 1 1830 RNG/WHT 1
D 2 2
26 4210 LGN A C450 2070 BLK
J3-ACS
F
RIGHT JOYSTICK 4 9660 PUR 4 RIGHT
2270 BLK H (TO DLX CAB HARNESS) JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1480 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5 C449
16 4275 LGN 3 2 2080 BLK 2 GND
LEFT JOYSTICK
9140 PUR/WHT 4 (TO DLX CAB HARNESS)
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI

27 2470 BLK C493
28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2
48 1260 RED/WHT 1170 RED/WHT 1 WIRING SCHEMATIC Printable Version Click Here
2240 BLK 4
(ACS / SJC MACHINE)
T650 (S/N ALJG11001 - ALJG12302)
1760 RNG/WHT
2280 BLK
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT
Sheet 18 of 18
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED DECEMBER 2016)
HARNESS)
754 of 1288
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C425 BRAKE SOLENOID 3 9 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C426 CAN(Remote Start Tool, ACD) 7 7
C105 HYD CHARGE PRESSURE SENSOR 3 9 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C434-1 LEFT FRONT WORKLIGHT 1 (37W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 C434-2 LEFT FRONT WORKLIGHT 2 (50W) 2 13 J2A AUX CONTROLLER 34 9,12,15
C110 ALTERNATOR 2 8 C435-1 RIGHT FRONT WORKLIGHT 1 (37W) 2 13 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C435-2 RIGHT FRONT WORKLIGHT 2 (50W) 2 13
C112 HYD OIL FILTER SWITCH 2 9 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C441 TWO SPEED SOLENOID 2 15
C114 HAND THROTTLE 6 8 C446 HYDRAULIC FAN 2 9
C115 FOOT THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C116 FOOT THROTTLE INTDM 3 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW2 BEACON SWITCH 6 15
C479 LEFT PANEL(BLACK) 12 7,10 SW3 HAZARD SWITCH 6 15
C480 LEFT PANEL(GRAY) 12 10 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C118 ENG-CROSSOVER 4 8 C482 SEATBAR SENSOR 3 11
C126 HORN 2 15 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C129 CAB ACCESSORY 3 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 C489 MFR ACCESSORY 2 5,6
C212 POWER SOCKET 2 11 C492 ACS/SJC/AWS-MFR HARN 8 5,7,11 SW9 TRAVEL CONTROL SWITCH 6 10
C252 WASHER PUMP INTDM 2 11 C493 ACS/SJC/AWS-MFR HARN 4 4,6 SW10 BLOWER SWITCH 6 14
C253 WASHER PUMP 2 11 C497 SJC HORN/BLINKER 3 15 SW11 AC SWITCH 3 14

C277 AIR RIDE SEAT 6 15 C499 PTOL 4 10 SW12 DPF SWITCH 10 10
C278 RIGHT SPEAKER 2 15 C500 RH KEY SWITCH 6 10
C279 LEFT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 9 C602 LEFT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10
C350 AC EVAPORATOR SWITCH 2 14 C603 RIGHT REAR TAIL LIGHT 2 13 T3 FLASHER 2 15
C355 FUEL HARNESS 6 8,15 C606 POWER BOBTACH OPEN 2 15 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,12 C607 POWER BOBTACH CLOSE 2 15 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C610 HVAC DUCT FAN 2 14 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C611 BLOWER MOTOR 4 14 T13 BUZZER POWER 1 10
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C630 THERMOSTAT 3 14
T14 PRE HEATER 1 8
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C635 HEATER VALVE 6 14 T15 RIGHT REAR WORK LIGHT(+) 1 13
C410 LEFT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T16 RIGHT REAR WORK LIGHT(-) 1 13
C411 LEFT HANDLE 5 WAY 5 15 C670 EXTERIOR BEACON HARNESS 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C676 RADIO 6 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T19 BACKUP ALARM 1 12
C418 FRONT ROD 2 9 T20 BACKUP ALARM(GND) 1 12
C419 FRONT BASE 2 9 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 9 T37 DOME LIGHT(+) 1 11
C421 TILT SPOOL LOCK 3 12 T38 DOME LIGHT(-) 1 11
C422 LIFT SPOOL LOCK 3 12
C423 BUCKET POSITION SOLENOID 2 15
(ACS / SJC MACHINE)

T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 1 of 18
7253420 (0)
755 of 1288
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD

A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR CTRL 7228632
EXMF MFR CTRL 7265268
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824
SUSP JSTK 7163706
BRAKE ADAPTER 7165061 WIRING SCHEMATIC
TRK 2 SPD 7214626 (ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 2 of 18
7253420 (0)
Printed In U.S.A.
756 of 1288
LEGEND
CONNECTOR J7
PIN FUNCTION
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 13
13 OPTIONS PAGE 15
15
19 ECU RUN SIGNAL

21
24
25
26 A B C D
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29 PEDAL POS 2

SENSOR TEMP
34 WATER FUEL SENSOR GND
E F G H
45 ECU RELAY GND
47 ECU CAN 1 LO
48 ECU CAN 1 HI
J K L M
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 3 of 18
Printed In U.S.A.
7253420 (0)
757 of 1288
UNSWITCHED BATT POWER C408 1240 RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
FRC1 FUSE RELAY CENTER SP7 1420 RED/WHT
SHEET 10
SHEET 10
+12V 1025 RED
FUSE 13 25 A
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
T4 1 C493
1280 RED 1235 RED/WHT 2
SHEET 8
STARTER
FUSE 4 25 A
SHEET 14
FRC1 HVAC RELAY
FUSE 3 30 A

SHEET 9
FUSE 1 15 A
1320 RED/WHT
SHEET 13
1340 RED SHEET 13
SP26 1330 RED/WHT
FUSE 20 5 A
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60 Printable Version Click Here
WIRING SCHEMATIC
1050 RED
SHEET 5
(ACS / SJC MACHINE)
1030 RED
SHEET 8
T650 (S/N ALJG12303 - ALJG17414)
FRC1 STARTER RELAY
(S/N B2KZ11001 - B2KZ12035)
Sheet 4 of 18
7253420 (0)
Printed
758 of 1288
In U.S.A.
+12V
FRC1
ENGINE ECU
SWITCHED POWER J7A ENGINE ECU
PWR RELAY -G 1506 RNG/WHT 1


85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT SHEET 8 ENG-CROSSOVER
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489
SP50

FUSE 6 25 A
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
SP11 1950 RNG/WHT
FUSE 7 25 A SP65 SP42
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1 FUSE 23 15 A Printable Version Click Here
POWER RELAY -A
1050 RED
+12V
PWR 30
WIRING SCHEMATIC
SHEET 4 3450 LBL 21
GND 85
87
86
J1A
GWY CTRLR
C428
(LT GRAY) (ACS / SJC MACHINE)
SHEET 6
SP37
C449 LH JOYSTICK
T650 (S/N ALJG12303 - ALJG17414)
1740 RNG/WHT 6
C492
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
(S/N B2KZ11001 - B2KZ12035)
(8 PIN)
Sheet 5 of 18
7253420 (0)
Printed In U.S.A.
759 of 1288
2320 BRN
SHEET 9
GROUND
2370 BRN J1B
SHEET 11 GWY CTRLR
2220 BRN SP12 2230 BRN 17
SHEET 9
2190 BRN
2 2001 BLK SHEET 9
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2810 BLK 2180 BRN
J7A SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
SHEET 8 2695 BRN
C115 FOOT THROTTLE
2080 BLK C493 3 2235 BLK

2070 BLK (4 PIN)
SHEET 10 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 13
SHEET 10
C499 PTOL 2745 BLK
SP3 SHEET 14
SHEET 10

(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 15
2700 BLK 2770 BLK
SHEET 10 SHEET 15
2785 BLK 2200 BLK
SHEET 15 SHEET 9
2620 BLK
SHEET 13 C103 C489
T16 RH REAR WORK LIGHT B 2720 BLK
SHEET 12 2650 BLK SP6
SP51 2600 BLK B 2390 BLK T1 T10
C602 LH REAR TAIL LIGHT 2455 BLK
SHEET 15
2610 BLK C423 BKT POSITION SOLENOID SP27
C603 RH REAR TAIL LIGHT SHEET 7
2630 BLK C426 REMOTE RUN, ACD
SHEET 13 2715 BLK
T18 LH REAR WORK LIGHT SHEET 7
C169 ENGINE CAN
2290 BLK
2045 BLK SHEET 14 Printable Version Click Here
SHEET 13 D4 COMPRESSOR DIODE
SHEET 9 2035 BLK
2115 BLK
SP55
2105 BLK
SP5
2000 BLK
WIRING SCHEMATIC
SHEET 13
SHEET 5
2055 BLK SHEET 12 2520 BLK
C410 LEFT HANDLE
(ACS / SJC MACHINE)
FRC1 SWITCHED POWER RELAY 2530 BLK
SHEET 14 2030 BLK
SHEET 12
C409 RIGHT HANDLE T650 (S/N ALJG12303 - ALJG17414)
FRC1 HVAC RELAY
SHEET 8
FRC1 STARTER RELAY
2005 BLK (S/N B2KZ11001 - B2KZ12035)
SHEET 13
2120 BLK
Sheet 6 of 18

7253420 (0)
Printed In U.S.A.
760 of 1288
J7A
ECU CNTRLR
CAN BUS J1B
GWY CTRLR
47 9200 PUR 9215 PUR 9210 PUR 9205 PUR 20

CAN LO
CAN HI
R18 R21
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)

8 9260 PUR 9230 PUR 9250 PUR 9270 PUR 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
R14 R19
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
C492
(8 PIN)
1830 RNG/WHT 1
SHEET 5 C450
9290 PUR 7 2070 BLK 2
9190 PUR/WHT 8 9320 PUR/WHT 3
9420 PUR 4
9240 PUR 1
9140 PUR/WHT 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
9300 PUR/WHT 3
9400 PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
14 9500 PUR/WHT A 9280 PUR 8
CAN HI Printable Version Click Here
20 9180 PUR/WHT 9
CAN LO 9600 PUR B
WIRING SCHEMATIC
J1B
GWY CTRLR (ACS / SJC MACHINE)
21 3090 LBL D
C
SHEET 5
SHEET 4
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER
UNSWITCHED POWER
(S/N B2KZ11001 - B2KZ12035)
2710 BLK G GROUND
SHEET 6 Sheet 7 of 18
7253420 (0)
761 of 1288
FRC1
NOTE: SEE ENGINE HARNESS ON Sheet 16 of 18
ENGINE
STARTER RELAY - M C111
+12V HARN ENG START CONN
PWR 30 STARTER
1030 RED
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 ALTERNATOR G
J1A C405 EXCITATION
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6
C116 C115
SHEET 11
33 3695 LBL A 3695 LBL A
SIG
SHEET 6
E
FOOT THROTTLE D

ADAPTER HARNESS F
7217683
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND
SHEET 6 (30 - 270 OHM)
10 3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
5690 YEL 7 5690 YEL C +5V PWR
SHEET 11 3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
SIG

C118
ENG-CROSSOVER

To C154 - PIN1 and
C155 - PIN 3
WIRING SCHEMATIC
28 8013 TAN 8013 TAN 2
MAF FREQ
MAF TEMP
35 8014 TAN 8014 TAN 3
MAF Sensor - PIN 1
MAF Sensor - PIN 4
(ACS / SJC MACHINE)
4
1065 RED/WHT
+12V
PWR 30
3420 LBL
TO J4B - PIN 179 T650 (S/N ALJG12303 - ALJG17414)
SHEET 4 87 8525 TAN 8500 TAN Sheet 16 of 18
56 8510 TAN 85 86 1445 RED/WHT
SHEET 4
PRE-HEATER (S/N B2KZ11001 - B2KZ12035)
PREHEATER
RELAY - C
Sheet 8 of 18
7253420 (0)
Printed In U.S.A.
762 of 1288
FRC1
TRACTION LOCK
HYDRAULICS C425
+12V RELAY - D B C308
4100 LGN BRAKE
1360 RED/WHT PWR 30
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
7165061
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG
HYDRAULIC OIL
SHEET 6
C446

7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE) WIRING SCHEMATIC
3.3 OHM PWM
C419 (ACS / SJC MACHINE)
1 2340 BRN 2 GND FRONT BASE
3.3 OHM PWM
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
19 13 Sheet 9 of 18
J2B
AUX CTRLR

7253420 (0)
Printed In U.S.A.
763 of 1288
SHEET 5
1940 RNG/WHT
T13
BUZZER (+)
LEFT PANEL
CAB DISPLAY C499
7040 WHT
C479 (PTOL)
T2
10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1

3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
DOOR SIGNAL
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
SW12 8
DERATE OVERRIDE SWITCH 6 RIGHT PANEL DELUXE DISPLAY
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 3 8060 TAN
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED
WIRING SCHEMATIC
(ACS / SJC MACHINE)
Printed In U.S.A. T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 10 of 18
7253420 (0)
764 of 1288
SW4
HAND/FOOT *
SHEET 5
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
3
6
CAB
2060 BLK 5
C492
SHEET 12 4230 LGN
C438
(DK GRAY)
SHEET 11
4 * DLX CAB HARN 7253375 ONLY
(8 PIN) CAB-MFR HARN CONN 3
5
SHEET 12 4240 LGN SP29
7 4235 LGN
4220 LGN 4235 LGN
3 4275 LGN 8 4275 LGN
9
2 4550 LGN
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
*C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* T37
DOME LIGHT (+)
SHEET 4 1390 RED/WHT
SP41 DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
SP8
DOME LIGHT (-)

SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
SP44
2210 BLK SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B 7310 WHT
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 3
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

+5V Printable Version Click Here
SP13
5690 YEL
SHEET 8
SHEET 8 5695 YEL WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378 (ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
* C252
A
C253
1
PWR
(S/N B2KZ11001 - B2KZ12035)
7310 WHT WASHER
MOTOR
2845 BLK B 2845 BLK 2 GND Sheet 11 of 18

765 of 1288
MANUAL CONTROLS C409
RIGHT HANDLE
(MANUAL/ACS ONLY) C466
J2A
2530 BLK K A
SHEET 6
AUX CTRLR 4230 LGN G B HANDLE LOCK (ACS)
C404 SHEET 11
C103 1530 RNG/WHT A
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE

C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 1 SIG TILT SPOOL LOCK 20 4640 LGN D FLOAT (ACS)
4980 LGN
2 17.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 3 11 4810 LGN F SIDE SHIFT
2990 BRN GND
1 LIFT SPOOL LOCK 1520 RNG/WHT A
4990 LGN SIG SHEET 5
17.8 OHM 12V J C465
2
4240 LGN H A
SHEET 11
2520 BLK E B HANDLE LOCK (ACS)
SHEET 6
7 5
J1B SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 12 of 18
7253420 (0)
Printed In U.S.A.
766 of 1288
LIGHTS
C434-1
C408
(BLACK)
C434-2
SHEET 6
50.00 Watts
C435-1
FRC1 WORK LIGHT
2760 BLK B GND
LIGHTS RELAY - J
C438 C435-2
50.00 Watts
13 6610 PNK
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
PWR 2610 BLK 2 GND

TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
RELAY - E
+12V
1320 RED/WHT SP96
86 SHEET 6
2045 BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 13 of 18
Printed In U.S.A.
767 of 1288 7253420 (0)
HVAC * C610
2440 BLK 2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483

C BLK
B (TEMP CONTROL
7425 WHT WHT SWITCH)
* DLX CAB HARN 7253375 ONLY C635
* D
(NOT IN STD CAB HARN) 2130 BLK C
SIG
GND HEATER
SP48 B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY - B CAB-MFR HARN CONN 3 SWITCH

1140 RED/WHT PWR 30 OFF

1
GND 85 86 4
2030 BLK
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6 2745 BLK 11 2745 BLK SP16 *
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

A 7024 WHT
C486
7025 WHT 1 SIG
2290 BLK 2280 BLK

2 GND
MAGNET CLUTCH
(COMPRESSOR) WIRING SCHEMATIC
SHEET 6
D4 (ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 14 of 18
7253420 (0)
Printed In U.S.A.
768 of 1288
# C607
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
OPTIONS
POWER BOB
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
# DLX FUEL HARN 7266824 ONLY
GND 2 2470 BLK 2770 BLK B 2770 BLK
CLOSE SHEET 6
SW5
*POWER 2 1
#
GND
C606
2 2480 BLK
BOBTACH
SWITCH 5
3
4
6
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10 4480 LGN (NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
PWR
C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
(FLASHER) 5 WAY C SHEET 10 3500 LBL D1
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK D2 6430 PNK SWITCH
LEFT 3 6400 PNK
2725 BLK 6

3400 LBL
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
4
2 *SW6
OPTIONS DWG)
POSITION 5 POSITION C
2830 BLK
6.13 OHM SHEET 6 6
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1
SHEET 6
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
SIG
PWR
B
A
7210 WHT
1460 RED/WHT
13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2 AIR RIDE
C497
SJC RIGHT
*-
C278
2 7810 WHT 6 3 SEAT
5 7200 WHT C SPEAKER 1 5 1510 RNG/WHT 4 PWR
HORN/BLINKER 7800 WHT SHEET 11
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL 1885 RNG/WHT SHEET 11
3 6520 PNK B SHEET 11 6
J2A OPTIONS DWG) 2885 BLK 2
SHEET 11
AUX CTRLR
C415
A SIG
SOLENOID
4460 LGN
7.5 OHM 12 V
J2B Printable Version Click Here
26
AUX CTRLR
C441
WIRING SCHEMATIC
J1A
GWY CTRLR
26 2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER (ACS / SJC MACHINE)
J1B 26
OPTIONS DWG)
T650 (S/N ALJG12303 - ALJG17414)
GWY CTRLR
(S/N B2KZ11001 - B2KZ12035)
Sheet 15 of 18
7253420 (0)
Printed In U.S.A.
769 of 1288
LEGEND
ENGINE
PARTIAL CONNECTOR
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164 C136
TO C113 PIN 3
5 POSITION SIGNAL 116 See Sheet 5 of 14 4
EGR VALVE
DC MOTOR 3 POSITION RETURN 172 120 SENSOR GROUND 3
6 192 137 5V 2 MAF
H BRIDGE POS
SENSOR
2 H BRIDGE NEG 193 TO C113 PIN 2 1
See Sheet 5 of 14

C149
COOLANT TEMP
165 VREF3 OIL PRESSURE 3
OIL PRESSURE &
C148 111 OIL PRESSURE SENSOR 4 TEMPERATURE
1 FUEL TEMP SENSOR 110 148 1 SENSOR
FUEL TEMP RETURN GND
SENSOR 2 FUEL RETURN 146
104 OIL TEMPERATURE SENSOR 2
C147
2 SENSOR SIGNAL 131
ENGINE BLOCK
SHIELD 128 .
169 RETURN 1 INTAKE
2 SENSOR SIGNAL 132 TEMPERATURE
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
C144
C138
1 SENSOR RETURN 147 . 161 INTAKE MANIFOLD PRESSURE 1
CAM SHAFT 2 159
POS SENSOR 112 3
SENSOR INTAKE PRESS SENSOR INTAKE MANIFOLD
167 INTAKE PRESS RETURN 2
TO C118 - PIN 1 SENSOR
RAIL
PRESSURE 2 SENSOR RETURN 119
SENSOR C139
3 VREF1 SENSOR 138
C141 126 2 CYL 1 Printable Version Click Here
FUEL INJECTOR LSD1A
CYL 3 175 C140
2 FUEL INJECTOR LSD1B 150 FUEL INJECTOR HSDB 2
CYL 2
WIRING SCHEMATIC
C142 174 FUEL INJECTOR LSD2B 1
CYL 4
1
2
125 C154
(ACS / SJC MACHINE)
FUEL INJECTOR LSD2A
177 2
PWM
TO C118 - PIN 1 1
INLET METERING
VALVE
T650 (S/N ALJG12303 - ALJG17414)
SEE Sheet 8 of 18 (S/N B2KZ11001 - B2KZ12035)
Sheet 16 of 18
7253420 (0)
Printed In U.S.A.
770 of 1288
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 1 LIFT C TWO SPD

4260 LGN 4280 LGN
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
D 4610 LGN 8 F
7 A
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GND
C
J 4660 LGN 3 SIG K 4645 LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 GND 4
TILT PEDAL
5760 YEL 1 +5V PWR HALL SENSOR 2990 BRN 1 GND
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H
3980 LBL
E 3990 LBL
(ACS / SJC MACHINE)
T650 (S/N ALJG12303 - ALJG17414)
(S/N B2KZ11001 - B2KZ12035)
Sheet 17 of 18
7253420 (0)
Printed In U.S.A.
771 of 1288
SJC A
B
C
D
E
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
A
B
C
D
E
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
A
B
C
D
E
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
2
3
4
5
6
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
CONTROLS
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
C429 ACTUATOR
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
4 19 L JOYSTICK Y
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
34 TILT ACTUATOR
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
6 27 GROUND
23 2990 BRN 1 GND
24 28 GROUND
4640 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
31 L REV DRIVE

8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
SWASHPLATE E 35 SAFETY OUT
5860 YEL 2 C542
H
F
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1 D
9140 PUR/WHT 47 UNSWITCHED BATTERY
41 2680/BRN BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
C544 C
K
A 1 1
C474 1830 RNG/WHT +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493

28 2490 BLK 2235 BLK 3
2240 BLK 4
(ACS / SJC MACHINE)
1760 RNG/WHT
2280 BLK T650 (S/N ALJG12303 - ALJG17414)
2270 BLK
2260 BLK (S/N B2KZ11001 - B2KZ12035)
1180 RED/WHT
1190 RED/WHT Sheet 18 of 18
B ALARM C404 ON MFR (PRINTED NOVEMBER 2016)
HARNESS)
772 of 1288
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C425 BRAKE SOLENOID 3 9 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C426 CAN(Remote Start Tool, ACD) 7 7
C105 HYD CHARGE PRESSURE SENSOR 3 9 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C434-1 LEFT FRONT WORKLIGHT 1 (37W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 C434-2 LEFT FRONT WORKLIGHT 2 (50W) 2 13 J2A AUX CONTROLLER 34 9,12,15
C110 ALTERNATOR 2 8 C435-1 RIGHT FRONT WORKLIGHT 1 (37W) 2 13 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C435-2 RIGHT FRONT WORKLIGHT 2 (50W) 2 13
C112 HYD OIL FILTER SWITCH 2 9 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C441 TWO SPEED SOLENOID 2 15
C114 HAND THROTTLE 6 8 C446 HYDRAULIC FAN 2 9
C115 FOOT THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C116 FOOT THROTTLE INTDM 3 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW2 BEACON SWITCH 6 15
C118 ENG-CROSSOVER 4 8 C479 LEFT PANEL(BLACK) 12 7,10 SW3 HAZARD SWITCH 6 15
C126 HORN 2 15 C480 LEFT PANEL(GRAY) 12 10 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C129 CAB ACCESSORY 3 11 C482 SEATBAR SENSOR 3 11
C169 ENGINE CAN (Diagnostic) 6 7 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C212 POWER SOCKET 2 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C252 WASHER PUMP INTDM 2 11 C489 MFR ACCESSORY 2 5,6
C253 WASHER PUMP 2 11 C492 ACS/SJC/AWS-MFR HARN 8 5,7,11 SW9 TRAVEL CONTROL SWITCH 6 10
C277 AIR RIDE SEAT 6 15 C493 ACS/SJC/AWS-MFR HARN 4 4,6 SW10 BLOWER SWITCH 6 14

C278 RIGHT SPEAKER 2 15 C497 SJC HORN/BLINKER 3 15 SW11 AC SWITCH 3 14
C279 LEFT SPEAKER 2 15 C499 PTOL 4 10 SW12 DPF SWITCH 10 10
C308 BRAKE SOLENOID 2 9 C500 RH KEY SWITCH 6 10 T1 BATT GROUND 1 6
C350 AC EVAPORATOR SWITCH 2 14 C503 RH DLX PANEL 6 7,10 T2 BUZZER GROUND 1 10
C355 FUEL HARNESS 6 8,15 C602 LEFT REAR TAIL LIGHT 2 13 T3 FLASHER 2 15
C404 BU ALARM-MFR HARN 2 5,12 C603 RIGHT REAR TAIL LIGHT 2 13 T4 MEGAFUSE LOAD SIDE 1 4
C405 AIR FILTER SWITCH 2 8 C606 POWER BOBTACH OPEN 2 15 T6 BATT GROUND 1 6
C406 FUEL SENDER 2 8 C607 POWER BOBTACH CLOSE 2 15 T8 BATT GROUND 1 6
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C610 HVAC DUCT FAN 2 14
T10 ENGINE SYSTEM GROUND 1 6
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C611 BLOWER MOTOR 4 14 T13 BUZZER POWER 1 10
C410 LEFT HANDLE (MAN/ACS) 10 12 C630 THERMOSTAT 3 14
T14 PRE HEATER 1 8
C411 LEFT HANDLE 5 WAY 5 15 C635 HEATER VALVE 6 14 T15 RIGHT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C667 DOOR HARNESS 6 11 T16 RIGHT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 C670 EXTERIOR BEACON HARNESS 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C418 FRONT ROD 2 9 C676 RADIO 6 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C419 FRONT BASE 2 9 T19 BACKUP ALARM 1 12
C420 HYD LOCK 2 9 T20 BACKUP ALARM(GND) 1 12
C421 TILT SPOOL LOCK 3 12 T32 ECU CASE GROUND 1 6
C422 LIFT SPOOL LOCK 3 12 T37 DOME LIGHT(+) 1 11
C423 BUCKET POSITION SOLENOID 2 15 T38 DOME LIGHT(-) 1 11
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 1 of 18
773 of 1288 7279775 (A)
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD

A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR CTRL 7276760
EXMF MFR CTRL 7276758
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824
TAILGATE EUR 7217483 WIRING SCHEMATIC
SUSP JSTK 7266829
BRAKE ADAPTER 7165061 (ACS / SJC MACHINE)
TRK 2 SPD 7214626 T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 2 of 18
7279775 (A)
774 of 1288
Printed In U.S.A.
LEGEND
CONNECTOR J7
PIN FUNCTION
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 13
13 OPTIONS PAGE 15
15
19 ECU RUN SIGNAL

21
A B C D
24
25

26
SENSOR FREQUENCY
29
E F G H
SENSOR TEMP
34 WATER FUEL SENSOR GND
45 ECU RELAY GND J L
K M
47 ECU CAN 1 LO
48 ECU CAN 1 HI
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 3 of 18
7279775 (A)
775 of 1288
UNSWITCHED BATT POWER C408 1240 RED/WHT SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
FRC1 FUSE RELAY CENTER SP7 1420 RED/WHT
SHEET 10
SHEET 10
+12V 1025 RED
FUSE 13 25 A
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
T4 1 C493
1280 RED 1235 RED/WHT 2
SHEET 8
STARTER
FUSE 4 25 A

SHEET 14
FUSE 1 15 A
1320 RED/WHT
SHEET 13
FUSE 2 20 A 1350 RED/WHT SHEET 13
1340 RED
SP26 1330 RED/WHT
1335 RED FUSE 20 5 A
1345 RED/WHT SHEET 5
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
(OPTIONS)
FUSE 24 25 A Printable Version Click Here
SHEET 11
C408 CAB-MFR CONN
1055 RED
(ACCESSORIES) WIRING SCHEMATIC
SP60 (ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
1050 RED
SHEET 5
(S/N B2KZ12036 - B2KZ12105)
1030 RED
SHEET 8
Sheet 4 of 18
Printed In U.S.A.
FRC1 STARTER RELAY (PRINTED NOVEMBER 2016)
7279775 (A)
776 of 1288
FRC1
+12V ENGINE ECU
PWR RELAY -G
SWITCHED POWER 1506 RNG/WHT
J7A ENGINE ECU
1

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT
C404
(SEE ADDITIONAL
OPTIONS DWG)

FUSE 5 25 A C489
SP50
1760 RNG/WHT
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
1950 RNG/WHT
SP11 SHEET 10 C500 RH PANEL KEY SWITCH
FUSE 7 25 A SP65 SP42
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1 FUSE 23 15 A
POWER RELAY -A
+12V WIRING SCHEMATIC
PWR 30
SHEET 4 1050 RED
87 3450 LBL 21
J1A C428 (ACS / SJC MACHINE)
GWY CTRLR (LT GRAY)
GND 85 86
SHEET 6 2055 BLK 3380 LBL 4 CAB-MFR HARN CONN 2
SP37
SHEET 7
T650 (S/N ALJG17415 - ALJG19316)
C449 LH JOYSTICK
C492 1830 RNG/WHT
SHEET 7
(S/N B2KZ12036 - B2KZ12105)
1740 RNG/WHT 6 ACS/SJC/AWS-MFR HARN
C450 RH JOYSTICK
(8 PIN)
Sheet 5 of 18
777 of 1288
2320 BRN
SHEET 9
2370 BRN
GROUND
J1B
SHEET 11 GWY CTRLR
2220 BRN SP12 2230 BRN 17
SHEET 9
2190 BRN
2 SHEET 9
4 2002 BLK SP53 2810 BLK 2180 BRN
J7A SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
SHEET 8 2695 BRN
C115 FOOT THROTTLE
2080 BLK C493 3 2235 BLK

2070 BLK (4 PIN)
SHEET 10 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 13
SHEET 10
C499 PTOL 2745 BLK
SP3 SHEET 14

SHEET 10
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 15
2700 BLK 2770 BLK
SHEET 10 SHEET 15
2785 BLK 2200 BLK
SHEET 15 SHEET 9
2620 BLK
SHEET 13 C103 C489
T16 RH REAR WORK LIGHT B 2720 BLK
SHEET 12 2650 BLK SP6
SP51 2600 BLK B 2390 BLK T1 T10
C602 LH REAR TAIL LIGHT 2455 BLK
SHEET 15
2610 BLK C423 BKT POSITION SOLENOID SP27
C603 RH REAR TAIL LIGHT SHEET 7
2630 BLK C426 REMOTE RUN, ACD
SHEET 13 2715 BLK
T18 LH REAR WORK LIGHT SHEET 7 Printable Version Click Here
C169 ENGINE CAN
2290 BLK
SHEET 13
2045 BLK SHEET 14
D4 COMPRESSOR DIODE WIRING SCHEMATIC
SHEET 9 2035 BLK
2115 BLK
SP55
2105 BLK
SP5
2000 BLK
(ACS / SJC MACHINE)
SHEET 13
SHEET 5
2055 BLK SHEET 12
2520 BLK
C410 LEFT HANDLE
T650 (S/N ALJG17415 - ALJG19316)
SHEET 14 2030 BLK
SHEET 12 2530 BLK
C409 RIGHT HANDLE
(S/N B2KZ12036 - B2KZ12105)
FRC1 HVAC RELAY
SHEET 8 2005 BLK Sheet 6 of 18
FRC1 STARTER RELAY
2120 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY 7279775 (A)
Printed In U.S.A.
778 of 1288
J7A
ECU CNTRLR
CAN BUS J1B
GWY CTRLR
47 9200 PUR 9215 PUR 9210 PUR 9205 PUR 20

CAN LO
CAN HI
R18 R21
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)
GWY CTRLR

CAB-MFR HARN CONN 1
8 9260 PUR 9230 PUR 9250 PUR 9270 PUR 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
R14 R19
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
C492
(8 PIN)
1830 RNG/WHT 1
SHEET 5 C450
9290 PUR 7 2070 BLK 2
9190 PUR/WHT 8 9320 PUR/WHT 3
9420 PUR 4
9240 PUR 1
9140 PUR/WHT 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
9300 PUR/WHT 3
9400 PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
14 9500 PUR/WHT A 9280 PUR 8 Printable Version Click Here
CAN HI 9
20 9180 PUR/WHT
CAN LO 9600 PUR B
WIRING SCHEMATIC
J1B
GWY CTRLR
(ACS / SJC MACHINE)
21 3090 LBL D
C
SHEET 5
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER
UNSWITCHED POWER
(S/N B2KZ12036 - B2KZ12105)
SHEET 4
SHEET 6
2710 BLK G GROUND
Sheet 7 of 18
Printed In U.S.A.
7279775 (A)
779 of 1288
SHEET 4
1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M
87
ENGINE 8200 TAN
C111
HARN ENG START CONN
A 8220 TAN
STARTER
S B SHEET 4
M
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 ALTERNATOR G
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B GND 2015 BLK
SHEET 6 AIR FILTER SHEET 6
16 3150 LBL A SIG
C116 C115

SHEET 11
33 3695 LBL A 3695 LBL A
SIG
SHEET 6
E
FOOT THROTTLE D
ADAPTER HARNESS F
7217683
J1B C355

GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 SHEET 6
3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
5690 YEL 7 5690 YEL C +5V PWR
SHEET 11 3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
SIG
C118
ENG-CROSSOVER
To C154 - PIN 1, &
1511 RNG/WHT 1
SHEET 5 To C114, Pin 3, Sheet 16 of 18
28 8013 TAN 8013 TAN 2
MAF FREQ MAF Sensor - PIN 1, Sheet 16 of 18
35 8014 TAN 8014 TAN 3 Printable Version Click Here
MAF TEMP MAF Sensor - PIN 4, Sheet 16 of 18
+12V 3420 LBL 4
TO GLOW PLUG, J7B - PIN 79,
PWR 30
87 8525 TAN 8500 TAN Sheet 16 of 18 WIRING SCHEMATIC
56 8510 TAN 85 86 1445 RED/WHT
SHEET 4 PRE-HEATER (ACS / SJC MACHINE)
PREHEATER
RELAY - C T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 8 of 18
Printed In U.S.A.
780 of 1288
7279775 (A)
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
C425
B C308
BRAKE
1360 RED/WHT PWR 30
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035 BLK OPTIONS DWG)
7165061
8 4110 LGN
13 3430 LBL
C108
GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG
HYDRAULIC OIL
SHEET 6
C446

7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 6
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330 BRN 2 GND FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330 LGN 1 SIG
C419
3.3 OHM PWM
(ACS / SJC MACHINE)
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
T650 (S/N ALJG17415 - ALJG19316)
3.3 OHM PWM
(S/N B2KZ12036 - B2KZ12105)
19 13 Sheet 9 of 18
J2B
AUX CTRLR (PRINTED NOVEMBER 2016)
7279775 (A)
Printed In U.S.A.
781 of 1288
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
T2
LEFT PANEL
BUZZER
C479
LEFT PANEL (BLACK)
CAB DISPLAY C499
(PTOL)
BUZZER (-) 1930 RNG/WHT 1

10 C408
2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12

1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
DOOR SIGNAL
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
SW12 8
DERATE OVERRIDE SWITCH 6 RIGHT PANEL DELUXE DISPLAY
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 3 8060 TAN
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED

(ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 10 of 18
7279775 (A)
782 of 1288
SW4
HAND/FOOT *
CAB
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
C492
SHEET 12 4230 LGN (DK GRAY)
SHEET 11
CAB-MFR HARN CONN 3

(8 PIN)
5
SHEET 12 4240 LGN
4220 LGN
SP29
4235 LGN 7 4235 LGN
3 4275 LGN 8 4275 LGN
2 4550 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45

* T37
DOME LIGHT (+)
SP41 DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
DOME LIGHT (-)

SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
2730 BLK 11 2730 BLK
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
2370 BRN 2370 BRN A SENSOR 7310 WHT 3
4 GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

+5V Printable Version Click Here
SP13
SHEET 8 5690 YEL

SHEET 8 5695 YEL WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378 (ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
* C252
A
C253
1
PWR
WASHER (S/N B2KZ12036 - B2KZ12105)
7310 WHT
MOTOR
2845 BLK B 2845 BLK 2 GND Sheet 11 of 18
7279775 (A)
Printed In U.S.A.
783 of 1288
MANUAL CONTROLS 2530 BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
K
C466
A
J2A SHEET 6
AUX CTRLR 4230 LGN G B HANDLE LOCK (ACS)
C404 SHEET 11
C103 1530 RNG/WHT A
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE

C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 1 SIG TILT SPOOL LOCK 20 4640 LGN D FLOAT (ACS)
4980 LGN
2 17.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 3 11 4810 LGN F SIDE SHIFT
2990 BRN GND
1 LIFT SPOOL LOCK 1520 RNG/WHT A
4990 LGN SIG 17.8 OHM 12V SHEET 5
J C465
2
4240 LGN H A
SHEET 11
2520 BLK E B HANDLE LOCK (ACS)
SHEET 6
7 5 SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS

J1B
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 12 of 18
7279775 (A)
Printed In U.S.A.
784 of 1288
C434-1
C408
LIGHTS
(BLACK)
C434-2
SHEET 6
50.00 Watts
C435-1
8 6000 PNK 6120 PNK A SIG RIGHT FRONT
RC1 WORK LIGHT
2760 BLK B GND
LIGHTS RELAY 1
C438 C435-2
SHEET 4 87 6620 PNK 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK
2120 BLK 85 86
SHEET 6
6630 PNK
6000 PNK
RC2
FRONT WORK
LIGHTS RELAY 2 C103
PWR 2610 BLK 2 GND

TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1
RELAY - E
+12V
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SP96 6200 PNK SIG LEFT REAR
2045 BLK 86 SHEET 6
(ACS / SJC MACHINE)

T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 13 of 18
7279775 (A)
785 of 1288
* C610
HVAC 2440 BLK

7440 WHT
2560 BLK
7420 WHT
* C483
2
1
C
A
GND
SIG
BLK
DBL
HVAC DUCT
FAN
POTENTIOMETER
B (TEMP CONTROL
7425 WHT WHT SWITCH)
* DLX CAB HARN 7253375 ONLY * C635

D SIG
(NOT IN STD CAB HARN) 2130 BLK C GND
A +12V PWR
HEATER
VALVE
7430 WHT
SP48 B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY - B CAB-MFR HARN CONN 3 SWITCH

1140 RED/WHT PWR 30 OFF
1
GND 85 86 4
2030 BLK
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
J1A
30 3050 LBL
SHEET 6 2745 BLK 11 2745 BLK SP16 *
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

A 7024 WHT Printable Version Click Here
C486
7025 WHT 1 SIG
MAGNET CLUTCH
WIRING SCHEMATIC
2 GND
SHEET 6
2290 BLK 2280 BLK
(COMPRESSOR)
(ACS / SJC MACHINE)
D4
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 14 of 18
7279775 (A)
786 of 1288
SIG
# C607
1 4470 LGN
C355
FUEL HARN
E 4470 LGN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
11 4470 LGN
OPTIONS
POWER BOB
GND 2 2470 BLK 2770 BLK B 2770 BLK
# DLX FUEL HARN 7266824 ONLY
CLOSE SHEET 6
SW5 (NOT IN STD FUEL HARN 7149219)
*POWER 2 1
# C606 BOBTACH 3
POWER BOB
GND 2 2480 BLK SWITCH 5 4
SIG 1 4480 LGN F 4480 LGN 10 4480 LGN
OPEN
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
PWR
C411
B
SHEET 4
L
* FLASHER
T3
LEFT HANDLE CONN

(FLASHER) 5 WAY C SHEET 10 3500 LBL D1
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK D2 6430 PNK SWITCH
LEFT 3 6400 PNK
2725 BLK 6

3400 LBL
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
4
2 *SW6
OPTIONS DWG)
POSITION 5 POSITION C
SOLENOID B 2450 BLK 2830 BLK
GND 2455 BLK SHEET 6 6 SWITCH A
6.13 OHM SHEET 6
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1
SHEET 6
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
SIG
PWR
B
A
7210 WHT
1460 RED/WHT
13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2 AIR RIDE
C497
SJC RIGHT
*- C278
2 7810 WHT 6 3 SEAT
5 7200 WHT C SPEAKER 1 5 1510 RNG/WHT 4 PWR
HORN/BLINKER 7800 WHT SHEET 11
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL 1885 RNG/WHT SHEET 11
3 6520 PNK B SHEET 11 6
J2A OPTIONS DWG) 2885 BLK 2
AUX CTRLR
SHEET 11
C415
A SIG SOLENOID
4460 LGN
7.5 OHM 12 V
J2B
AUX CTRLR
26
C441
TRACK 2 SPEED
(ACS / SJC MACHINE)
J1A 26 2350 BRN 2 GND TWO SPEED
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL T650 (S/N ALJG17415 - ALJG19316)
OPTIONS DWG)
J1B
GWY CTRLR
26
(S/N B2KZ12036 - B2KZ12105)
Sheet 15 of 18
Printed In U.S.A.
7279775 (A)
787 of 1288
LEGEND
ENGINE
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164
TO C118 PIN 3
5 POSITION SIGNAL 116 See Sheet 8 of 18 4
EGR VALVE
3 172 120 SENSOR GROUND 3 MAF
DC MOTOR POSITION RETURN
SENSOR
6 192 137 5V 2
H BRIDGE POS
2 H BRIDGE NEG 193 TO C118 PIN 2 1
See Sheet 8 of 18

C149
COOLANT TEMP C136
165 VREF3 OIL PRESSURE 3
OIL PRESSURE &
C148 111 OIL PRESSURE SENSOR 4 TEMPERATURE
1 FUEL TEMP SENSOR 110 148 1 SENSOR
FUEL TEMP RETURN GND
SENSOR 2 FUEL RETURN 146
104 OIL TEMPERATURE SENSOR 2
C147
2 SENSOR SIGNAL 131
ENGINE BLOCK
SHIELD 128 .
169 RETURN 1 INTAKE
2 132 TEMPERATURE
SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
C144
C138
1 SENSOR RETURN 147 INTAKE MANIFOLD PRESSURE 1
CAM SHAFT 2 159
POS SENSOR
SENSOR 112 INTAKE PRESS SENSOR 3 INTAKE
167 INTAKE PRESS RETURN 2
TO C118 - PIN 1 SENSOR
RAIL
PRESSURE 2 SENSOR RETURN 119
SENSOR C139
3 VREF1 SENSOR 138
C141 126 FUEL INJECTOR LSD1A 2 CYL 1 Printable Version Click Here
1 FUEL INJECTOR HSDB 151
CYL 3 2 FUEL INJECTOR LSD1B 175
150 FUEL INJECTOR HSDB
C140
2 WIRING SCHEMATIC
C142 174 1 CYL 2
CYL 4
FUEL INJECTOR LSD2B
(ACS / SJC MACHINE)
2 FUEL INJECTOR LSD2A 125 C154
177 PWM 2
INLET METERING T650 (S/N ALJG17415 - ALJG19316)
TO C118 - PIN 1 1 VALVE
SEE Sheet 8 of 18 (S/N B2KZ12036 - B2KZ12105)
Sheet 16 of 18
7279775 (A)
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER HANDLE
G B
A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 4

9140 PUR/WHT G 4280 LGN 1 LIFT C TWO SPD
4260 LGN
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
D 4610 LGN 8 F
7 A
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GND
C
J 4660 LGN 3 SIG K 4645 LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 GND 4
TILT PEDAL
5760 YEL 1 +5V PWR HALL SENSOR 2990 BRN 1 GND
3990 LBL 2 SIG
5750 YEL
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H
3980 LBL
E 3990 LBL
(ACS / SJC MACHINE)
T650 (S/N ALJG17415 - ALJG19316)
(S/N B2KZ12036 - B2KZ12105)
Sheet 17 of 18
7279775 (A)
Printed In U.S.A.
789 of 1288
SJC
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 6 ISO LITE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
CONTROLS G
H
GROUND
GROUND
G
H
J
K
TILT HANDLE
LIFT PEDAL
TILT PEDAL
G
H
J
K
PEDAL ENABLE
GROUND
GROUND
TILT MOTOR 2
8
9
10
11
12
R SWASH PLATE ANGLE
SPARE ANALOG 4
SPARE ANALOG 5
L FWD RETURN
CAN HIGH
C429 ACTUATOR
4600 LGN 5 4680
6
16 H PAT LITE
SUSP JSTK 7284703
4610 LGN 8 4690 17 RR ANGLE
4 19 L JOYSTICK Y
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
34 TILT ACTUATOR
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
6
23
27 GROUND
2990 BRN 1 GND
24 28 GROUND
4640 LGN 5 4780
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7198705) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8 4790
31 L REV DRIVE

8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
F
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
C544 C
K
A 1 1
C474 1830 RNG/WHT +12V PWR
D
26 4210 LGN A 2 2070 BLK 2 GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1480 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493

28 2490 BLK 2235 BLK 3
2240 BLK 4
(ACS / SJC MACHINE)

1760 RNG/WHT
2280 BLK T650 (S/N ALJG17415 - ALJG19316)
2270 BLK
2260 BLK (S/N B2KZ12036 - B2KZ12105)
1180 RED/WHT
1190 RED/WHT Sheet 18 of 18
B ALARM C404 ON MFR (PRINTED NOVEMBER 2016)
HARNESS)
790 of 1288
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
8 SH08 - HYDRAULICS
BATT FEED, GENERAL RED RED LEGEND
1000 THROUGH 1499
10 SH10 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
11 SH11 - MANUAL CONTROLS
12 SH12 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
13 SH13 - HVAC
14 SH14 - OPTIONS 1 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
15 SH15 - OPTIONS 2
1 1
HARNESS PART NUMBER LIGHT GREEN
HYDRAULIC 4000 THROUGH 4999 LGN
MF MFR CTRL 7300790 1 1
EXMF MFR CTRL 7300339 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7301237 * LIGHTS 6000 THROUGH 6999 PINK PNK SHT1/F2
WIRE #
SHT1/F2
WIRE #
STD CAB 7303755 * WHITE
SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHT
STD FUEL 7149219
DLX FUEL 7266824
BCT ENG 7220812 COMMUNICATION PURPLE PUR

9000 THROUGH 9999
9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALJG19317-ALJG23962, ALJG23985

B2KZ12106-B2KZ13525
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899 TOLERANCES: ECN 101943 Printed On August 2018
csf

ACS / SJC Machine S/N B2KZ12106
B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
B3 MOVED "GND" TEXT FROM A5 TO A2 104399 AEW 3 OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
UNLESS OTHERWISE SPECIFIED SCHEM ELEC CTRL
B2 2195 ASSIGNED SIZE OF 18
Click Here For Interactive PDF
104399 AEW 11 COPYRIGHT C
Sheet 1 of 17
7300789
B1 9205 SWAPPED SIZE AND MATERIAL VALUES 104399 AEW 5 TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
791 of 1288
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
1400 RED/WHT
C408 SHT10/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
1160 RED/WHT
SP36
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1

FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/C3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/C3
RED
FUSE 18 25 A
1055

18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

ACS / SJC Machine S/N B2LA11412
B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 2 of 17
7300789
B SEE SHEET 1 104399 AEW IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE Printable Version Click Here
792 of 1288
FRC1 ENGINE
ECU RELAY - G
SWITCHED
ENG ECU CTRLR
1506 RNG/WHT
1
G1
POWER
SHT2/D1 87 1540 RNG/WHT SP54 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT

SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT10/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT9/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT SP42 1590 RNG/WHT
2 2 SHT9/E4
1555 RNG/WHT
SHT15/F4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
B3 A4 7A 7B SHT5/B8
86 85 GND
A5 A2
BUS BAR
1725 RNG/WHT
SHT5/C2
1580 RNG/WHT
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
J1A
C428
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3
C492
1740 RNG/WHT
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 3 of 17
7300789
B SEE SHEET 1 104399 AEW TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
793 of 1288
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7
6 2370 BRN GATEWAY CTRLR
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/F4 SHT8/D7 J1B
2180 BRN
SHT6/D7
C493
2150 BRN
ACS/SJC/AWS CONN 2 SHT6/F7
2235 BLK 2695 BRN
2080 BLK 3 3 SHT6/E7
SHT5/E3
2240 BLK
2070 BLK 4 4
SHT5/F3
C493 T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16

SHT15/D4
AUX CTRLR 2780 BLK
2890 BLK 2550 BLK 2090 BLK SHT14/E7
SHT15/H4 15
2065 BLK SP28 2730 BLK
C428
2930 BLK
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND AUX CTRLR
SHT12/C4 B B 2195 BRN
SP51 SHT11/G2 SP58 2995 BRN
2610 BLK 2185 BRN 17 SENSOR GROUND
SHT12/E4 SHT15/E7
J2B
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
SHT5/C2
2505 BLK 2290 BLK

SHT15/G4 SHT13/B8
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55 SP5 2000 BLK

2115 BLK 2105 BLK
SHT12/D8
2055 BLK 2520 BLK

SHT3/C1 SHT11/D2
2030 BLK 2530 BLK

SHT13/F8 SHT11/F2
2005 BLK
SHT6/G7
2120 BLK
SHT12/E8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 4 of 17
7300789
794 of 1288
CAN BUS
RE016 RE019
C408
GATEWAY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR C479
R3-1 SP19 SP18 LEFT PANEL (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31 TP-12 TP-12 SP79 TP-14 9270 PUR TP-14 TP-16 9220 PUR TP-16 TP-01 TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08 9460 PUR TP-08
9230 PUR 9250 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR
SP30 SP80 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
R3-2 SP20 R2
J1B TP-11 TP-13 TP-15 TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
9440 PUR TP-06
C492 4 CAN LO
ACS/SJC/AWS-MFR HARN (8 PIN)
9340 PUR/WHT
9290 PUR TP-15 2 CAN HI
7 7
9190 PUR/WHT C503

8 8
*
9240 PUR TP-13
1 1 C450 C460
RIGHT JOYSTICK CONN RIGHT JOYSTICK RIGHT JOYSTICK
9140 PUR/WHT 1830 RNG/WHT 1830 RNG/WHT +12V PWR
4 4 SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
4 4

AUX CTRLR 4 4
9280 PUR TP-11
8
*
CAN LO
C449 C459
9180 PUR/WHT LEFT JOYSTICK CONN LEFT JOYSTICK LEFT JOYSTICK
9 CAN HI 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
J2B 2080 BLK 2080 BLK GND
THESE SCHEMATICS86(',161ALJG19317-ALJG23962, ALJG23985 SHT4/G8 2 2 2 2
B2KZ12106-B2KZ13525 3 3 3 3
4 4 4 4
FOR TELEMATICS SEE CAN BUS6+((7,1 SUSP SEAT JOYSTICK HARNESS
R18 R21
C426 ENG ECU CTRLR 120 OHM 0.5W RESISTOR 120 OHM 0.5W RESISTOR
AUX CTRLR B1 GATEWAY CTRLR
Remote Run Tool, ACD R1-1 SP90 R2-1
TP-22 TP-22 TP-17 TP-17 TP-18 TP-18 TP-20 TP-21 9205 PUR TP-21
9500 PUR/WHT 9200 PUR 9215 PUR 9210 PUR TP-20
CAN HI 14 A A CAN HI ENG CAN LO 47 20 ENG CAN LO
9600 PUR
9100 PUR/WHT
SP91 9110 PUR/WHT 9105 PUR/WHT
9115 PUR/WHT
J2B ENG CAN HI 48 14 ENG CAN HI
R1-2 TP-19 R2-2
3095 LBL J7A J1B
REMOTE RUN KEY 24
J2A C169
ENGINE CAN
GATEWAY CTRLR
1725 RNG/WHT
3090 LBL 3085 LBL SHT3/D1 1
REMOTE RUN KEY 21 D D REMOTE RUN KEY
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT TP-19

3 ENG CAN HI
1735 RNG/WHT
9255 PUR
4 ENG CAN LO
1165 RED/WHT
C169
2710 BLK
SHT4/C6 G G GROUND
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 5 of 17
7300789
795 of 1288
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/E7
SHT3/C1 C C
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR

3560 LBL FOOT THROTTLE
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN
B
GND FOOT THROTTLE HARNESS
SHT4/G3
AIR FILTER C110 ALTERNATOR
7217683 1020 RED
3150 LBL SWITCH (NC) C116 D S
AIR FILTER SENDER SIGNAL 16 A SIG
E
FOOT THROTTLE INTDM F L
C405 5695 YEL
5695 YEL +5V PWR
SHT10/C8 C C C 2015 BLK 1
3695 LBL SHT4/E3
3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A T11
2695 BRN 2695 BRN GND
SHT4/G3 B B B 1

T12
C115
J1A
C355
FUEL HARN
3180 LBL 3180 LBL HAND THROTTLE
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT10/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
3690 LBL
C406
3690 LBL SIG
2690 BRN GND
SHT10/D5 B
C114
8007 TAN
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL FRC1 FRC1
SIG
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT7/G3
8014 TAN
J7A 4 4 SHT7/H7
ENG-CROSSOVER
3420 LBL
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 6 of 17
7300789
796 of 1288
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALJG19317-ALJG23809
B2KZ12106-B2KZ13527
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT6/B5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR EXHAUST GAS TEMP SENSOR 2 6 2
T
1 64 VREF 3 EGR C131
MAF SENSOR
4 OPEN MAF FREQ
SHT6/B5 1
MAF TEMP
C151 SHT6/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1

KNOCK SENSOR 1 SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
T
SHIELD-01
C150
INTAKE MANIFOLD PRESSURE SENSOR
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
1 SHT6/B5 FUEL INJECTOR #2 LSD2B 74 2
INJECTOR #3

P
INJECTOR #4
2 19
C143
INLET METERING VALVE FUEL INJECTOR #4 LSD2A 25 2

1 SHT6/C5 C142
C154
J7B
J7B
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 7 of 17
7300789
B SEE SHEET 1 104399 AEW IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
SHT 7 / 15
797 of 1288
HYDRAULICS
FRC1
C425
4100 LGN
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
TRACTION LOCK RELAY SIGNAL 8
3430 LBL
TRACTION LOCK RELAY FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1

C446
2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
J1A
1
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
4330 LGN GND

PRESS SENDER
TRACTION SOLENOID
HYD CHARGE PRESS
1
HYDRAULIC
HYD LOCK
HYD CHARGE
SOLENOID
AUX CTRLR
SENDER POWER
3.3 OHM PWM

FAN
2330 BRN SIG

OUTPUT
C418
4340 LGN GND
1
GATEWAY CTRLR 3.3 OHM PWM
2340 BRN SIG
J2A C419
J2B
19
13
FRONT BASE
FRONT ROD
SOLENOID
SOLENOID
AUX CTRLR
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 8 of 17
7300789
798 of 1288
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10
SHT4/G8 2 20 1 1 2
SHT2/G1 1 19 12 12 4
SHT3/E1 5 C499
GATEWAY CTRLR C500
SHT14/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 8 24 2 2 2
1960 RNG/WHT J1A

SHT3/E1
SW9 3040 LBL

3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5

5 4 SHT2/G1 1
9

SW9 SW9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12
2065 BLK 8070 TAN

SHT4/E8 2 4 9 DESOX INHIBIT
SHT3/E1 10 8 5 DESOX INHIBIT LAMP
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 9 of 17
7300789
799 of 1288
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6
SHT10/D1 5
4230 LGN 4
SHT11/F2 THESE CAB SCHEMATICS USED IN S/N ALJG19317-ALJG23962, ALJG23985
4240 LGN SW4 3
SHT11/D2 B2KZ12106-B2KZ13525
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
*
3 3 8 8
C212
4550 LGN 4550 LGN
2 2 9 9 POWER SOCKET
2795 BLK GND
SHT3/F1 2 2
1375 RED/WHT +12V PWR
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
SP8 SP41
*
SHT3/D1 5 5 B B +12V SW PWR T38
2800 BLK
C C GND

1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/B2
2885 BLK
SHT14/B3
2060 BLK
SHT10/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT6/D4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
SP13 SP52
5100 YEL 5370 YEL 5370 YEL 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5690 YEL
5695 YEL SHT6/E4
SHT6/F7
HARNESS WASHER PUMP
* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJG19317
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412 through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 10 of 17
DWG. NO.
7300789
800 of 1288
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
B2 SHT4/D3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE 4910 LGN RIGHT POSITION SWITCH
C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8 4230 LGN
T20 SHT10/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
RIGHT HANDLE
TRIGGER RETURN
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GATEWAY CTRLR
TILT SPOOL LOCK 2980 BRN GND

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT10/G8 H
LIFT SPOOL LOCK 2990 BRN GND 2520 BLK
SOLENOID GROUND 2 3 SHT4/B6 E
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
SIG
1 SHT3/E3 A
C422 LEFT HANDLE RIGHT ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
4840 LGN
4810 LGN
J1B
4820 LGN
7

C410
LOCK SOLENOID
LOCK SOLENOID
J2A
TILT SPOOL
LIFT SPOOL
TRIGGER
GATEWAY CTRLR
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 11 of 17
DWG. NO.
7300789
801 of 1288
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8

6630 PNK
6320 PNK

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR RELAY 5
C602
3460 LBL
MRKR LIGHT PWR RELAY FEEDBACK 31
REAR LIGHT RELAY 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
RIGHT REAR
WORK LIGHT
6210 PNK
J1A FRC1

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 12 of 17
DWG. NO.
7300789
SHT 12 / 15
802 of 1288
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
B
C483
7425 WHT
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
3

SW10
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL

3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
C350
D4
MAGNET CLUTCH
SHT4/C6
GND
2
C486
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 13 of 17
DWG. NO.
7300789
803 of 1288
# C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
*
2470 BLK 2770 BLK 2770 BLK
2 GND B B SW5
#
SHT4/E6
SP33 POWER BOBTACH SWITCH DLX FUEL HARN 7266824 ONLY
#
C607
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
RIGHT POSTION SWITCH
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
SW3 2
*
6415 PNK C103
D
HAZARD SWITCH
6570 PNK
TAILGATE HARN

6515 PNK
A
E E 1
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK
SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
BUCKET A SIG 5 5 1
POSITION 2
*
D3
SOLENOID 3
2450 BLK 2455 BLK 2905 BLK
9.8 OHM B GND SHT4/C6 4 SHT15/F6
2970 BLK
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK
D D C670
SW6 SW6 SHT15/D5
LEFT HANDLE F F
2830 BLK EXTERIOR HARNESS
AUX CTRLR SHT4/E8 6540 PNK
LIFT (ACS/AHC ONLY)
B B (SEE ADDITIONAL
C676 OPTIONS DWG)
HORN SIGNAL 5
7200 WHT
C497
C C
LEFT SPEAKER
* * RADIO CONN C
A
C
A
SJC HORN/BLINKER 7820 WHT LEFT
6420 PNK 1 3
HANDLE LOCK (ACS ONLY) RIGHT BLINKER SIGNAL 4 A A (SEE ADDITIONAL SPEAKER (+)
OPTIONS DWG) 7830 WHT LEFT
2 4
*
6520 PNK SPEAKER (-)
LEFT BLINKER SIGNAL 3 B B
C279
FLOAT (ACS/AHC ONLY) 2460 BRN RIGHT SPEAKER 1
*
HIGH FLOW SOLENOID GROUND 26
2
J2A GND 7810 WHT RIGHT L010
B 2 6 3 AIR RIDE SEAT
RIGHT POSTION SWITCH HIGH FLOW SPEAKER (-)
1510 RNG/WHT
SOLENOID 7800 WHT RIGHT SHT10/E1 4 PWR
SIG 7.5 OHM 12 V 1 5 SPEAKER (+) PWR
PADDLE A
C278 1885 RNG/WHT
C415 SHT10/E1 1 2210 BLK GND
4460 LGN
HIGH FLOW SOLENOID 26 SHT10/E1 5
2885 BLK GND
J2B SHT10/D1 2 6
C408 GATEWAY CTRLR C676 C277
MFR HARN CONN 1 C126
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
_
C412 SOLENOID (SEE ADDITIONAL
HORN 4350 LGN OPTIONS DWG)
SIG
1 5.1 OHM 12 V
2785 BLK GND +
SHT4/E8 B B TWO SPEED SIGNAL 26 C441
J1B
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 14 of 17
DWG. NO.
7300789
804 of 1288
AUX CTRLR
C438
*SW7
RIDE CONTROL
OPTIONS 2
23
3410 LBL
14 14
3410 LBL
1 2
2890 BLK
SHT4/E8
RIDE CONTROL SW AUTO
SW7 SW7
RIDE CONTROL
RELAY - L
3480 LBL
RIDE CONTROL RELAY SIGNAL 7 FUSE RELAY CENTER
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL
RIDE CONTROL
COIL FRC1 FRC1
SP32 COIL
2040 BLK 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
*
C428 SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
2905 BLK 2970 BLK
SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW8 SW8
J2A REVERSING

FAN COIL
3485 LBL
C442
2185 BRN
SHT4/D3 A
5105 YEL
PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
P697 P697
PROPRIETARY NOTICE
S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317
WARNING through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
csf

B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 15 of 17
DWG. NO.
7300789
SHT 15 / 15
805 of 1288
ACS CONTROLLER
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
HARNESS PART NUMBER

J1-ACS
CONTROLLER
ACS 7164144 EXMF, LF
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 FLOW

H 2270/BLK 2510/BLK 3 F
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317 through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899 Printed On August 2018
B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
Sheet 16 of 17
806 of 1288

S550
S650
T630
T550
T650 S/N ALJ818499
AHGL12984
AHGM12591
AJDT13779 through
AJZV16256
ALJG19317 through
through
throughALJ821599
AJZV18499
AJDT15599
ALJG23699
AHGL13799
AHGM13899 Printed On August 2018
B2L511148
B3GY11170
B2KZ12106 through
through
throughB2L511399
B2LA11899
B2KZ13499
B3GY12000 7300789 (B)
Sheet 17 of 17
807 of 1288
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
8 SH08 - HYDRAULICS
BATT FEED, GENERAL RED RED LEGEND
1000 THROUGH 1499
10 SH10 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
11 SH11 - MANUAL CONTROLS
12 SH12 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
13 SH13 - HVAC
14 SH14 - OPTIONS 1 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
15 SH15 - OPTIONS 2
1 1
HARNESS PART NUMBER LIGHT GREEN
HYDRAULIC 4000 THROUGH 4999 LGN
MF MFR CTRL 7322232 1 1
EXMF MFR CTRL 7322233 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7329485 * LIGHTS 6000 THROUGH 6999 PINK PNK SHT1/F2
WIRE #
SHT1/F2
7329492 *
WIRE #
STD CAB WHITE
SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHT
STD FUEL 7149219
DLX FUEL 7266824


9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALJG23963-ALJG23984, ALJG23986 & ABOVE
B2KZ13526 & ABOVE
FOR S/N ALJG23985, ALJG23962 & BELOW, B2KZ13525 & BELOW SEE PREVIOUS SCHEMATIC

S650
T630
T650 S/N ALJG23700
AHGL13800&&&Above
AJDT15600
ALJ821600
WARNING Above
Above PROPRIETARY NOTICE TOLERANCES: ECN 106368
Printed On August 2018
csf


B2L511400 &
B2LA11900 & Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 1 of 17
A PARTSHere
Click LIST STRUCTURE REVISED PDF
For Interactive 112541 RWE COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
REV
PER THIS DRAWING
DESCRIPTION CHG NOTICE DWN SHEET
SHT 1 / 15
7322231
808 of 1288
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
1400 RED/WHT
C408 SHT10/D3
6 6 SHT5/E7
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
1160 RED/WHT
SP36
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1

FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/C3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/C3
1055 RED
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT6/G8

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 2 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 2 / 15
7322231
809 of 1288
FRC1 ENGINE
ECU RELAY - G
ENG ECU CTRLR

1506 RNG/WHT
1 SWITCHED
SHT2/D1 G1 87 1540 RNG/WHT SP54 1507 RNG/WHT
86 85
G4
1508 RNG/WHT
3
POWER
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT

SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
C428 1785 RNG/WHT
SHT10/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT9/F4
FRC1 SWITCHED 2 2 SHT9/E4
POWER RELAY - A 1555 RNG/WHT
SHT15/F4
1050 RED 30 FUSE 7 25 A SP65

+12V PWR
A4 7A 7B SHT5/B8
86 85 2055 BLK
A5 A2 GND 1725 RNG/WHT
SHT5/C2
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
3390 LBL
FRC1 SWITCHED
FRC1 FRC1
POWER RELAY - F
2055 BLK
SHT4/B8
1200 RED 30
SHT2/B1
+12V PWR
F1 87 1585 RNG/WHT
F4
3385 LBL 86 85 2065 BLK GATEWAY CTRLR
F5 F2 GND
SHT4/C8
SP100 3450 LBL
FRC1 21 SWITCHED POWER RELAY FEEDBACK
FRC1
3380 LBL
J1A
C428
9 9 SHT5/E3
C492 1830 RNG/WHT

1740 RNG/WHT SHT5/F3
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 3 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
3 / 15
7322231
Version Click Here
810 of 1288
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7
6 2370 BRN GATEWAY CTRLR
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/F4 SHT8/D7 J1B
2180 BRN
SHT6/D7
C493
2150 BRN
2605 BLK ACS/SJC/AWS CONN 2 SHT6/F7
SHT5/E7 2235 BLK 2695 BRN
2080 BLK 3 3 SHT6/E7
SHT5/E3
2240 BLK
2070 BLK 4 4
SHT5/F3
C493 T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16

SHT15/D4
AUX CTRLR 2780 BLK
2890 BLK 2550 BLK 2090 BLK SHT14/E7
SHT15/H4 15
2065 BLK SP28 2730 BLK
C428
2930 BLK
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK T1 AUX CTRLR
SHT12/C4 B B 1 BATT GND 2195 BRN
SP51 SHT11/G2 SP58 2995 BRN
2610 BLK 2185 BRN 17 SENSOR GROUND
SHT12/E4 SHT15/E7
J2B
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
2065 BLK SHT5/C2
SHT3/C6
2505 BLK 2290 BLK
SHT15/G4 SHT13/B8
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55 SP5
2115 BLK 2105 BLK 2000 BLK
SHT12/D8
2055 BLK 2520 BLK

SHT3/C1 SHT11/D2
2030 BLK 2530 BLK

SHT13/F8 SHT11/F2
2005 BLK
SHT6/G8
2120 BLK
SHT12/E8

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 4 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
4 / 15
7322231
Version Click Here
811 of 1288
CAN BUS
Z3 C408 C479
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) Z4 LEFT PANEL (BLACK)
120 OHM 0.5 W RESISTOR SP19 SP18 120 OHM 0.5 W RESISTOR
SP31 SP79 SP39 SP35
9260 PUR 9230 PUR 9250 PUR 9270 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
SP30 SP80 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
SP20
J1B
C479
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C503
9290 PUR RH DLX PANEL
7 7
9440 PUR TP-06
9190 PUR/WHT 4 CAN LO
8 8
9340 PUR/WHT
9240 PUR 2 CAN HI
1 1
9140 PUR/WHT C503

4 4
* C450 C460
RIGHT JOYSTICK
AUX CTRLR RIGHT JOYSTICK CONN RIGHT JOYSTICK
9280 PUR SHT3/B1 1 1 1 1
8 CAN LO 2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9180 PUR/WHT 9320 PUR/WHT 9560 PUR/WHT CAN HI
9 CAN HI 3 3 3 3

J2B 4 4 4 4
TELEMATICS USED IN S/N ALJG23963-ALJG23984,
ALJG23986 & ABOVE, B2KZ13526 & ABOVE
* C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
TELEMATICS FOR S/N ALJG23985, ALJG23962 & BELOW, SHT3/B1 1 1 1 1
PWR 10
1305 RED/WHT
SHT2/G1
B2KZ13525 & BELOW SEE PREVIOUS SCHEMATIC SHT4/G8 2 2 2 2
9300 PUR/WHT 9540 PUR/WHT CAN HI
2605 BLK 3 3 3 3
GND 11 SHT4/G8 C448 9400 PUR 9640 PUR CAN LO
4 4 4 4
Z5 SP104 MFR HARN CONN 4 (BLACK)
120 OHM 0.5 W RESISTOR 9500 PUR/WHT SUSP SEAT JOYSTICK HARNESS
9515 PUR/WHT 9505 PUR/WHT 7 7
CAN HI 3 9510 PUR/WHT
9 9
9610 PUR
9615 PUR 9605 PUR 10 10
CAN LO 4 9600 PUR Z1 Z2
8 8 ENG ECU CTRLR 120 OHM 0.5W RESISTOR GATEWAY CTRLR
C481 SP103 SP90 120 OHM 0.5W RESISTOR
ENG CAN LO 9200 PUR 9215 PUR 9210 PUR 9205 PUR
47 20 ENG CAN LO
C426
AUX CTRLR SP91
Remote Run Tool, ACD 9100 PUR/WHT 9115 PUR/WHT 9110 PUR/WHT 9105 PUR/WHT
9500 PUR/WHT 9510 PUR/WHT ENG CAN HI 48 14 ENG CAN HI
CAN HI 14 A A CAN HI
J7A J1B
9600 PUR 9610 PUR C169

ENGINE CAN
J2B
1725 RNG/WHT
3615 LBL SHT3/D1 1
CAN SELECT 25 C C CAN SELECT
3095 LBL
REMOTE RUN 24 2715 BLK
SHT4/C6 2
J2A
GATEWAY CTRLR 9155 PUR/WHT

3 ENG CAN HI
3090 LBL 3085 LBL REMOTE RUN KEY
REMOTE RUN KEY 21 D D
SP93 9255 PUR
4 ENG CAN LO
J1B
C169
1735 RNG/WHT
1165 RED/WHT
2710 BLK
SHT4/C6 G G GROUND

S650
T630
T650 S/N ALJG23700
AHGL13800&&&Above
AJDT15600
ALJ821600
WARNING Above
csf


B2L511400 &
B2LA11900 & Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 5 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
5 / 15
7322231
Version Click Here
812 of 1288
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M SLEEVE
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
85 T9
8210 TAN 3560 LBL
M5 M2 B B SLEEVE B
86
1
FRC1 FRC1
2005 BLK
SHT4/B8 SHT2/E7
SHT3/C1 C C
1015 RED
GATEWAY CTRLR

3560 LBL FOOT THROTTLE
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN
B
GND FOOT THROTTLE HARNESS
SHT4/G3
AIR FILTER C110 ALTERNATOR
7217683 1020 RED
3150 LBL SWITCH (NC) C116 D S
AIR FILTER SENDER SIGNAL 16 A SIG
E
FOOT THROTTLE INTDM F L
C405 5695 YEL
5695 YEL +5V PWR
SHT10/C8 C C C 2015 BLK 1
3695 LBL SHT4/E3
3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A T11
2695 BRN 2695 BRN GND
SHT4/G3 B B B 1

T12
C115
J1A
C355
FUEL HARN
3180 LBL 3180 LBL HAND THROTTLE
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT10/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
3690 LBL
C406
3690 LBL SIG
2690 BRN GND
SHT10/D5 B
C114
8007 TAN
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL SIG FRC1 FRC1
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT7/G3
8014 TAN
J7A 4 4 SHT7/H7
ENG-CROSSOVER
3420 LBL

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 6 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 6 / 15
7322231
813 of 1288
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALJG23810 & ABOVE
B2KZ13528 & ABOVE
ENG ECU CTRLR
GLOW PLUG FEEDBACK

FOR S/N ALJG23809 & BELOW, B2KZ13527 & BELOW SEE
PREVIOUS SCHEMATIC
SHT6/B5 79 GLOW PLUG FEEDBACK
EGR VALVE DC MOTOR
1 64 VREF 3 EGR
OPEN
MAF SENSOR
4 MAF FREQ
SHT6/B5 1
MAF TEMP
C151 SHT6/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148

KNOCK SENSOR 1 SHIELD-01
SHIELD-01 BOOST PRESSURE AND TEMP SENSOR
BOOST TEMP SIGNAL 94 2
BOOST PRESSURE PWR 61 3
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD T
BOOST PRESSURE SIGNAL 12 4 P
C147
BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 SHIELD-02 C150
SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
1 SHT6/B5 FUEL INJECTOR #2 LSD2B 74 2
INJECTOR #3

P
INJECTOR #4
2 19
C143
FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
1 SHT6/C5 C142
C154
J7B
J7B

S650
T630
T650 S/N ALJG23700
AHGL13800&&&Above
AJDT15600
ALJ821600
WARNING Above
csf


B2L511400 &
B2LA11900 & Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 7 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 7 / 15
7322231
814 of 1288
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/E1 D1 87 4200 LGN 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
TRACTION LOCK RELAY SIGNAL 8
3430 LBL
TRACTION LOCK RELAY FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1

C446
2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
J1A
1
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT10/C8 B
C105
4200 LGN
J1B
19
13
4330 LGN GND

PRESS SENDER
TRACTION SOLENOID
HYDRAULIC
HYD LOCK
1
HYD CHARGE
SOLENOID
AUX CTRLR
3.3 OHM PWM
FAN
2330 BRN SIG

OUTPUT
C418
4340 LGN GND
1
GATEWAY CTRLR 3.3 OHM PWM
2340 BRN SIG
J2A C419
J2B
19
13
FRONT BASE
FRONT ROD
SOLENOID
SOLENOID
AUX CTRLR

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 8 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 8 / 15
7322231
815 of 1288
1940 RNG/WHT
T13
SHT3/E1 1
7040 WHT
1 C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10
SHT4/G8 2 20 1 1 2
SHT2/G1 1 19 12 12 4
SHT3/E1 5 C499
GATEWAY CTRLR C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 11
SHT14/F4 8 24 2 2 2
1960 RNG/WHT J1A

SHT3/E1
SW9
TRAVEL CONTROL SWITCH(OPTIONAL) 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5

5 4 SHT2/G1 1

SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12
2065 BLK 8070 TAN

SHT4/E8 2 4 9 DESOX INHIBIT
SHT3/E1 10 8 5 DESOX INHIBIT LAMP
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 9 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 9 / 15
7322231
816 of 1288
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT10/D1 5
SHT11/F2
4230 LGN 4 THESE CAB SCHEMATICS USED IN S/N ALJG23963-ALJG23984,
SHT11/D2
4240 LGN SW4 3 ALJG23986 & ABOVE, B2KZ13526 & ABOVE
SW4
C492
C438
ACS/SJC/AWS-MFR HARN (8 PIN)
MFR HARN CONN 3 (DK GRAY) FOR S/N ALJG23985, ALJG23962 & BELOW, B2KZ13525 & BELOW
5 5
4220 LGN SP29 4235 LGN
7 7
4235 LGN SEE PREVIOUS SCHEMATIC
4275 LGN 4275 LGN
3 3 8 8
4550 LGN 4550 LGN

* C212
2 2 9 9 POWER SOCKET
2795 BLK GND
SHT3/F1 2 2
1375 RED/WHT +12V PWR
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK

C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B3
2060 BLK
SHT10/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
2690 BRN
(SEE ADDITIONAL
SHT6/D4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5690 YEL
5695 YEL SHT6/E4
SHT6/F7
HARNESS WASHER PUMP
SHT8/D7
5190 YEL * C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S650
T630
T650 S/N ALJG23700
AHGL13800&&&Above
AJDT15600
ALJ821600
WARNING Above
csf


B2L511400 &
B2LA11900 & Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 10 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 10 / 15
7322231
817 of 1288
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
SHT4/D3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8 4230 LGN
T20 SHT10/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
RIGHT HANDLE
TRIGGER RETURN
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GATEWAY CTRLR
TILT SPOOL LOCK 2980 BRN GND

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT10/G8 H
LIFT SPOOL LOCK 2990 BRN GND 2520 BLK
SOLENOID GROUND 2 3 SHT4/B6 E
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
SIG
1 SHT3/E3 A
C422 LEFT HANDLE RIGHT ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
4840 LGN
4810 LGN
J1B
4820 LGN
7

C410
LOCK SOLENOID
LOCK SOLENOID
TILT SPOOL
J2A
LIFT SPOOL
TRIGGER
GATEWAY CTRLR

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 11 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
11 / 15
7322231
Version Click Here
818 of 1288
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8

6630 PNK
6320 PNK

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR RELAY 5
C602
3460 LBL
MRKR LIGHT PWR RELAY FEEDBACK 31
REAR LIGHT RELAY 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
RIGHT REAR
6210 PNK
FRC1 WORK LIGHT

J1A

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 12 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 12 / 15
7322231
819 of 1288
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
B
C483
7425 WHT
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW

SW10 3
85 7400 WHT
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL

3
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
7015 WHT
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
D4
C350 MAGNET CLUTCH

SHT4/C6 GND
2
C486

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 13 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 13 / 15
7322231
820 of 1288
C355 C428
# FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
1 SIG F F 10 10 2
3 DLX CAB HARN 7329485 ONLY
POWER BOB
OPEN 2480 BLK SW5
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
SHT2/C1 1 1 X T3
* FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8
SP21 D1
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D2
6430 PNK
*SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
6415 PNK SW3 2
C103
D
* HAZARD SWITCH
6570 PNK
6515 PNK TAILGATE HARN
A
E E 1
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK
*
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) AUX CTRLR 6540 PNK
B B (SEE ADDITIONAL
C676 OPTIONS DWG)
C497
HORN SIGNAL 5
7200 WHT
C C
LEFT SPEAKER
* * RADIO CONN
SJC HORN/BLINKER 7820 WHT LEFT

6420 PNK 1 3
HANDLE LOCK (ACS ONLY) RIGHT BLINKER SIGNAL 4 A A (SEE ADDITIONAL SPEAKER (+)
OPTIONS DWG) 7830 WHT LEFT
6520 PNK 2 4
L010
LEFT BLINKER SIGNAL 3 B B
C279
SPEAKER (-)
* HEATED SEAT
FLOAT (ACS/AHC ONLY) 2460 BRN RIGHT SPEAKER 1510 RNG/WHT
HIGH FLOW SOLENOID GROUND 26 SHT10/E1 4
J2A
* 7810 WHT
PWR
PWR
GND RIGHT
B 2 6
RIGHT POSTION SWITCH HIGH FLOW SPEAKER (-)
GND
2210 BLK
SOLENOID 7800 WHT RIGHT SHT10/E1 5
SIG 7.5 OHM 12 V 1 5 SPEAKER (+) GND
PADDLE A C277
C278 1885 RNG/WHT
C415 SHT10/E1 1
HIGH FLOW SOLENOID 26
4460 LGN
SEE OPTION PAGES FOR HARNESS
2885 BLK
J2B SHT10/D1 2
C408 GATEWAY CTRLR C676
MFR HARN CONN 1 C126
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
+ SOLENOID (SEE ADDITIONAL
C412 4350 LGN OPTIONS DWG)
HORN SIG
1 5.1 OHM 12 V
GND
_
2785 BLK
SHT4/E8 B B TWO SPEED SIGNAL 26 C441
J1B

S650
T630
T650 S/N ALJG23700
AHGL13800&&&Above
AJDT15600
ALJ821600
WARNING Above
csf


B2L511400 &
B2LA11900 & Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 14 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 14 / 15
7322231
821 of 1288
AUX CTRLR
C438
*SW7
RIDE CONTROL
OPTIONS 2
3410 LBL 3410 LBL 2890 BLK * DLX CAB HARN 7329485 ONLY
SW7 SW7
FRC1 SWITCHED
3480 LBL POWER RELAY - L
RIDE CONTROL RELAY SIGNAL 7
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL
RIDE CONTROL
COIL FRC1 FRC1
SP32 COIL
2040 BLK 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428 SW13
3475 LBL
3475 LBL
* REVERSING FAN
2905 BLK 2970 BLK
SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
REVERSING

J2A
FAN COIL
3485 LBL
C442
2185 BRN
SHT4/D3 A
5105 YEL
PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700
WARNING Above
csf


B2L511400
B2KZ13500 && Above
Above 7322231 (A)
SCHEM ELEC CTRL
Sheet 15 of 17
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
15 / 15
7322231
Version Click Here
822 of 1288
ACS CONTROLLER
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
HARNESS PART NUMBER

J1-ACS
CONTROLLER
ACS 7164144 EXMF, LF
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 FLOW

H 2270/BLK 2510/BLK 3 F
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700 Above
Above Printed On August 2018
B2L511400
B2KZ13500 && Above
Above 7322231 (A)
Sheet 16 of 17
823 of 1288

S650
T630
T650 S/N ALJ821600
AHGL13800
AJDT15600 &&&Above
ALJG23700 Above
Above Printed On August 2018
B2L511400
B2KZ13500 && Above
Above 7322231 (A)
Sheet 17 of 17
824 of 1288
LEGEND
PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CONNECTOR C426 To Mainframe
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN SSL 7-PIN
CAN CONNECTOR D F C E A B G
Harness

9800
1160
9700
1710
9500
9600
2710
WIRE BREAK KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
(TWO WIRE BREAKS UNSW POWER F 1160 RED/WHT 2720 H GROUND

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
JOIN ONE WIRE) SW POWER E 1730 RNG 9 1720 B SW POWER ACD
ENGINE 8000 THROUGH 8999 TAN TAN 9 Machine
SHEET # CAN LOW B 9620 PUR 9610 E CAN LOW
Connector to
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR CAN HIGH A 9520 PUR 14 9510 D CAN HIGH Engine
GROUND G 2730 BLK 13 C OPEN Compartment
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT Connector 7-PIN A
C666 ATTACHMENT
OPEN
on Loader G OPEN
CONNECTOR
SSL 7-PIN Boom
CAN CONNECTOR J
BOOM-MOUNTED
N ACD CONNECTORS
KEY "RUN" D 9800 D SW POWER K 1740
UNSW POWER 2 1160 F

GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
CAN SHIELD C 9700 C F OUTPUT F 5350 5350 H F OUTPUT
SW POWER 1 1710 E G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
CAN LOW B 9600 A Output
C OUTPUT C 5300 5300 G C OUTPUT
CAN HIGH A 9500 B Connector to
D OUTPUT D 5150 5150 D D OUTPUT
Engine
GROUND 3 2700 G A OUTPUT A 5250 5250 F A OUTPUT Compartment
7-PIN M E
Connector M OUTPUT 5200 5200 B OUTPUT
on Loader C666 C426 ATTACHMENT

CONNECTOR
ID (K TO L)
ID (K TO P)
L
P
5910
12
5000 A
K
J OUTPUT
Boom 5510 5450 K OUTPUT

T650 Aljg #5,8,10

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T650 Aljg #5,8,10

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Service Manual

Dealer Copy -- Not for Resale

Compact Track Loader

S/N ALJG11001 & Above

CORRECT CORRECT CORRECT

P-90216 NA1711 NA1715

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1722 NA1725 B-6589

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 1288 1-3 T650 Service Manual

6 of 1288 1-4 T650 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 1288 1-5 T650 Service Manual

8 of 1288 1-6 T650 Service Manual

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 all machine fluid

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 1288 1-7 T650 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 1288 1-8 T650 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

11 of 1288 1-9 T650 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

12 of 1288 1-10 T650 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

13 of 1288 1-11 T650 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale

14 of 1288 1-12 T650 Service Manual

Always use the serial number of the loader when Figure 3